OHS in Glass Cutting and Handling Work

Glass handling safety rests on two risks: cuts and toppling

Injuries to workers in flat glass workshops, glass balcony and window frame manufacturing, or facade installation on construction sites mostly come from two directions. The first is cuts: a sheet with an unground edge, a piece slipping during snapping, or glass cracking while being carried is not easily escaped. The second is toppling: a stack of sheets sliding off a rack or crate both crushes and cuts the person standing in front of it. Glass handling safety therefore does not end with choosing gloves; you need to know the sheet's weight, choose the right handling device and set up the storage arrangement.

This article focuses on flat glass cutting, handling and installation work. For the general rules of glass installation at height, see our article on work at height.

Calculate the weight first: how many kilos is the sheet?

The density of glass is about 2.5 g/cm³. In practical terms: each 1 mm of thickness weighs about 2.5 kg per square metre. Without knowing the sheet's weight, you cannot decide how many people or which device should carry it.

Thickness	Weight per m²	2.0 × 1.5 m sheet (3 m²)	Suitable handling method (example)
4 mm	~10 kg	~30 kg	Two people, with hand suction cups
6 mm	~15 kg	~45 kg	Two people, with hand suction cups
8 mm	~20 kg	~60 kg	Two or three people, or a glass trolley
10 mm	~25 kg	~75 kg	Vacuum lifter or mechanical aid
4+4 laminated	~20 kg	~60 kg	Two or three people, or a mechanical aid

The last column is not a legal table but a planning example. The Regulation on Manual Handling requires mechanical aids to be used first to avoid manual handling and, where it cannot be avoided, the risk to be assessed. A glass sheet is both heavy and hard to grip; its large surface catches the wind and blocks the carrier's view. To calculate the load per person, you can use the method in our article on the NIOSH lifting equation.

Glass cutting injuries: at the table, snapping and edge grinding

On the cutting table, glass is first scored with a cutting wheel and then snapped along the line. Injuries mostly occur at the moment of snapping and when the cut piece is taken off the table.

Snapping: Glass-breaking pliers are used to snap along the score line; narrow strips are not snapped by hand. The place where the snapped piece will fall is cleared in advance.
Edges: The edges of pieces to be carried are ground where possible, or at least the sharp tip is broken off. An unground edge is where the hand holding the sheet is most often injured.
Broken glass: Broken pieces accumulating on the table and floor are not picked up by hand; a brush, dustpan and lidded broken glass bin are used. The broken glass bin is emptied before it is full.
Eyes: Safety glasses with side protection are worn against splinters during snapping and edge grinding. For selection, see our article on safety glasses and face shields.
Floor: Cutting oil and grinding water make the floor slippery. A person carrying glass slipping is one of the scenarios that leads to the most serious cuts.

On automatic cutting tables, the moving bridge and breaking bars also pose a crushing risk. Check that guards and the emergency stop button work and that energy is isolated and locked out during fault interventions; for general principles, read our article on machine guards.

Suction cup glass handling: hand suction cups and vacuum lifters

Hand suction cups are the basic tool for handling flat glass, but when used incorrectly they release the sheet at the worst moment. Before use, check:

Is the rubber surface clean, uncracked and flexible? Rubber that hardens in the cold grips less well.
Is the glass surface dry and free of oil? Cutting oil and dust weaken the grip.
On pump-action suction cups, if the indicator line is visible, the vacuum is dropping; the cup is pressed again or replaced.
Does the lifting capacity on the label cover the weight of the sheet? No load above the capacity is attached.
The suction cup is placed on a sound area of the sheet, away from edges and corners prone to breaking.

Vacuum lifters are fitted to a crane, overhead crane or forklift to move large sheets. Annex III of the Regulation on Health and Safety Requirements for the Use of Work Equipment lists vacuum lifters among "lifting accessories and carriers": unless the standard sets a shorter interval, periodic inspection is carried out once a year, based on the criteria of TS EN 13155. The inspection is carried out by an authorised person registered on EKİPNET (the Ministry's register of authorised inspectors). In daily use, the vacuum gauge, low vacuum alarm, reserve vacuum volume or battery status, and seals are checked. Nobody stands under suspended glass. You can find the intervals in our article on work equipment periodic inspection intervals.

