Codeof Practice

Glass Handling, Storage and Transport

This Code of Practice is issued by the Glass andGlazing Federation for guidance, but withoutresponsibility for any advice given or not given orfor the consequences of acting in reliance on theadvice. All liability on the part of the Glass andGlazing Federation arising in connection with thisdocument is hereby expressly disclaimed.

44-48 Borough High StreetLondon SE1 1XBTelephone: 0870 042 4255 Facsimile: 0870 042 4266info@ggf.org.ukwww.ggf.org.uk

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Glass Handling, Storage and TransportCode of Practice

1 Introduction

2 Legislation

2.1 Introduction

2.2 Regulations

2.3 Enforcement

3 Storage of glass

3.1 General principles

3.2 Types of storage3.2.1 Wall racks3.2.2 End caps3.2.3 Toast type or bin racks3.2.4 Glass supporting frames3.2.5 Large racks for float, wired etc.3.2.6 Double tier racking3.2.7 Pallets

3.3 Storage of glass on sites

4 Handling of glass

4.1 Manual handling4.1.1 Straps or slings4.1.2 Webbing lifts4.1.3 Suction pads4.1.4 Warehouse trucks4.1.5 Glass carriers

4.2 Mechanical handling4.2.1 Electric overhead cranes4.2.2 Forklift trucks4.2.3 Ancillary glass handling equipment

4.3 Legislation – lifting equipment4.3.1 Procedures for the use of lifting equipment4.3.2 Recommendations on safe practices using mechanical handling

equipment.

5 Unloading suppliers’ vehicles

5.1 General principles

5.2 Loose glass5.2.1 Loose glass products on enclosed lorries5.2.2 Outside frails/frames

5.3 Jumbo-size glass delivered on stillages

5.4 End caps

5.5 Pallets

5.6 Cases – timber packages

6 Transit of glass

7 Risk assessment

8 Personal protective equipment

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1 Introduction

This Code of Practice has been drawn up by the Glass and Glazing Federation to provideguidance of recommended best practice in the safe handling, transport and storage offlat glass, in the warehouse, processing shops and on sites.

It addresses the general duties placed upon the employer by the Health & Safety at WorkAct l974 and the more specific requirements of other relevant Acts and regulationsAdherence to this Code may be seen to demonstrate competence in meeting propersafety standards.

2 Legislation

2.1 Introduction

The Health and Safety at Work Act l974 and the Management of Health and Safety atWork Regulations 1999 are fundamental pieces of health and safety law in Great Britain.They provide the legal framework to promote, stimulate and encourage high standards.They place responsibility upon employers and employees to produce together theirown solutions to health and safety problems, as far as is reasonably practicable. TheAct incorporates duties of a general nature, which are directed at employers, employees,contractors, the self-employed, manufacturers, designers, and importers of workequipment and materials. It contains provisions for the health and safety of peopleat work, the protection of others against health and safety risks from work activities,the control of danger from articles and substances used at work and controls certainatmospheric emissions.

2.2 Regulations

Legislation has been and will continue to be introduced from Europe, which supplementsother regulations associated with certain types of activities, premises or workplaces.These regulations are,

The Management of Health and Safety at Work Regulations 1999The Manual Handling Operations Regulations 1992The Health and Safety (Display Screen Equipment) Regulations 1992The Provision and Use of Work Equipment Regulations 1998 (PUWER 98)The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)The Personal Protective Equipment at Work Regulations 1992The Workplace (Health, Safety and Welfare) Regulations 1992

Glass Handling, Storage and Transport

Code of Practice

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These regulations imposed upon employers duties of ensuring that:

1) Competent persons are appointed and clearly identified as having theresponsibilities for managing Health and Safety

2) Written assessments are made of the risks at the workplace

3) People are clearly informed of the results of the assessments and the measuresbeing taken to reduce the risks to a minimum

4) There is adequate provision for personal protective equipment for all employeesas detailed in the risk assessment measures

5) The organisation monitors and evaluates the measures put in place to provide asafe working environment

Further information can be obtained from the GGF Health and Safety manual

2.3 Enforcement

The Health and Safety Commission and its operating arm the Executive (HSC/E), arecontinually modernising the structure of Health and Safety law. Their aims are toprotect the health, safety and welfare of employees, and to safeguard others,principally the public, who may be exposed to risks for industrial activity. The Healthand Safety Executive has the ability to enforce the Act and Regulations through theHSE Inspectors and the local authority environmental health departments. Both haveconsiderable powers of access and may prohibit activities or cause improvements tobe made.

3 Storage of glass

3.1 General principles

Glass is generally stored in dry conditions, on its edge. Whether storage is on theshort or the long edge is dependent on size, substance, availability of space etc.

Factors to consider in storing glass on edge are:

(i) The glass should not be in contact with any substance that is harder than itself,eg. concrete, stone, ferrous metals. This will minimise the risk of damage andbreakage, and can be implemented by cladding all supporting structures withtimber, felt, rubber or plastic material. Care should be taken to ensure that allnails and screws are counter-sunk below the surface likely to come in contactwith the glass.

