Case Study:Emergency 5-Storey Glass Balustrade Replacement and Metal Works

We received an emergency call to remove and replace a large glass balustrade on a five-storey high balcony at residential apartments in Deptford, Southeast London.   

Discover how our highly experienced technicians removed and replaced the glass using rope access, elevated work platforms and a truck-mounted hoist to save our client a considerable amount of money.

The Logistics

The property management company and pre-existing client, Rendall & Rittner, hired us for an emergency balustrade glass replacement. We have done similar work for them on their other properties so they knew we could repair this quickly for them.

As standard practice, we visited the property to conduct a pre-site assessment, where we found the following issues:

• The largest glass pane on the balcony was shattered and required replacing, along with metalwork on the handrail and trimming.
• The balcony was five storeys up on the building and required rope access.
• The property sits on the corner of a busy public road where cars would drive fast beneath.

With our pre-site visit complete and our glass balustrade replacement strategy established, we got to work on establishing the access methods to gain safe and controlled access to the balcony.

The Project

The type of glass broken on the balcony required a custom-made replacement shipped from central Europe. Before we could remove and replace the glass, we had to gain safe access to the balcony, which we managed with an elevated work platform and rope access. This method of access did not only allow us to attend to the balcony quickly but also enabled our client to make significant savings otherwise spent on scaffolding. 

Traditionally, balustrade glass is two panes pressed together with a layer of film to prevent pieces from falling onto the balconies or street below. After gaining access, the next vital stage guaranteed we could remove the glass without letting a single piece fall. Our spectrum technicians carefully removed the glass before guiding it down to the ground level with the support of the MEWP. Once removed and guided safely down to ground level, they ensured the balcony was safe to use and placed the glass in a temporary plyboard timber ready for transportation.

With the glass removed safely, we sent it to a specialist manufacturer to remake the balustrade. The glass needed specific measurements that required precise cutting from the manufacturer alongside laser-cut holes for the eventual fixings. Due to the specialism required to remake the glass, sometimes this process can take up to two weeks to finish. When the glass was ready, we delivered it back to the site and prepared it for installation. Because of the weight, the most effective way to move the 200kg glass pane was by applying battery-powered suction cups. A powered hoist from a truck-mounted cherry picker (MEWP) elevated the pane with a team of two crew members and two abseilers who assisted from above via rope access.

The fixings at the bottom of the balcony were covered by an aluminium trim alongside the top of the glass held in by the handrail. We ensured we provided replacement trims and a new handrail to completely renew and secure the integrity and aesthetic of the balcony.

The Site

Casting House, in Deptford, London, is an affluent residential property, home to multiple apartments in the borough of Lewisham.

The building is located on a corner of a busy road. So, we had to consider residents and neighbouring properties during the project.

When using the mobile elevating work platform (MEWP) for the glass removal and replacement, we had to ensure that cars coming around the corner would not disturb the work, especially with a 200kg glass pane lifted and installed five storeys high above a public road.

Therefore, the complexity of the project and scale of the property meant there was a high degree of danger which we had to calculate.

Challenges

The first challenge was the manual handling of the removal and replacement of the glass pane. Not only did the glass pane weigh 200kg, but it also needed handling from five storeys high. To ensure no mistakes, we planned thoroughly and used specialist equipment like battery-powered suction cups to secure the glass during transportation.

We also had to control the traffic speed from each street corner. Any accident upon the MEWP when in operation would risk life-threatening consequences. And during the pre-site assessment, we did notice the speed that some cars were travelling on the road was excessive.

To increase the health and safety of the project, we introduced precautions on the street with a crew member asking traffic to slow down as it came around the corner, alongside placing additional signage to warn traffic that work was in progress.

In using a 32m truck-mounted hoist to assist us in replacing and removing the glass, there was no need to close any public areas. We positioned the MEWP on private grounds included in the development while checking they were the appropriate height and weight.

The Result

In three to four weeks, we managed to remove the broken glass, measure the replacement, and make the balcony safe before delivering the new glass balustrade pane and installing it, with a fortnight required for the glass manufacturer to provide the balustrade replacement.

Alongside replacing the glass panel and restoring the fixtures, we reestablished a safety barrier on the balcony without any unobstructed views.

Here is a quick overview of our glass balustrade replacement service from start to finish:

• An extensive pre-site assessment provided a strategy for the glass replacement and metal works.
• We established rope access on the roof and used a MEWP to support the glass removal.
• Precautions on the ground level ensured the work was not disturbed from below without closing any public areas.
• We measured the glass before removing and delivering it to the manufacturer.
• We picked up the new glass pane from the manufacturer and delivered it to the sight.
• Hiring a 32-meter truck-mounted hoist and battery-powered suction cups helped us lift the glass into place for installation.
• Technicians installed the glass and replaced the aluminium trimming on the bottom and above, along with the handrail.

What was a highly complex and potentially dangerous project worked smoothly, thanks to the experience and skills of our rope access technicians.

So, if you require any rope access repair or restoration services, get in touch today to receive a free quote. 

Elijah Howell,  Head of Operations

Managing the on-site execution of Spectrum's services, Elijah handles the day to day operations of Spectrum's teams. He has supported maintenance teams within the rope industry for over ten years.