Facade Silicone / Sealant Application (Heights) SWMS

Facade silicone and sealant application at height involves applying structural and weather-seal silicones to curtain wall systems, glazing perimeters, and panel joints — typically from swing stages, boatswain chairs, mast climbers, or elevating work platforms above two metres. The work combines fall-from-height exposure, isocyanate and solvent chemical exposure from neutral-cure and structural silicones, and manual handling of sausage packs and bulk drums at elevation. Under WHS Regulation 2011 r291, any work performed where a person could fall more than two metres is classified as High Risk Construction Work (HRCW), and structural silicone weatherproofing on facades almost always meets this threshold. A documented Safe Work Method Statement is mandatory before work commences, must be prepared in consultation with workers performing the task, and must be available at the workplace for the duration of the high-risk activity. This SWMS template addresses curtain wall sealing, perimeter weather seals, and structural silicone glazing in a single editable document.

Hazards identified

7 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Elimination — Eliminate ladder use entirely by specifying mast climbers or BMU cradles for all facade sealant runs above 2 metres at design stage.
2. 2Elimination — Pre-apply structural silicone in factory-controlled glazing fabrication where curtain wall design permits, removing on-site at-height chemical exposure.
3. 3Substitution — Substitute solvent-based primers with low-VOC water-based alternatives where adhesion specifications and manufacturer data sheets permit substitution.
4. 4Substitution — Use one-part neutral-cure silicone over acetoxy systems to reduce acetic acid vapour irritation in confined reveal zones.
5. 5Engineering — Install perimeter edge protection, kick boards, and tool lanyards on all swing stages and EWP baskets per AS/NZS 1576.
6. 6Engineering — Provide forced local exhaust ventilation in enclosed atrium and lift-shaft facade sections to maintain solvent vapour below WES limits.
7. 7Administrative — Conduct daily pre-start SWMS sign-on, wind-speed check against cradle rating, and verify dogman exclusion zone below work area.
8. 8Administrative — Rotate caulkers every 90 minutes to limit repetitive trigger actuation and schedule chemical work outside peak UV and thermal load periods.
9. 9PPE — Issue full-body harness with twin shock-absorbing lanyards rated to AS/NZS 1891.1, attached to engineered anchor or static line.
10. 10PPE — Provide nitrile chemical gloves, P2 organic vapour respirators fit-tested annually, wrap-around safety glasses, and long-sleeve barrier clothing per SDS.

Applicable Codes of Practice

High-Risk Construction Work triggered

Worked example

On a 14-storey commercial refurbishment, a facade caulking crew is scheduled to apply structural silicone to a north-elevation curtain wall replacement panel from a twin-point swing stage at level 11. At the 6:30am pre-start brief, the leading hand opens this SWMS on a site tablet and walks the two-person crew through each hazard line by line. The dogman confirms the ground-level exclusion zone is barricaded and signed, addressing the dropped-object hazard. The crew checks the day's forecast against the swing stage wind rating — 38 km/h gust forecast versus a 45 km/h cradle limit — and the leading hand notes a stop-work trigger at 40 km/h on the SWMS. Each caulker signs the SWMS sign-on register, confirming P2 respirator fit-test currency and harness inspection tag dates. Mid-morning, the wind picks up and a worker notices vapour pooling in an enclosed reveal where the cradle sits tight against a return wall. They pause, refer back to the SWMS engineering control requiring forced ventilation in enclosed zones, and rig a portable extraction fan before resuming. At smoko, the leading hand records the control adjustment in the SWMS variation log so the change is captured for the next shift and available if a regulator inspects the document on site.

Related legislation

• WHS Act 2011 (model)
• WHS Regulation 2025
• Managing the Risk of Falls at Workplaces CoP

Frequently asked questions