Factory inspectors have considerable powers!

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(ii) The angle of inclination or lean of the glass should be 3° from the vertical onstatic racks. For transportable racks, pallets and stillages, an angle of 5° – 6° isrecommended. If the angle is increased above 6°, it will tend to put extra loadon the back sheets of the stack and may cause breakage.

(iii) Glass stored on its edge should be supported as evenly as possible over its surfacearea. The support should ideally cover either the total length or the total widthof the glass. It can take the form of flat bearers at least 50mm in width, whichmay be spaced to suit the size of the sheet being stored.

Inadequate or uneven supporting bearers will cause the back sheets of a stackto break when the weight of sheets in a full pack is applied. Examples of typesof static racking are described in Section 3.2.

(iv) Glass stored on its edge leaning against a wall at an angle of 3° has 99.86% of itsweight loading in a downward or vertical direction. It is therefore essential thatthe flooring be of adequate strength to support the weight of the stack, and ifpossible the base of the rack should aim to spread the weight over the largestpossible floor area, ie. a distributed floor loading is preferable to a concentratedloading, especially when glass is being stored at first floor level or above.

3.2 Types of storage

This section outlines some of the types of storage racks that are available. The typeof rack selected obviously depends on the size of the glass to be held, the volume ornumber of sheets to be stacked, and the method of handling to and from the particularrack, ie. mechanical handling devices may require a specific type of rack construction.All materials used in the construction of storage racks should be of sound quality andthey should be examined periodically.

3.2.1 Wall racks – Probably the simplest methods of holding glass in stock is thatof standing the glass on strips of timber that are at right angles to the wall of abuilding (see Fig. 1). The bottom of the first piece of glass is placed far enoughaway from the wall to provide a safe angle of inclination, with the top edgesupported on some form of cushioning material between the wall and theglass. This type of racking is not recommended where a large volume is tobe stored due to the pressures, which may be exerted on the walls of thebuildings. Therefore, as a general rule, it is preferable that this type of rackingbe constructed with vertical timber back members, which are able to supportthe maximum volume of glass to be stocked. Where larger quantities are to bestored against a wall, it is recommended that single-sided freestanding racks beused, avoiding any imposed loading on the wall.

3.2.2 End caps – Generally end caps are not constructed to hold more than1.75 tonnes of glass. Beyond this weight the construction of an end cap wouldrequire an upgraded design and be of heavier construction. It follows that thenumber of sheets in a pack varies according to the size and thickness of theglass and the larger the glass the thinner the pack is overall. This can lead toinstability of single packs stored free-standing. It is recommended such packsbe twinned by binding or stabiliser legs be fitted (see Fig. 2).

Right!

Fig. 1

Wrong!

✓ ✘

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3.2.3 Toast or bin racks – This form of rack is used a great deal throughout thetrade, and is considered the best means of storing small quantities of a size, eg.slow moving patterns of figured rolled and miscellaneous glasses (See Fig. 3).The construction should include ‘cross bracing’ along the length of the rackand each end must be firmly secured to the floor and/or ceiling.

End cap storage should be only one high wherever practicable. In exceptionalcircumstances two tier stacking may be permitted providing the end caps arebanded. The stacking should be in a pyramid formation with each layer of thesame height and the end caps secured on to the other with a linking rail orbanding. If an end cap is to be removed it should be disengaged and theremainder made secure to each other before it is lifted out. Since end capsmay only be removed from the top row when stored in this manner, the packsshould be identical to avoid double handling.

When packing glass into end caps the glass should be leant on to a pair ofsteads at 3° – 5°. The end caps should then be applied. Packing material isneeded around the glass within the end caps to prevent sideways movementof the glass and to ensure it is upright within the end caps. Metal banding istensioned around the end caps to secure them on to the glass. The slingingblocks on each end cap should be checked to ensure they are securely fixed.

Care should be taken when removing metal banding from end caps. The glassshould be placed on steads set at 3° – 5° lean. Eye protection and glovesshould be worn by the person cutting the banding and no one should be nearenough to be struck by a strap whipping when cut.

Single pack

Single packTwo packs

Fig. 2 Storage of narrow width end caps

✓ ✓

✘

Fig. 3 Toast type or bin racks

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Great care must be taken when loading and unloading, and the following pointsshould be considered when using this type of racking.

(i) Glass should be kept as upright as possible. An excessive lean may resultin damage to the glass edges, with a possible risk of injury when removingthe glass from the rack.

(ii) Only single sheets should be turned over so as to stop a suddenredistribution of weight at any time. This will avoid excessive stress beingplaced upon the vertical supports of the racks.

(iii) Wherever possible the glass should lean in alternate direction along thelength of rack.

