Code

of Practice

Glass Handling,
Storage and Transport
This Code of Practice is issued by the Glass and
Glazing Federation for guidance, but without
responsibility for any advice given or not given or
for the consequences of acting in reliance on the
advice. All liability on the part of the Glass and
Glazing Federation arising in connection with this
document is hereby expressly disclaimed.

44-48 Borough High Street

London SE1 1XB
Telephone: 0870 042 4255
Facsimile: 0870 042 4266
info@ggf.org.uk
www.ggf.org.uk
Glass Handling, Storage and Transport
Code 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 storage
3.2.1 Wall racks
3.2.2 End caps
3.2.3 Toast type or bin racks
3.2.4 Glass supporting frames
3.2.5 Large racks for float, wired etc.
3.2.6 Double tier racking
3.2.7 Pallets
3.3 Storage of glass on sites

4 Handling of glass
4.1 Manual handling
4.1.1 Straps or slings
4.1.2 Webbing lifts
4.1.3 Suction pads
4.1.4 Warehouse trucks
4.1.5 Glass carriers
4.2 Mechanical handling
4.2.1 Electric overhead cranes
4.2.2 Forklift trucks
4.2.3 Ancillary glass handling equipment
4.3 Legislation – lifting equipment
4.3.1 Procedures for the use of lifting equipment
4.3.2 Recommendations on safe practices using mechanical handling
equipment.

5 Unloading suppliers’ vehicles

5.1 General principles
5.2 Loose glass
5.2.1 Loose glass products on enclosed lorries
5.2.2 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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 Glass Handling,
Storage and Transport

Code of Practice

1 Introduction

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

It addresses the general duties placed upon the employer by the Health & Safety at Work
Act l974 and the more specific requirements of other relevant Acts and regulations
Adherence to this Code may be seen to demonstrate competence in meeting proper
safety standards.

2 Legislation

2.1 Introduction
The Health and Safety at Work Act l974 and the Management of Health and Safety at
Work 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 their
own solutions to health and safety problems, as far as is reasonably practicable. The
Act incorporates duties of a general nature, which are directed at employers, employees,
contractors, the self-employed, manufacturers, designers, and importers of work
equipment and materials. It contains provisions for the health and safety of people
at 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 certain
atmospheric emissions.

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

The Management of Health and Safety at Work Regulations 1999

The Manual Handling Operations Regulations 1992
The Health and Safety (Display Screen Equipment) Regulations 1992
The 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 1992
The Workplace (Health, Safety and Welfare) Regulations 1992

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 These regulations imposed upon employers duties of ensuring that:

1) Competent persons are appointed and clearly identified as having the

responsibilities 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 measures
being taken to reduce the risks to a minimum

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

5) The organisation monitors and evaluates the measures put in place to provide a
safe 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), are
continually modernising the structure of Health and Safety law. Their aims are to
protect the health, safety and welfare of employees, and to safeguard others,
principally the public, who may be exposed to risks for industrial activity. The Health
and Safety Executive has the ability to enforce the Act and Regulations through the
HSE Inspectors and the local authority environmental health departments. Both have
considerable powers of access and may prohibit activities or cause improvements to
be made.

Factory inspectors have considerable powers!

3 Storage of glass

3.1 General principles

Glass is generally stored in dry conditions, on its edge. Whether storage is on the
short 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 and
breakage, and can be implemented by cladding all supporting structures with
timber, felt, rubber or plastic material. Care should be taken to ensure that all
nails and screws are counter-sunk below the surface likely to come in contact
with the glass.

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 (ii) The angle of inclination or lean of the glass should be 3° from the vertical on
static racks. For transportable racks, pallets and stillages, an angle of 5° – 6° is
recommended. If the angle is increased above 6°, it will tend to put extra load
on 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 surface
area. The support should ideally cover either the total length or the total width
of the glass. It can take the form of flat bearers at least 50mm in width, which
may be spaced to suit the size of the sheet being stored.

