Glass Lifter Safe Work Method Statement

The most critical hazard in glass lifter operation is sudden loss of vacuum pressure causing release of the glass panel being handled. This can occur due to vacuum pump failure, electrical power loss, battery depletion in battery-powered units, air leakage through damaged suction pad seals, inadequate initial vacuum pressure, or loss of suction on certain glass coatings or contaminated surfaces. When vacuum pressure drops below the safe threshold, suction pads release their grip and the glass panel falls. If this occurs while glass is suspended during positioning or transport, the falling panel can crush operators' feet or hands, strike workers positioned below, or shatter causing severe lacerations from flying glass fragments. Modern glass lifters include audible low-pressure alarms and visual indicators, but operators must respond immediately to vacuum loss warnings and implement emergency procedures. The risk is heightened when handling large heavy panels where even momentary loss of control can result in catastrophic outcomes.

Consequence: Severe crushing injuries to hands and feet, deep lacerations from broken glass, fatalities from being struck by falling heavy glass panels, and injuries to bystanders or other workers in the vicinity of the lifting operation.

Each glass lifter has a specified safe working load (SWL) determined by the number and size of suction pads, vacuum pressure capacity, and structural strength of the frame. Operating beyond this rated capacity overloads the vacuum system and increases risk of suction failure, pad detachment, or structural frame failure. Glaziers may be tempted to use undersized equipment to avoid mobilising larger units, or may miscalculate glass weight when panels are larger or thicker than typical. Some glass types including laminated and insulated glazing units (IGUs) have significantly greater weight than standard glass of equivalent dimensions. Wind loading on large panels during outdoor installation adds dynamic forces beyond static weight. Using equipment at or near its maximum capacity leaves no safety margin for unexpected factors. Additionally, distributing suction pads incorrectly across the glass panel can create uneven loading where individual pads exceed their capacity even if total panel weight is within equipment rating.

Consequence: Sudden equipment failure causing glass to fall, resulting in crushing injuries, lacerations, property damage, and potential fatalities. Structural damage to the lifting equipment rendering it unsafe for continued use.

Modern architectural glass often includes low-emissivity (Low-E) coatings, solar control films, or other surface treatments that can significantly reduce the effectiveness of vacuum suction pads. These coatings are sometimes applied to surfaces that may not be immediately visible to operators, particularly on insulated glass units where coatings may be on internal surfaces. If suction pads are applied to a coated surface with reduced adherence properties, adequate vacuum pressure readings may be achieved initially but the bond can fail under load or during movement. Additionally, contamination on glass surfaces including dust, moisture, oils from handling, or residues from manufacturing or transport can prevent proper suction pad seal formation. Cold or wet glass surfaces present particular challenges as condensation interferes with vacuum seals. Operators must understand which glass surfaces are suitable for suction application and verify adequate adhesion before committing the panel to suspension.

Consequence: Loss of suction and glass panel falling during handling, causing severe injuries from crushing or lacerations, damage to expensive architectural glass, and potential cascade failures if falling glass strikes other installed panels.

Many portable glass lifters use battery-powered vacuum pumps to provide operational flexibility without requiring connection to electrical power sources. However, battery charge depletion during operation presents a serious hazard as vacuum pressure will drop rapidly once battery capacity is exhausted. This risk is heightened on projects with extended installation sequences where lifters are in continuous use, in cold weather conditions where battery performance is reduced, or when equipment battery maintenance has been neglected. Some operators may commence work with partially charged batteries to avoid delays, gambling that charge will last through the immediate task. If battery failure occurs while glass is suspended during positioning, operators have only seconds to respond before vacuum pressure drops below safe levels. While modern equipment includes low battery warnings, these alarms may not provide sufficient notice for safe glass placement if operators are in the middle of a critical positioning operation when the warning sounds.

Consequence: Mid-operation vacuum loss causing glass to fall and potentially crush operators, severe lacerations from broken glass, and injuries to other workers in the vicinity. Project delays while equipment is recharged and potential damage to partially installed glazing systems.

Vacuum suction pads are the critical interface between lifting equipment and glass panels, and their condition directly affects the safety and reliability of the lifting operation. Suction pad deterioration occurs through normal wear, exposure to weather and UV radiation, chemical attack from glass cleaning agents or sealants, and physical damage from impacts or rough handling during transport and storage. Cracks, tears, or hardening of pad rubber reduces the pad's ability to conform to the glass surface and create an airtight seal. Oil, dust, or debris on pad surfaces prevents proper sealing. Even minor pad damage can result in slow air leakage that gradually reduces vacuum pressure during extended lifts. Operators may not detect pad deterioration during brief pre-use tests if damage only manifests under sustained load. Using damaged equipment under time pressure or due to lack of replacement pads compounds the risk. Contamination can also occur from site conditions where pads come into contact with concrete dust, silicone residues, or other substances between lifts.

Consequence: Progressive vacuum loss during glass handling causing panel release, severe crushing or laceration injuries, damage to glass panels, and compromise of the entire glazing installation if falling glass damages completed work.

Vacuum glass lifters require specific operational procedures to be followed during attachment, lifting, positioning, and release of glass panels. Common operator errors include failing to verify adequate vacuum pressure before lifting glass from horizontal surfaces, attempting to lift glass before pump has achieved full vacuum, positioning suction pads too close to glass edges where structural strength is reduced, failing to maintain vacuum pressure during extended positioning operations, releasing vacuum prematurely before glass is fully secured in frames, and inadequate communication with team members during coordinated lifts. Inexperienced operators may not recognise signs of impending vacuum loss such as changes in alarm tone or vacuum gauge readings. Fatigue during extended installation sequences reduces operator vigilance. Working under time pressure may lead to shortcuts such as inadequate pre-lift checks or premature release procedures. Language barriers in diverse work crews can impair communication about vacuum status and lifting coordination.

Consequence: Glass panel release causing injuries, damage to materials, and safety incidents requiring incident investigation and potential work stoppages. Near-miss events that undermine worker confidence in equipment safety and create ongoing anxiety about equipment reliability.