(iv) A clearly defined gangway should be provided in front of the rack wideenough to enable the operator to turn the sheet through 90° when clearof the front of the rack.

(v) It is recommended that 50mm wide timber bearers are laid at rightangles to the glass on the floor of the rack. This will avoid damage byglass particles, which may become embedded in the rack floor.

3.2.4 Glass supporting frames (plank and pin racks) – These are free standingracks and may be of the single or double side design (See Fig. 4). Theirmanufacture is based on jig-welded frames of 50mm x 25mm rectangularhollow sections bolted to lengths of 150mm x 100mm floor timbers using152mm x 76mm x 6mm thick metal plates bolted on the under surface.The support for the glass in approximately 75mm x 50mm timber bolted orclipped to the rectangular hollow sections. (The material dimensions are therecommended minimum). These racks are used in pairs aligned and suitablyspaced to the required width of glass. The length of the timber base may beadjusted to suit the volume of glass to be held. A standard design double-sidedrack has a 2032mm long base and is capable of holding 6 packs of 3 or 4mmwith spacers. The height of the rack can be varied to hold glass up to 2440mmin length.

Two-safety features, which should be considered, are:

(i) The floor on which these racks sit should be as flat and even as possible,so that they do not move or rock when empty or lightly laden.

(ii) Clearly defined gangways of at least one metre must be provided in frontof each rack to avoid the danger of an operator tripping over any exposedtimber bases when carrying glass.

Fig. 4 Glass supporting frames

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3.2.5 Large racks for float, wired etc. (‘A’ frame racks) – see Fig. 5. The construction of racks of this type for large sizes of glass may vary fromcast iron, fabricated angle iron, tubular/rectangular section or timber. The basicdesign where glass is to be stored on both sides of the rack is to space theuprights at approximately 900mm centres, and secure them with a numberof metal tie rods. The length of rows will depend on the size of glass to becarried. All metal faces likely to come in contact with glass should be clad withtimber and/or felt.

3.2.6 Double tier racking – Construction of this type of racking demands a highdegree of engineering competence.

3.2.7 Pallets – Pallets may be used as a means of storage as well as a means oftransporting glass. They may vary in design according to the size of glass tobe held, but are usually fabricated of tubular or square hollow steel, with asuitable felt or rubber lining. They are designed to stack one upon another, theheight of stack being governed by the construction and strength of each pallet,and the available floor loading. Methods of handling pallets are described underSection 5.5 of this Code of Practice.

3.3 Storage of glass on sites

The glazier/fixer requires a more highly developed sense and wider knowledge of safetyand health requirements than other glass workers. He is subject to the full rangeof hazards when working with glass plus the range of hazards presented by the sitelocation, weather and particular conditions for movement and storage. A risk assessmentmust be carried out to ascertain where the glass is actually going to be stored and tocheck the following points.

(i) Is the glass at ground level? If not, are the floor loadings of the building orplatform sufficient to take the weight?

(ii) Will it be necessary to distribute the weight of glass over the floor?

(iii) Is the access sufficient to allow a delivery vehicle on to the site?

(iv) What type of racking will be required to hold the glass? Is the ground suitable toerect the racking? What means of handling are available to unload glass from thelorry to the racking area? Is it of sufficient capacity?

Fig. 5 ‘A’ frame racks

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(v) Are any freak wind conditions likely to be encountered on the site?

(vi) Is the area where the glass is to be stored secure and safe from accidentaldamage by other contractors on site? Will it present a hazard to anyone notassociated directly with this work?

(vii) Can dry storage conditions be provided?

All these points should be checked and agreed and, if possible, any racking shouldbe erected prior to the arrival of the glass on the site, away from the workingarea. It is also recommended that the glass supplier has direct liaison with thesite concerned to ensure deliveries are made at an agreed date, and in a loadform suitable for the site conditions.

Glaziers on sites and lorry drivers delivering glass to sites become subject toregulations in force on the premises they are visiting. Employees working on sitesmust, therefore, be provided with the personal protective equipment detailedfor the conditions from the risk assessments recorded.

4 Handling of glass

Glass is a potentially dangerous material. Training must be given to employees who willhandle it, whether on site or in the warehouse, for their own safety and that of othersworking with them or in the vicinity of their work. They should learn how to detectflawed glass, the correct way of lifting and setting down glass, what protective clothingshould be worn and the procedures when using various lifting and carrying aids. Therecommended induction period for glass handling and safety awareness is one week.The completion of the training programme for each worker should be recorded andsigned by the appropriate supervisor/manager. These records will become part of thecompany’s Health and Safety arrangements, which should be reviewed at least annually.

Are freak wind conditions likely to be encountered?

Training is important.