Inadequate or uneven supporting bearers will cause the back sheets of a stack
to break when the weight of sheets in a full pack is applied. Examples of types
of 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 its
weight loading in a downward or vertical direction. It is therefore essential that
the flooring be of adequate strength to support the weight of the stack, and if
possible the base of the rack should aim to spread the weight over the largest
possible floor area, ie. a distributed floor loading is preferable to a concentrated
loading, 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 type
of rack selected obviously depends on the size of the glass to be held, the volume or
number of sheets to be stacked, and the method of handling to and from the particular
rack, 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 and
they should be examined periodically.

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

✓ ✘
Right! Wrong!
Fig. 1

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

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 End cap storage should be only one high wherever practicable. In exceptional
circumstances two tier stacking may be permitted providing the end caps are
banded. The stacking should be in a pyramid formation with each layer of the
same height and the end caps secured on to the other with a linking rail or
banding. If an end cap is to be removed it should be disengaged and the
remainder made secure to each other before it is lifted out. Since end caps
may only be removed from the top row when stored in this manner, the packs
should be identical to avoid double handling.

When packing glass into end caps the glass should be leant on to a pair of
steads at 3° – 5°. The end caps should then be applied. Packing material is
needed around the glass within the end caps to prevent sideways movement
of the glass and to ensure it is upright within the end caps. Metal banding is
tensioned around the end caps to secure them on to the glass. The slinging
blocks 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 glass
should be placed on steads set at 3° – 5° lean. Eye protection and gloves
should be worn by the person cutting the banding and no one should be near
enough to be struck by a strap whipping when cut.

✘ Single pack

✓ ✓
Single pack
Two packs

Fig. 2 Storage of narrow width end caps

3.2.3 Toast or bin racks – This form of rack is used a great deal throughout the
trade, 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 rack
and each end must be firmly secured to the floor and/or ceiling.

Fig. 3 Toast type or bin racks

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

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

(ii) Only single sheets should be turned over so as to stop a sudden

redistribution of weight at any time. This will avoid excessive stress being
placed upon the vertical supports of the racks.

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

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

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

3.2.4 Glass supporting frames (plank and pin racks) – These are free standing
racks and may be of the single or double side design (See Fig. 4). Their
manufacture is based on jig-welded frames of 50mm x 25mm rectangular
hollow sections bolted to lengths of 150mm x 100mm floor timbers using
152mm x 76mm x 6mm thick metal plates bolted on the under surface.
The support for the glass in approximately 75mm x 50mm timber bolted or
clipped to the rectangular hollow sections. (The material dimensions are the
recommended minimum). These racks are used in pairs aligned and suitably
spaced to the required width of glass. The length of the timber base may be
adjusted to suit the volume of glass to be held. A standard design double-sided
rack has a 2032mm long base and is capable of holding 6 packs of 3 or 4mm
with spacers. The height of the rack can be varied to hold glass up to 2440mm
in length.

Fig. 4 Glass supporting frames

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 front
of each rack to avoid the danger of an operator tripping over any exposed
timber bases when carrying glass.

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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 from
cast iron, fabricated angle iron, tubular/rectangular section or timber. The basic
design where glass is to be stored on both sides of the rack is to space the
uprights at approximately 900mm centres, and secure them with a number
of metal tie rods. The length of rows will depend on the size of glass to be
carried. All metal faces likely to come in contact with glass should be clad with
timber and/or felt.

Fig. 5 ‘A’ frame racks

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

3.2.7 Pallets – Pallets may be used as a means of storage as well as a means of

transporting glass. They may vary in design according to the size of glass to
be held, but are usually fabricated of tubular or square hollow steel, with a
suitable felt or rubber lining. They are designed to stack one upon another, the
height of stack being governed by the construction and strength of each pallet,
and the available floor loading. Methods of handling pallets are described under
Section 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 safety
and health requirements than other glass workers. He is subject to the full range
of hazards when working with glass plus the range of hazards presented by the site
location, weather and particular conditions for movement and storage. A risk assessment
must be carried out to ascertain where the glass is actually going to be stored and to
check the following points.

(i) Is the glass at ground level? If not, are the floor loadings of the building or
platform 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 to
erect the racking? What means of handling are available to unload glass from the
lorry to the racking area? Is it of sufficient capacity?

