Windscreen Replacement SWMS
Automotive windscreen removal and replacement — isocyanate urethane adhesive handling, cold-knife and wire-cut removal, ADAS sensor recalibration, mobile-onsite fitment hazards.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Windscreen replacement involves removal of bonded automotive glass using cold-knife or wire-cut methods, followed by primer application and bonding with single-component polyurethane (isocyanate) urethane adhesive, plus ADAS camera/sensor recalibration. This SWMS addresses workshop and mobile-onsite fitment under the WHS Act 2011 (model), WHS Regulation 2025 Chapter 7 (Hazardous Chemicals) and Chapter 4 Part 4.5 (Plant), and is required where isocyanate exposure, manual glass handling, and laceration risks meet the threshold for documented risk control.
Hazards identified
8 hazards covered, sorted by priority.
Occupational asthma, respiratory sensitisation and dermatitis from inhalation or skin contact with uncured MDI adhesive.
Headaches, CNS depression and flammable vapour ignition during primer application in poorly ventilated areas.
Deep cuts to hands, forearms and eyes during urethane bead cut-out and glass removal.
Whip-back injuries to face, eyes and hands when fibre or braided wire fails during removal.
Musculoskeletal strain to back, shoulders and wrists from awkward lifting of heavy laminated screens.
Post-fitment vehicle safety system failure causing collision risk to driver and road users.
Struck-by vehicles or slips/trips when fitting kerbside or in customer driveways without exclusion zones.
Premature release results in screen detachment in collision, failing FMVSS 212 retention requirements.
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Apply urethane adhesive and MEK primer in ventilated area; use organic vapour P2 respirator (AS/NZS 1716) when LEV unavailable.
- 2Wear cut-resistant gloves (EN 388 Level 5), wrap-around safety glasses (AS/NZS 1337) and nitrile gloves under cut-gloves for chemical barrier.
- 3Use two-person lift or vacuum suction cups for windscreens >15 kg; maintain neutral spine and stable footing.
- 4Conduct ADAS static/dynamic recalibration per OEM procedure using calibrated targets; document results before vehicle release.
- 5Establish 2 m exclusion zone with cones/signage for mobile fitments; park on level ground and chock wheels.
- 6Verify Safe Drive-Away Time (SDAT) from adhesive SDS and brief customer in writing before release.
- 7Maintain SDS register and conduct health monitoring for isocyanate-exposed workers per WHS Reg Schedule 14.
Applicable Codes of Practice
Governs isocyanate adhesive and MEK primer storage, labelling, SDS access and exposure standard compliance during glass bonding.
Applies to windscreen lifting, awkward postures during cut-out and repetitive primer/adhesive bead application tasks.
Sets product performance and application standards for urethane adhesives used in automotive windscreen bonding.
High-Risk Construction Work triggered
Daily handling of MDI-based polyurethane urethane adhesive and MEK glass primer — both Schedule 14 hazardous chemicals requiring controlled exposure.
HRCW classification under WHS Reg s291 mandates a written SWMS before work starts; failure attracts penalties up to $30,000 (individual PCBU).
Who this is for
- →Automotive glass fitters and apprentice windscreen technicians
- →Mobile windscreen replacement businesses and sole-trader installers
- →Smash repair workshop managers supervising glass replacement
What you receive
- ✓Editable DOCX SWMS pre-filled for windscreen replacement
- ✓State-specific WHS legislation schedule (all states/territories)
- ✓Hazard register covering isocyanate, glass and ADAS risks
- ✓Worker sign-on register for SWMS consultation evidence
Worked example
A mobile fitter replaces a Toyota HiLux windscreen in a customer driveway. Before starting, they cone off a 2 m zone, don P2 respirator and cut-resistant gloves, and use a vacuum lifter for two-person glass removal. After wire cut-out, MEK primer is applied with the door open for ventilation, urethane bead laid, and the new screen set. ADAS forward camera is recalibrated dynamically, and the customer is given written 1-hour SDAT instructions before driving.
Related legislation
- Work Health and Safety Act 2011 (model)
- Work Health and Safety Regulation 2025 — Chapter 7 Hazardous Chemicals
- WHS Regulation 2025 — Chapter 4 Part 4.5 Plant
- WHS Regulation 2025 Schedule 14 — Health monitoring (isocyanates)
- Safe Work Australia Workplace Exposure Standards for Airborne Contaminants