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4.1 Manual handling

Working in the warehouse

The size and substance of the glass to be handled determines the number of peoplerequired. The distance to be covered in the move and the method also play a part inthe decision. Probably the most common handling movements are selecting fromstock, carrying, laying glass on the bench and cutting and placing the cut glass in therack ready for dispatch. Whether the activity requires one or any number of peoplethe same basic criteria apply viz:

(i) check the condition of the glass, look particularly for edge runs

(ii) ensure there is plenty of room for manoeuvre and look out for obstacles

(iii) check that the destination is prepared with satisfactorily insulated seatingin place

Working on sites

Discussions with the site personnel prior to work commencing should take place toagree a safe method of working and storage for materials together with provisions forlifting and placing materials at the required level.

The following criteria, over and above the normal storage conditions for glass as notedin 3.1 should be observed.

(i) Site access is adequate to permit vehicles to approach.

(ii) Storage position is accessible for delivery and distribution of materials.

(iii) Bulk glass is distributed over floors or on scaffolding within the particular safeloading capacity.

(iv) Suitable racking arrangements are made so that the glass is safely positioned andcannot be damaged by others working on site.

(v) Storage conditions are dry.

(vi) Tinted glass is placed out of direct sunlight.

(vii) There should be room to safely manoeuvre the glass.

(viii) If glass breaks during handling it should be allowed to fall, no attempt shouldbe made to intercept it.

(ix) On windy locations the glass should be tied to prevent it blowing over.

(x) A safe lifting posture should be used.

(xi) When lifting, the glass should be kept upright and the movement smoothto avoid undue flexing.

(xii) The floor should be checked for obstacles or slippery patches.

(xiii) The correct personal protective equipment must be used for the job in hand.

Generally

• Wherever possible mechanical means for moving glass in bulk should beinvestigated and adopted.

• Loads must be kept within the manageable capacity of those handling them.

• Persons with a history of back injury should not engage in manual lifting.

4.1.1 Straps or slings – Usually made of leather or plastic with timber handlesat each end. They are used for handling large sizes of glass, with the slingspassed under the bottom edge of the glass so that operators can share theweight of the load. Special care must be taken to support the top of tall plates.

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4.1.2 Webbing lifts – Usually cut to suitable length from 75mm – 100mm widewoven webbing. Used as slings when glazing shopfront plates. The flatness ofthe webbing allows it to be withdrawn from beneath the plate supported onits setting blocks.

4.1.3 Suction pads (josters) – Two or three rubber pads per frame are placedon the surface of the glass and fixed by operating a small lever. When theseare used in a lengthy operation it is recommended that they be released andrefixed at frequent intervals. The surface of the glass must be clean and dry.

4.1.4. Warehouse trucks – Truck design varies enormously throughout the tradeand it is not possible to describe here all the various types available. Theyshould however be as light as possible in construction, easily moveable, andonly used within the design limitations. The safe carrying load of the truckmust not be exceeded by weight or size.

4.1.5 Glass carriers – (see Fig. 6) Glass carriers for moving single large plates canbe based on a pair of wheels centrally placed and secured to a timber base.The glass may be supported manually or by a vertical member fitted with aset of hand suction pads.

4.2 Mechanical handling

There is available today a very wide range of cranes, conveyors and powered mobiletrucks which could be used as mechanical handling equipment in a modern glasswarehouse. This section of the Code of Practice briefly describes the more commontypes of mechanical equipment and lays down some guidelines as to safe workingpractices.

4.2.1 Electrical overhead travelling cranes – One of the best and most versatilepieces of equipment, it may form an integral part of the building or may beconstructed within an existing building providing sufficient headroom is available.Care should be taken in design before installing a crane to ensure that alldimensional allowances are made to establish correct lifting clearance toaccommodate the various items of ancillary glass handling appliances. It maybe used for a variety of handling operations, from carrying individual plates tomoving whole blocks of glass on and off vehicles and within the confines of thewarehouse. It may be operated by a suspended control pendant, or from cabcontrols which move with the crane itself. The capacity of the crane dependson the heaviest load to be lifted, but users should satisfy their own requirementsor needs. Manufacturers state that a 3 tonne capacity crane should be adequatefor their normal deliveries.

Lifting equipment is subject to testing by a competent person at intervals.A certificate must be issued following each test. Records will need to be keptand cranes must therefore be identifiable by marking or otherwise, and thesafe working load must be prominently visible. Obviously, this must never beexceeded except under direct test and under controlled conditions.

Fig 6 Glass carrier

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A recognised competent person must supply operator training, as even pendentcontrol cranes can be dangerous. This is because the method of attaching theload to the crane requires knowledge, and because the capacity of the cranemust not be exceeded. Records of this training should be reviewed with theHealth and Safety arrangements at least annually. Selection of operators maybe required if there is a high physical content to the work. This will be coveredby the Manual Handling Operations Regulations 1992 and the associated riskassessments, but the MHSW Regulations also require an assessment ofindividual capability in certain circumstances. Only those known to be fit andstrong enough, and with adequate eyesight, should be allowed to work withoverhead cranes.