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

Are freak wind conditions likely to be encountered?

(vi) Is the area where the glass is to be stored secure and safe from accidental
damage by other contractors on site? Will it present a hazard to anyone not
associated directly with this work?

(vii) Can dry storage conditions be provided?

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

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

4 Handling of glass

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

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 people
required. The distance to be covered in the move and the method also play a part in
the decision. Probably the most common handling movements are selecting from
stock, carrying, laying glass on the bench and cutting and placing the cut glass in the
rack ready for dispatch. Whether the activity requires one or any number of people
the 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 seating
in place

Working on sites

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

The following criteria, over and above the normal storage conditions for glass as noted
in 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 safe
loading capacity.

(iv) Suitable racking arrangements are made so that the glass is safely positioned and
cannot 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 should
be 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 smooth
to 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 be

investigated 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 handles
at each end. They are used for handling large sizes of glass, with the slings
passed under the bottom edge of the glass so that operators can share the
weight 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 wide
woven webbing. Used as slings when glazing shopfront plates. The flatness of
the webbing allows it to be withdrawn from beneath the plate supported on
its setting blocks.

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

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

4.1.5 Glass carriers – (see Fig. 6) Glass carriers for moving single large plates can
be 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 a
set of hand suction pads.

Fig 6 Glass carrier

4.2 Mechanical handling

There is available today a very wide range of cranes, conveyors and powered mobile
trucks which could be used as mechanical handling equipment in a modern glass
warehouse. This section of the Code of Practice briefly describes the more common
types of mechanical equipment and lays down some guidelines as to safe working
practices.

4.2.1 Electrical overhead travelling cranes – One of the best and most versatile
pieces of equipment, it may form an integral part of the building or may be
constructed within an existing building providing sufficient headroom is available.
Care should be taken in design before installing a crane to ensure that all
dimensional allowances are made to establish correct lifting clearance to
accommodate the various items of ancillary glass handling appliances. It may
be used for a variety of handling operations, from carrying individual plates to
moving whole blocks of glass on and off vehicles and within the confines of the
warehouse. It may be operated by a suspended control pendant, or from cab
controls which move with the crane itself. The capacity of the crane depends
on the heaviest load to be lifted, but users should satisfy their own requirements
or needs. Manufacturers state that a 3 tonne capacity crane should be adequate
for 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 kept
and cranes must therefore be identifiable by marking or otherwise, and the
safe working load must be prominently visible. Obviously, this must never be
exceeded except under direct test and under controlled conditions.

10
 A recognised competent person must supply operator training, as even pendent
control cranes can be dangerous. This is because the method of attaching the
load to the crane requires knowledge, and because the capacity of the crane
must not be exceeded. Records of this training should be reviewed with the
Health and Safety arrangements at least annually. Selection of operators may
be required if there is a high physical content to the work. This will be covered
by the Manual Handling Operations Regulations 1992 and the associated risk
assessments, but the MHSW Regulations also require an assessment of
individual capability in certain circumstances. Only those known to be fit and
strong enough, and with adequate eyesight, should be allowed to work with
overhead cranes.

The operator of an overhead crane must have a clear view at all times of the
object being lifted and the route to be taken. The most common accident
occurs when a crane is traversing with a slung load which catches behind a
stack 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 on
the lifting system to prevent over-winding should be present and working, and
on tracked cranes there will need to be limit switches to prevent over-run of
the track ends. The lifting equipment used with the crane must be examined
regularly and tested as required by Regulations. It should be marked clearly for
identification, and with the safe working load.

Consider setting up a permit to work system in the operating area. Potential

problems include working on electric systems not properly isolated, hazards
from equipment not locked off for safety during maintenance, and presence of
bare power supply conductors.

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

Drivers of forklift trucks must be trained properly and certificated as competent

operators. Use of such equipment should be authorised only to those employees
with 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 are

aware of widths of doorways and access points, presence of slopes and
reversing hazards, the availability of banks men when the operator’s view
is obscured or impaired, and centre of gravity of the truck system.

