Vacuum Lifter Glass and Panel Lifting — Safe Work Method Statement
Safe Work Method Statement for lifting and installing glass, facade panels and sheet materials with a vacuum lifting device attached to a crane, mini crane or glazing robot, covering capacity checks, pad attachment, vacuum loss, wind and installation at the slab edge.
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Vacuum lifters let glaziers and facade installers lift and place large glass units, stone-look panels, cladding and sheet materials without slings. The lifter hangs from a crane, mini crane, telehandler or glazing robot and holds the panel by suction. The work is usually high-risk construction work (HRCW): installers often work at open slab edges or from EWPs more than 2 metres above the ground, and the crane or robot is powered mobile plant working among other trades. A SWMS is required before work starts.
The defining hazard is loss of vacuum. A panel held only by suction can drop without warning if a pad is placed over a dirty, wet, textured or curved surface, if a seal is damaged, or if the battery or pump fails. Good vacuum lifters have a vacuum gauge, an audible and visual low-vacuum warning, and a reserve tank or circuit that holds the load for long enough to land it. Workers must never be under a vacuum-held load. Glass is heavy for its size, about 25 kg per square metre for each 10 mm of thickness, so even mid-sized units can exceed a lifter's rating. It also acts like a sail, so wind limits are lower than the crane's.
The crane or mini crane operator needs the high-risk work licence for that crane type, and any slinging or directing of the lift out of the operator's view needs a licensed dogman. Vacuum lifter operators must be trained on the specific device, including its warning system and emergency procedures. EWP operators need the licence that matches the machine. Check your state or territory regulator for local licensing requirements.
The SWMS must address the combined weight of the panel and lifter against the crane's chart, pad layout and rated capacity, surface preparation, the low-vacuum response, wind limits, the path from the stillage to the opening, and how installers at the edge are protected from falling.
Customise this template with the panel types, sizes and weights, the vacuum lifter make, model and rated capacity (and capacity when tilting), the crane or robot used, the wind limit, the edge protection or restraint arrangement at each opening, the exclusion zone below, and the licensed operators and dogman.
Personal Protective Equipment
High Risk Construction Work Types
- •Risk of a person falling more than 2 metres
- •Work in an area with movement of powered mobile plant
Risk Assessment
1.Lift planning and capacity check
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Panel and lifter combined exceeding the lifter or crane capacity | Catastrophic | Calculate each panel's weight from its size and make-up (glass is about 25 kg per square metre per 10 mm of thickness). Check that the panel weight is within the vacuum lifter's rated capacity for the orientation and tilt being used, and that the panel plus lifter is within the crane's load chart at the maximum radius. Record weights in the lift plan. | Low | Supervisor / Crane Operator |
| Wind catching the panel during the lift | High | Set a wind stop limit in the SWMS for the panel sizes being lifted, lower than the crane's own limit. Monitor wind at the lift height with an anemometer and stop if gusts reach the limit. Use tag lines on every crane lift. | Moderate | Supervisor / Crane Operator |
2.Pre-use inspection of the vacuum lifter
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Vacuum loss from a damaged pad, leak or flat battery | Catastrophic | Before each shift, inspect pads and seals for cuts, hardening or distortion. Check the hoses, fittings, battery charge, vacuum gauge and the audible and visual low-vacuum alarm. Do a vacuum hold test on a clean test surface as the manufacturer describes. Check that the WLL label is legible and the periodic inspection is current. Tag out and report any fault. | Low | Vacuum Lifter Operator |
3.Attaching the lifter to the panel
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Pads losing grip on dirty, wet, coated or textured surfaces | High | Clean and dry the pad area on each panel. Check that the surface is suitable for vacuum lifting under the manufacturer's guidance, especially for textured, coated, film-protected or curved panels. Place pads in the layout the manufacturer specifies for the panel size, centred on the panel's centre of gravity. Wait for full vacuum on the gauge before lifting. | Low | Vacuum Lifter Operator |
| Glass breaking or cutting workers while removing it from the stillage | High | Secure the stillage and the remaining panels before releasing restraints. Use the lifter to draw panels out of the stillage rather than handling them manually. Wear cut-resistant gloves and sleeves. Inspect glass edges for chips before lifting and do not lift damaged panels. | Low | Glaziers |
4.Lifting and travelling the panel
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Panel dropping onto people below after vacuum loss | Catastrophic | Raise 100 to 200 mm and hold for at least one minute while watching the gauge before continuing. Barricade the area under the lift path and keep everyone out. Never travel a vacuum-held load over people. If the low-vacuum alarm sounds, lower and land the panel immediately in the nearest safe area. | Low | Crane Operator / Dogman |
| Panel striking the structure or scaffold | High | Plan a clear path from the stillage to the opening. Use tag lines held from a safe position. A licensed dogman directs the lift by radio where the operator cannot see the load. | Moderate | Dogman |
5.Installing the panel at the opening
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Installer falling from the slab edge or opening while receiving the panel | Catastrophic | Keep edge protection in place up to the moment the panel is offered in, and remove only the section needed. Installers working within 2 m of the open edge wear a harness on a restraint line set so they cannot reach the edge. Reinstate edge protection if the panel cannot be installed straight away. Never lean out to grab the panel. | Moderate | Glaziers / Supervisor |
| Hands crushed between the panel and the frame | Moderate | Guide the panel with suction handles, not fingers on the edges. Lower slowly into the frame under the installer's direction. Keep hands clear of the bottom edge and setting blocks. | Low | Glaziers / Vacuum Lifter Operator |
6.Releasing the lifter and pack-up
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Releasing the vacuum before the panel is restrained | High | Release the vacuum only when the panel is fully seated, packed and restrained by glazing clips, beads or temporary restraints as the installation method requires. Raise the lifter clear before moving. At the end of the shift, charge the battery and store the lifter with the pads covered. | Low | Glaziers / Vacuum Lifter Operator |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.