The operator of an overhead crane must have a clear view at all times of theobject being lifted and the route to be taken. The most common accidentoccurs when a crane is traversing with a slung load which catches behind astack of glass. As the stack is at an angle of between 3° and 5° from the vertical,it requires comparatively little force to lever it over.

Points to check regularly on the crane itself will be specified by the manufacturer.They will include the control mechanism – this should be of the ‘dead man’type so that release of the control stops movement. Over-travel switches onthe lifting system to prevent over-winding should be present and working, andon tracked cranes there will need to be limit switches to prevent over-run ofthe track ends. The lifting equipment used with the crane must be examinedregularly and tested as required by Regulations. It should be marked clearly foridentification, and with the safe working load.

Consider setting up a permit to work system in the operating area. Potentialproblems include working on electric systems not properly isolated, hazardsfrom equipment not locked off for safety during maintenance, and presence ofbare power supply conductors.

4.2.2 Forklift trucks – These are also available in a number of specialised formswith applications in glass warehousing. The types in most common use arethe counter-balanced truck, reach truck and clamp truck. They may be usedinternally where the headroom is restricted, unloading lorries externally,stacking pallets and cases, and generally where heavy loads require to bemoved and stacked.

Drivers of forklift trucks must be trained properly and certificated as competentoperators. Use of such equipment should be authorised only to those employeeswith certificate proof.

Fork lift truck drivers should be properly trained and certificated for proof of experience.

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Driver training will include the elements of:

• principles of operation• attachments available• purpose and use of controls• practical handling• stability of machine and load• loading and unloading techniques• stacking and stability• operator maintenance and inspection• battery charging safety

In particular applications, it will be necessary to ensure that operators areaware of widths of doorways and access points, presence of slopes andreversing hazards, the availability of banks men when the operator’s viewis obscured or impaired, and centre of gravity of the truck system.

Where trucks are in operation, it will be necessary to designate and markoperating areas by signs or floor markings, allowing a safe passage distance fromany machines, and requiring those working within the operating area to wearhigh-visibility clothing. Any personnel assisting in loading operations must beinstructed specifically not to work or stand below loads.

Where loose loads are to be moved, overhead protective guards should befitted for the protection of the operator.

The most common causes of failure resulting in accidents are: overturning,overloading, collision, floor failure, loss of load, explosions and fire. Passengersmust never be carried unless there are special seats fitted for them.

Ramps and slopes should not exceed 1:10, unless the manufacturer advisesthat use of the truck on steeper gradients under load is within the capabilityof the machine.

Battery charging areas should be separate, well ventilated and lit, with ‘NoSmoking’ and ‘No Naked Lights’ signs displayed. Facilities to lift batteries maybe required.

4.2.3 Ancillary glass handling equipment – there is a large variety of ancillarylifting equipment available for use with either overhead cranes or forklift trucks.

Below is a list of those in most common use.

(i) Wire rope slings – only wire rope slings are recommended for handlingtimber cases and end caps. Frayed wires or damaged slings should bediscarded.

Care should be taken to ensure slings are correctly located on thelocation blocks fitted to the side of the end caps as lifting commences.

(ii) Chains and lifting beams – for handling pallets, cullet bins and metalcontainers. Worn links should be discarded before lifting, check chainsare not twisted and both lifting grapples are properly located in rings orhandles.

(iii) Over the top grabs (tuning fork design) – used for unloading packs ofloose glass up to 1500mm high.

Ensure the grab is centred over the packs and that the weight-bearingbars are properly located in their housings.

(iv) Side loading frames – for handling the packs of glass.

Ensure the frames are centred over the pack and the securing clamps areplaced correctly to hold the glass in place.

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(v) Turn-over grabs or rotating grabs – for unloading glass in landscapingposition turning at 90° and stacking it in the portrait position.

Check that the edges of the glass in the pack are flush before turningotherwise breakage is likely. Ensure the pack is securely clamped inthe grab.

(vi) Vacuum lifting frames – used for handling large individual sheetsof glass by means of rubber pads attached to the glass, to which avacuum is applied.

Make sure the glass to be lifted is dry and that all suction caps are incontact with the glass prior to lifting. The glass being lifted should beparted from any sheet it may be stacked against before moving it away.

It is recommended that a visual check of all pads is carried out daily toinspect for damage and build up of interleavant powder etc. All identifiedfaults must be rectified prior to further lifting operation.

Note: HSE guidance states that vacuum frames, when used in conjunctionwith lifting equipment, are fitted with an audible alarm system to indicateloss of vacuum.

(vii) Lifting beam with metal strap slings – for unloading packs of glass in thelandscape position.

Ensure the pack is in balance prior to lifting.

(viii) Scissor – grip grabs – not suitable for lifting sealed units.Not recommended for lifting more than two plates at a time.

The rubber facings of the grips should be well maintained.