Where trucks are in operation, it will be necessary to designate and mark

operating areas by signs or floor markings, allowing a safe passage distance from
any machines, and requiring those working within the operating area to wear
high-visibility clothing. Any personnel assisting in loading operations must be
instructed specifically not to work or stand below loads.

Where loose loads are to be moved, overhead protective guards should be

fitted 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. Passengers
must never be carried unless there are special seats fitted for them.

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

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

4.2.3 Ancillary glass handling equipment – there is a large variety of ancillary

lifting 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 handling
timber cases and end caps. Frayed wires or damaged slings should be
discarded.

Care should be taken to ensure slings are correctly located on the

location blocks fitted to the side of the end caps as lifting commences.

(ii) Chains and lifting beams – for handling pallets, cullet bins and metal
containers. Worn links should be discarded before lifting, check chains
are not twisted and both lifting grapples are properly located in rings or
handles.

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

Ensure the grab is centred over the packs and that the weight-bearing
bars 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 are
placed correctly to hold the glass in place.

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

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

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

Make sure the glass to be lifted is dry and that all suction caps are in
contact with the glass prior to lifting. The glass being lifted should be
parted 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 to

inspect for damage and build up of interleavant powder etc. All identified
faults must be rectified prior to further lifting operation.

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

(vii) Lifting beam with metal strap slings – for unloading packs of glass in the
landscape 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 and
Lifting Equipment Regulations 1998 SI I 1998/2307(LOLER). Equipment sold on as second
hand is classified as ‘new’ and must meet the requirements of all the regulations and
this applies also to hired or leased equipment. It should be noted that equipment on
construction sites is also covered by these regulations.

It is essential that a person be identified to be responsible for the various aspects

concerning the safe use of equipment This person is likely to be involved with any risk
assessment carried out in connection with equipment and will be therefore aware of
any defined hazards. A list of skill requirements may be compiled which will provide
the basis of operator training and assessment for competence towards the accreditation
of achievement for National Vocational Qualifications.

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

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

All chains, ropes and lifting tackle shall be thoroughly examined by a qualified
and 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 qualified
and competent person once in every period of 14 months. It is common practice
for 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 handling
equipment

(i) Only specifically authorised person should be allowed to operate cranes

or mechanical lifting gear.

(ii) Personnel must receive full training and instruction by a competent

person in the use of the equipment and be issued with a certificate
demonstrating their competence to operate the equipment eg crane,
forklift truck.

(iii) Personnel must be instructed in the use of ancillary lifting equipment

ie wire rope slings and chains etc, and be shown how to attach them
to the various types of loads.

(iv) As with all handling procedures the personal protective equipment

assessed for the job must be used.

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

(vi) Floor areas where glass is being handled should be kept free of
obstructions wherever possible, allowing the operators means of escape
should an accident occur, eg. broken glass falling from a ‘pack’ when it is
being 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 and
should make arrangements for their safe unloading. The recipient is responsible for
directing and supervising all unloading operations.

Drivers must consult with a responsible person before unloading.

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 handling
practices. 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 unloading
operation.

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

5.2 Loose glass

Upon receipt of the load the recipient should read carefully any warning labels affixed
to 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 conjunction
with the driver must ensure that the vehicle is standing on a solid floor, that the bed of
the vehicle is level and that the glass is leaning at a safe angle. Before the release of any
arms, winches or other retaining equipment, the load must be stable for off-loading
glass from the vehicle, either manually or by mechanical means outlined in Section 4.2
previously.
14
 Where glass is stacked lengthways along the vehicle, eg on cross stillages or tubular
stillages, unloading should take place from alternate sides, with arms and pads being
replaced on the side not being off loaded. In the case of long stillages, ie. with the
stacks of glass loaded across the vehicle, only one pad should be removed from a stack
which is being off-loaded manually.

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

Once unloading has started, ensure that the safe angle of lean is maintained and that
the 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 he
shall be deemed to be acting as an employee of the recipient and under the recipient’s
control.