When carrying by hand, the sheet is held upright with the bottom edge close to the ground; the carriers walk on either side of the glass and the person in front calls out the route. Doorways and corners are cleared in advance.

Glass racks, crates and the risk of toppling

Flat glass is stored upright, at a slight angle, on A-frame or L-frame racks and in crates. The rules that prevent toppling are simple but must be applied every day:

Balance: Both faces of an A-frame glass rack are loaded evenly; one side is not emptied completely while the other is left full.
Securing: Sheets are tied to the rack with a strap or securing arm. When undoing the strap, make sure the sheets are being held; the stack can slide forward the moment the strap loosens.
Capacity and floor: The rack's load capacity is written on it and must not be exceeded. The rack is placed on level, solid ground; on wheeled racks, the brakes are locked.
One-sheet rule: One sheet at a time is taken from the stack. Nobody goes between sheets or stands between the stack and a wall.
Unloading from vehicles: When unloading from a lorry, load security is checked first; when the rack is moved by forklift, the sheets are secured separately.

Glass in installation and on site

In facade, balustrade and window frame installation, glass is carried both at height and in an area exposed to wind. Large sheets behave like sails in the wind; installation with a vacuum lifter is stopped in strong wind, and for the criteria you can see our article on cranes and work at height in strong wind. The area below the facade being installed is closed off with barriers; a falling piece of glass can injure workers and pedestrians below. If the sheet is fitted from a platform, the rules for scissor lifts and boom lifts are followed. When tempered glass breaks it shatters into small pieces, but the whole sheet disintegrates at once; during installation, eyes and face are protected against this possibility. For general measures on construction sites, see our construction sector page.

Cut-resistant arm guards and other PPE

Gloves protect the hand, but a breaking sheet often strikes the wrist and forearm. In flat glass work, gloves should therefore be used together with cut-resistant arm guards.

Gloves and arm guards: Marked according to TS EN 388. Cut resistance is shown by a letter from A to F under the ISO 13997 test; upper levels are chosen for flat glass handling. The grip surface must not be slippery and must fit the hand. For details, see our article on choosing work gloves.
Apron: A cut-resistant apron is used for workers who carry large sheets resting against the body.
Footwear: Safety shoes with toe protection and puncture-resistant soles are worn.
Glasses and hard hat: Mandatory equipment for snapping, edge grinding and on-site installation.

PPE selection and issue are linked to the risk assessment within the framework of the Regulation on the Use of PPE. The first response to a deep cut is direct pressure; make sure your first aiders can apply it, and read our article on first aid for amputations and crush injuries.

Checklist for a glass workshop

Is a weight table posted for the sheet sizes and thicknesses used in the workshop?
Is it written down above which weight a mechanical aid will be used?
Are hand suction cups checked at the start of every shift?
Is the vacuum lifter's annual periodic inspection report up to date?
Are racks evenly loaded and secured?
Are broken glass bins lidded and sufficient in number?
Is the floor in the cutting area dry and clean?
Do workers have cut-resistant gloves, arm guards and safety glasses?
Has the "do not catch falling glass" rule been taught practically to new starters?

We go through this list together during site tours and enter any gaps in the risk assessment. For the scope of the service, see our OHS specialist services page, and to track periodic inspection dates, our OHS calendar tool. In glass and window frame workshops in Bursa and neighbouring provinces, we plan these checks around the business's production arrangements.

Frequently Asked Questions

Which gloves should be used when carrying glass?

Choose gloves with high cut resistance under TS EN 388 and good grip, and always use them together with cut-resistant arm guards. Gloves alone do not protect the wrist and forearm.

Is periodic inspection of a vacuum glass lifter mandatory?

Yes. Annex III of the Work Equipment Regulation lists vacuum lifters among lifting accessories; unless the standard sets a shorter interval, they are inspected at least once a year by an authorised person registered on EKİPNET.

How should a glass rack be loaded?

Both faces of an A-frame rack are loaded evenly, sheets are secured with straps and the rack is placed on level ground. One sheet at a time is taken from the stack, and before undoing the strap, check that the sheets are being held.

How many people should carry a glass sheet?

This depends on the sheet's weight and size. Each 1 mm of thickness weighs about 2.5 kg per square metre; calculate the weight, assess the carrying route, and use a vacuum lifter or glass trolley for heavy sheets.