4.3 Lifting equipment

The legislation covering lifting equipment is encapsulated in the Lifting Operations andLifting Equipment Regulations 1998 SI I 1998/2307(LOLER). Equipment sold on as secondhand is classified as ‘new’ and must meet the requirements of all the regulations andthis applies also to hired or leased equipment. It should be noted that equipment onconstruction sites is also covered by these regulations.

It is essential that a person be identified to be responsible for the various aspectsconcerning the safe use of equipment This person is likely to be involved with any riskassessment carried out in connection with equipment and will be therefore aware ofany defined hazards. A list of skill requirements may be compiled which will providethe basis of operator training and assessment for competence towards the accreditationof achievement for National Vocational Qualifications.

4.3.1 Procedure for the use of lifting equipment – No lifting tackle or liftingmachine shall be taken into use unless it has been tested and thoroughlyexamined, and a certificate of the test and examination specifying the safeworking load signed by a qualified and competent person obtained and keptavailable for inspection. Register (Form 88) of all items lifting equipment shallbe kept showing the prescribed particulars of all examinations.

All lifting equipment should have a clear distinguishing mark or number and beclearly marked with the safe working load as indicated on the test certificate.

All chains, ropes and lifting tackle shall be thoroughly examined by a qualifiedand competent person, once in every period of six months. The user, however,has a responsibility to see that lifting tackle is kept in good repair at all times.

All cranes and other lifting machines shall be thoroughly examined by a qualifiedand competent person once in every period of 14 months. It is common practicefor a company’s insurers to arrange all examinations under the regulations.

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4.3.2 Recommendations on safe practices when using mechanical handlingequipment

(i) Only specifically authorised person should be allowed to operate cranesor mechanical lifting gear.

(ii) Personnel must receive full training and instruction by a competentperson in the use of the equipment and be issued with a certificatedemonstrating their competence to operate the equipment eg crane,forklift truck.

(iii) Personnel must be instructed in the use of ancillary lifting equipmentie wire rope slings and chains etc, and be shown how to attach themto the various types of loads.

(iv) As with all handling procedures the personal protective equipmentassessed for the job must be used.

(v) Personnel must not be allowed to stand or pass directly under loadsraised from or lowered to the floor. Wherever practical, loads shouldbe carried approximately 300 – 400mm off the ground.

(vi) Floor areas where glass is being handled should be kept free ofobstructions wherever possible, allowing the operators means of escapeshould an accident occur, eg. broken glass falling from a ‘pack’ when it isbeing transported by grab-load through the warehouse.

5 Unloading suppliers’ vehicles

5.1 General principles

The recipient should ensure that he is fully equipped to handle consignments andshould make arrangements for their safe unloading. The recipient is responsible fordirecting and supervising all unloading operations.

Ensure that the supplier’s driver is met and instructed by a responsible person.Suppliers may give or display written instructions about unloading or safe handlingpractices. These should be heeded and your own people made aware of them.

You should require the delivery driver to remain with his vehicle during the unloadingoperation.

Loads should be inspected for damage to packaging or breakage before unloading beginsand appropriate care and action taken.

5.2 Loose glass

Upon receipt of the load the recipient should read carefully any warning labels affixedto packs of glass and act accordingly. After the driver has un-roped and/or un-sheeted,and before any securing arms/winches have been released, the recipient in conjunctionwith the driver must ensure that the vehicle is standing on a solid floor, that the bed ofthe vehicle is level and that the glass is leaning at a safe angle. Before the release of anyarms, winches or other retaining equipment, the load must be stable for off-loadingglass from the vehicle, either manually or by mechanical means outlined in Section 4.2previously.

Drivers must consult with a responsible person before unloading.

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Where glass is stacked lengthways along the vehicle, eg on cross stillages or tubularstillages, unloading should take place from alternate sides, with arms and pads beingreplaced on the side not being off loaded. In the case of long stillages, ie. with thestacks of glass loaded across the vehicle, only one pad should be removed from a stackwhich is being off-loaded manually.

Where glass is being mechanically off-loaded, restraining arms or pads should not beremoved until the glass is securely held by the lifting equipment.

Once unloading has started, ensure that the safe angle of lean is maintained and thatthe driver does not move the vehicle until he has re-secured the load.

The supplier’s driver is not bound to give any further assistance, but if he does so heshall be deemed to be acting as an employee of the recipient and under the recipient’scontrol.

5.2.1 Loose glass products on enclosed lorries – The driver should remove allsecuring straps and will present the glass to be unloaded. Composite loads maynecessitate the customer giving assistance to the driver in repositioning otherglass in order to release his glass for off-loading. The driver however, will stillbe responsible for the glass until it has been removed from the vehicle.

5.2.2 Outside frails/frames – Glass received on outside frails needs particularcare and close co-operation between driver and recipient. The driver mustensure that the lorry is standing on level ground before removing externalretaining bars or props. Alternatively, it is recommended that the lorry beequipped with wheel ramps to be used when unloading on uneven ground.