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

5.2.2 Outside frails/frames – Glass received on outside frails needs particular

care and close co-operation between driver and recipient. The driver must
ensure that the lorry is standing on level ground before removing external
retaining bars or props. Alternatively, it is recommended that the lorry be
equipped with wheel ramps to be used when unloading on uneven ground.

Ensure that the lorry is standing on level ground.

5.3 Jumbo-size glass delivered on stillages

Glass delivered in this manner may be unloaded on the stillage by in-house crane or
the stillage may be deposited on the ground outside or inside the warehouse by the
delivery 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 in
5.2 are applicable. If stillages are to be unloaded piece-meal from positions in the open
or in loading bays then wind conditions should be taken into consideration before glass
is unstrapped. Gusting wind can lift an unstrapped plate from the top of a pack or blow
over the last few plates left to be unloaded.

15
5.4 End caps
End caps are a form of packing where a block of glass is held together with a metal
banding over fabricated timber box-like end pieces enabling it to be free-standing, with
the glass held clear of the ground. There are special instructions readily available for
the handling of glass in end caps and the supplier should be consulted about them and
be informed of the method of unloading to be adopted. If manual off-loading is to be
undertaken then the suppliers must be advised at time of ordering, as they need to put
extra 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 rope
slings. 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 done
before any security equipment is removed. If the end caps are loaded cross-ship
then unloading should commence nearest the driver’s cab.

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

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

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

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

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

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

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

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

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

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

16
 (xi) All overhead crane operations must be carried out at ‘slow’ speed until the pack
is clear of the lorry.

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

(xiii) Operators should stand well clear of the load when it is being removed from the
lorry 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 before
lifting operations commence.

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

60° For patterned glass

For float glass

75°

90°
For special applications

120°
Not recommended

A A

B B

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

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 end
cap 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 a
lifting beam.

Supplier’s pallets may be fitted with three-slot lifting lugs, in which case the hooks
should 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 with
the back of the pallet facing the fork lift truck as received on the supplier’s vehicle. The
correct length and strength of forks should be used. Where the pallets are sent to be
an integral part of the lifting equipment then they must conform to the Lifting
Operations and Lifting Equipment Regulations 1998.

17
 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 they
should always be tied together and then roped to the lorry.

Pallets should be roped and tied together.

5.6 Cases – timber packages

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

6 Transporting glass

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

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

Glass should
be transported
on a suitably
designed vehicle.

6.2 There are certain requirements for glass carrying vehicles.

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

(ii) When glass is carried on an outside rack the weight should not cause the vehicle
to 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 should
be fitted at the end of the rack or horizontal straps should be used.

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

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6.3 The correct use of glass carrying vehicles includes the
following.
(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 the
smallest 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 and
damaging the glass.

(vi) Before moving a glass carrying vehicle or setting out on a journey the driver
must 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 lean
and as unloading progresses he should check that this lean remains positive on
the loose side.

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

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

Customers should handle and stack glass on their vehicles safely.

7 Risk assessment

7.1 The Regulations

Under the Management of Health and Safety at Work Regulations 1999 the employer is
required to “make a suitable and sufficient assessment of the risks to health and safety
of his employees to which they are exposed while they are at work, and the risks to
the health and safety of persons not in his employment, arising out of or in connection
with the conduct by him of his undertaking”. The assessments are done “for the
purpose of identifying the measures which the employer needs to take” to comply
with the requirements and prohibitions imposed upon him by or under the relevant
statutory provisions. If situations change then the assessment should be reviewed and
altered to suit.

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

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

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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 off
and walk routes segregated or chaperoned to keep people away from danger, for
example during replacement of shop fronts or working at heights.

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

(iii) Specific risks such as damage to the eyes, for instance when holes are cut in
glass, a shopfront plate is being trimmed for size in situ, a broken window is
being hacked out or single leaf toughened glass is being carried loose. All these
situations present the possibility of glass or debris entering the eye and suitable
protection 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 be
considered while undertaking risk assessment to determine PPE requirements for the
specific 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

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Supplied by
44-48 Borough High Street
London SE1 1XB
Telephone: 0870 042 4255
Facsimile: 0870 042 4266
info@ggf.org.uk
www.ggf.org.uk