5.3 Jumbo-size glass delivered on stillages

Glass delivered in this manner may be unloaded on the stillage by in-house crane orthe stillage may be deposited on the ground outside or inside the warehouse by thedelivery vehicle.

The delivery vehicle must be parked on sound/stable level ground prior to unloading.

The general directions for the stability of vehicles and security of glass given above in5.2 are applicable. If stillages are to be unloaded piece-meal from positions in the openor in loading bays then wind conditions should be taken into consideration before glassis unstrapped. Gusting wind can lift an unstrapped plate from the top of a pack or blowover the last few plates left to be unloaded.

Ensure that the lorry is standing on level ground.

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5.4 End caps

End caps are a form of packing where a block of glass is held together with a metalbanding over fabricated timber box-like end pieces enabling it to be free-standing, withthe glass held clear of the ground. There are special instructions readily available forthe handling of glass in end caps and the supplier should be consulted about them andbe informed of the method of unloading to be adopted. If manual off-loading is to beundertaken then the suppliers must be advised at time of ordering, as they need to putextra equipment on the lorry prior to dispatch.

Mechanical off-loading of glass in end caps may be carried out by one of several ways,ie. over the top grab, small side-loading grab, turn-over grab, and using wire ropeslings. With all these methods certain rules and safety checks should be followed.

(i) Before off-loading begins, ensure that the bed of the vehicle is level. If it is not,then corrective action should be taken by blocking up the wheels of the vehicle,or by propping the last end caps in each block of packs. This should be donebefore any security equipment is removed. If the end caps are loaded cross-shipthen unloading should commence nearest the driver’s cab.

(ii) If possible, clear any broken glass that may be protruding from the bottom edgeof the pack by the safest method available.

(iii) Before slings are attached check that the blocks at the slinging point are securelyfixed.

(iv) On no account should chocking points be used for slinging (see Fig. 7).

(v) The slings should be of appropriate length to maintain the recommended angleat the hook of the lifting point. This angle should be to the recommendationsshown in Fig. 7.

(vi) Only one end cap should be lifted at a time, unless properly banded together withsteel strapping, and only then provided the slings are long enough to maintainthe correct angle.

(vii) When off-loading tall end caps with glass heights at or above 1600mm, supportingbars should be used to prop the remaining caps on the vehicle.

(viii) When storing end caps, double-tiering should not be carried out unless usingspecial slot racks.

(ix) Unless special attachments are used end caps should be considered unsuitablefor fork lifting.

(x) Before attaching any lifting appliance the crane driver should check that each endcap has remained secure within the metal strapping. If the package has beendisturbed and is believed to be insecure then additional strapping or approvalsecuring ties should be applied by the recipient before lifting.

Do not lift end caps unless the metal banding is secure.

✘

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(xi) All overhead crane operations must be carried out at ‘slow’ speed until the packis clear of the lorry.

(xii) Special care should be taken when unloading the last two packs due to possibleloss of load stability. The last pack should be independently supported beforethe penultimate pack has been removed.

(xiii) Operators should stand well clear of the load when it is being removed from thelorry in case any broken sheets should fall out.

(xiv) End cap packs must not be lifted by slings unless the metal banding is still secure.If not secure then a new band or suitable alternative must be applied beforelifting operations commence.

(xv) The personal protective equipment assessed for the unloading operations mustbe worn at all times. Special attention should be paid to wearing gloves and eyeprotection when cutting metal banding.

A Sling point – This position applies to all end cap units, cases, and gusset cases.

B Chocking point – On no account must this be used for lifting.

60° – 75° Acceptable included slinging angle for patterned glass end cap units.

60° – 90° Acceptable included slinging angle for float glass end cap units.

90° – 120° Allowable included slinging angle for special applications – float glass endcap units only.

Above 120° Not recommended.

5.5 Pallets

Unloading of pallets may be carried out by either overhead crane or fork lift truck.When using an overhead crane the ancillary lifting equipment should preferably be alifting beam.

Supplier’s pallets may be fitted with three-slot lifting lugs, in which case the hooksshould be attached to whichever slot allows the pallet to be carried in a level position.When unloading pallets using a fork lift truck, keep the pallets as level as possible withthe back of the pallet facing the fork lift truck as received on the supplier’s vehicle. Thecorrect length and strength of forks should be used. Where the pallets are sent to bean integral part of the lifting equipment then they must conform to the LiftingOperations and Lifting Equipment Regulations 1998.

Fig 7 Correct usage of wire or chain slings when unloading end caps

60°

75°

90°

120°

A

For float glassFor patterned glass

Not recommended

For special applications

B

A

B

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Loaded pallets are normally received not more than two high on the vehicle. However,when returning empty pallets to the supplier they may be loaded three high, but theyshould always be tied together and then roped to the lorry.

5.6 Cases – timber packages

May be handled in a similar manner to pallets, but the ancillary equipment recommendedis wire rope slings. When unloading tall cases from a vehicle ensure the remaining casesare re-secured between lifts. Care should be exercised to ensure slings are applied tothe correct lifting end bits (where fitted) and all other lifting instructions on the caseare followed.

6 Transporting glass

All items below are in addition to any recommendations or codes of practice providedby the Freight Transport Association.

6.1 The various methods of packing glass have been discussed in part 5 and transport ofglass in boxes, pallets, end caps etc. may be by standard open vehicles. The mainconsiderations, provided the glass is packed securely, are that the vehicle is correctlyloaded and the packages properly secured. Mixed loads of glass, however, call forpurpose designed vehicles capable of carrying glass inside and outside which have thefacility for easy loading through the back or sideways on to the frail.

6.2 There are certain requirements for glass carrying vehicles.

(i) The extreme point of projection of an exterior rack must not protrude morethan 400mm beyond the outside edge of the illuminating surface of vehicle’slighting.

(ii) When glass is carried on an outside rack the weight should not cause the vehicleto lean over such that the rack loses its positive backward lean.

(iii) The recommended inclination for glass racks on vehicles is 5°.

(iv) To prevent glass from sliding beyond the end of external racking load stops shouldbe fitted at the end of the rack or horizontal straps should be used.

(v) Outside racks may be permanent fixtures or detachable.

Pallets should be roped and tied together.

Glass should be transported on a suitably designed vehicle.

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6.3 The correct use of glass carrying vehicles includes thefollowing.

(i) The glass, boxed or otherwise, must be adequately secured.

(ii) Loose glass should be interleaved with paper or powder to prevent transit rub.

(iii) When loose glass is carried the largest sizes should be at the rear and thesmallest at the front of a stack.

(iv) Metal parts must be insulated from direct contact with the glass.

(v) Other materials in the vehicle should be secured to prevent them moving anddamaging the glass.

(vi) Before moving a glass carrying vehicle or setting out on a journey the drivermust check the security of the load.

(vii) Personnel must never travel in the same compartment of the vehicle as the glass.

(viii) Before untying a load the driver should check that the glass has a positive leanand as unloading progresses he should check that this lean remains positive onthe loose side.

(ix) Care should be taken that once part of a load has been removed the vehicleremains evenly loaded for continuing deliveries.

6.4 Suppliers have a responsibility under the Health and Safety at Work legislation toinform customers of any potential hazards from the products and to ensure that thelimitations of use for product are identified. Advice should be made available tocustomers who collect glass and provide their own transport. They should be madeaware that their load must be in a safe condition for transporting it on the publichighway.

7 Risk assessment

7.1 The Regulations

Under the Management of Health and Safety at Work Regulations 1999 the employer isrequired to “make a suitable and sufficient assessment of the risks to health and safetyof his employees to which they are exposed while they are at work, and the risks tothe health and safety of persons not in his employment, arising out of or in connectionwith the conduct by him of his undertaking”. The assessments are done “for thepurpose of identifying the measures which the employer needs to take” to complywith the requirements and prohibitions imposed upon him by or under the relevantstatutory provisions. If situations change then the assessment should be reviewed andaltered to suit.

Where more than five people are employed a record should be made of significantfindings of an assessment.

The responsibility for carrying out assessments rests with the employer and with theself employed also.

Customers should handle and stack glass on their vehicles safely.

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7.2 Relevant situations

Working with glass in the presence of the public calls for particular care to be taken.This is a statutory requirement.

(i) Plate glazing in public places requires that the working area should be roped offand walk routes segregated or chaperoned to keep people away from danger, forexample during replacement of shop fronts or working at heights.

(ii) Glass stored temporarily on domestic premises should be covered over and thestorage area protected to prevent access by unauthorised people. The customershould be advised of the associated hazards of glass particularly where childrenare concerned.

(iii) Specific risks such as damage to the eyes, for instance when holes are cut inglass, a shopfront plate is being trimmed for size in situ, a broken window isbeing hacked out or single leaf toughened glass is being carried loose. All thesesituations present the possibility of glass or debris entering the eye and suitableprotection should be available.

8 Personal protective equipment

Typical operations within the glass industry include:

• aciders and strippers• bevellers and edge workers• cutters• crane operators and slingers• fork lift truck operators• drivers• glaziers and window fixers• fabricators of frames and factory glaziers• leaded light makers• sand blasters and sprayers• sealed unit makers, tougheners and laminators.

The following are suggested items for personal protective equipment that should beconsidered while undertaking risk assessment to determine PPE requirements for thespecific tasks above:

• helmet• eye protection• respirator• ear protection• upper arm and shoulder protection• gloves, gauntlets and cuffs• chemical suit• apron• overalls• waterproof clothing• safety footwear

Supplied by

44-48 Borough High StreetLondon SE1 1XBTelephone: 0870 042 4255 Facsimile: 0870 042 4266info@ggf.org.ukwww.ggf.org.uk