Curtain Walling RAMS: Risk Assessments for Unitised Facade Systems

Table of Contents

• Curtain Walling RAMS: Why They Are Complex
• Unitised vs Stick Systems: Different RAMS Requirements
• Key Hazards in Curtain Walling Installation
• Facade Access for Curtain Walling Projects
• Structural Silicone and COSHH Controls
• What Your Curtain Walling RAMS Must Cover
• Frequently Asked Questions
• Next Steps

Curtain Walling RAMS: Why They Are Complex

Curtain walling — the non-load-bearing external envelope system used on most modern commercial buildings — presents unique risk management challenges. Installation involves working at considerable heights on a facade that is, by definition, not yet complete. Unitised panels may weigh hundreds of kilograms. Structural silicone application requires careful COSHH controls. And the sequencing of installation must be carefully managed to ensure the building structure remains stable throughout.

Under CDM 2015, curtain walling contractors must produce Risk Assessments and Method Statements (RAMS) covering every stage of the installation process. For buildings over 18 metres, the Building Safety Act 2022 adds further requirements. This guide explains what a compliant curtain walling RAMS looks like in 2026.

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Unitised vs Stick Systems: Different RAMS Requirements

The installation methodology for curtain walling depends fundamentally on whether the system is unitised or stick-built. Your RAMS must reflect the specific system being installed.

Unitised systems — Pre-assembled floor-to-ceiling units are craned into position and connected to cast-in anchors. Key RAMS considerations include:

• Unit weights and crane lift planning in accordance with BS 7121 and LOLER
• Vacuum lifting equipment where glass-faced units are too fragile for conventional rigging
• Temporary support and restraint during installation before units are permanently fixed
• Sequence control to maintain structural frame integrity during installation

Stick systems — Mullions and transoms are installed first, followed by glass infill panels. Key RAMS considerations include:

• Temporary stability of the frame during installation before glazing is inserted
• Glass panel handling: weight, fragility, and vacuum cup lifting
• Structural silicone application: COSHH controls, mixing, curing time
• Sequential installation to prevent the frame from being overstressed by asymmetric loading

Key Hazards in Curtain Walling Installation

Your risk assessment must identify all significant hazards. For curtain walling, these typically include:

• Working at height — Operatives are routinely working at the perimeter of the building on incomplete floor levels or from suspended access equipment. Fall prevention and arrest systems must be specified under the Work at Height Regulations 2005 hierarchy.
• Dropped objects — Glass fragments, tools, fixings, and structural components falling from height create serious risk to workers below. Exclusion zones and overhead protection must be established.
• Glass breakage — Large glass units can shatter explosively if dropped, impacted, or thermally shocked. Safe handling procedures, appropriate PPE (cut-resistant gloves, face shields), and safe storage must be specified.
• Manual handling of heavy panels — Even with mechanical assistance, operatives must guide units into position. Manual handling assessments must consider weight, grip, posture, and duration.
• Crane lift risks — Curtain walling unit crane lifts are complex lifting operations requiring qualified Appointed Person planning and CPCS-certified crane operators.
• COSHH substances — Structural silicone, sealants, frame coatings, and cleaning agents may contain isocyanates, solvents, or skin sensitisers.
• Wind loading — Partially installed facades act as large wind sails. Wind speed limits must be specified for each installation activity.

Facade Access for Curtain Walling Projects

The choice of facade access system significantly affects the risk profile of a curtain walling project. Common approaches include:

• Mast-climbing work platforms (MCWPs) — Widely used on medium to high commercial buildings. Provide large working decks at height. Your RAMS must cover erection, dismantling, and daily use including wind speed limits and emergency procedures.
• Suspended access equipment (SAE) — Building maintenance units, motorised cradles, or IRATA rope access. Your RAMS must confirm equipment inspection records, operator certification, and rescue procedures.
• MEWPs — Suitable for lower levels and access to individual units for adjustment and sealing. IPAF-certified operators required.
• Scaffolding — Where the project programme and budget allow, scaffolding provides the most stable working platform. Cross-reference the scaffolding contractor's RAMS.

Regardless of access method, your RAMS must include a rescue plan for operatives who become stranded at height and confirm that a trained rescue team is available on site at all times when work is taking place at height.

Structural Silicone and COSHH Controls

Structural silicone is used to bond glass into frames in SSG (structural silicone glazing) systems and to provide weather sealing in all curtain wall systems. Structural silicone application requires careful COSHH controls:

• Two-component silicones — When mixing component A (base) with component B (curing agent), operatives are exposed to the uncured product, which may contain tin catalysts and isocyanates. COSHH assessments must be in place for specific products.
• Surface preparation solvents — Frame surfaces must be cleaned before silicone application using solvent-based cleaners. These require adequate ventilation and appropriate PPE.
• Primer systems — Adhesion primers for structural silicone may contain flammable solvents. Storage, application, and fire prevention controls must be specified.
• Mixing and dispensing — Two-component silicones must be mixed in the correct ratio (typically 1:1 by volume). Incorrect mixing ratios result in inadequate curing and structural failure. Your method statement must specify mixing procedure, ratio verification, and butterfly test requirements.

COSHH assessments for all silicone products must be available on site before work begins. Product safety data sheets should be obtained from the manufacturer and reviewed by a competent person.

What Your Curtain Walling RAMS Must Cover

A compliant curtain walling RAMS should include:

• System description: unitised or stick, manufacturer, system reference
• Installation sequence: detailed step-by-step method
• Facade access plan with equipment type, risk controls, and rescue plan
• Lifting plan reference for all crane lifts (BS 7121, LOLER)
• Glass handling procedure: type, weight, vacuum equipment, storage
• Structural silicone application procedure: mixing, verification, curing
• COSHH schedule: sealants, solvents, primers
• Working at height controls: fall prevention hierarchy, anchor point specification
• Wind speed limits for each installation activity
• Dropped object controls: exclusion zones, tool lanyards, overhead protection
• Fire compliance: material certificates for glazing infill panels
• PPE schedule
• Emergency arrangements

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Frequently Asked Questions

Q: What access method should our RAMS specify for curtain walling?
A: This depends on the building height and configuration. For most tall commercial buildings, mast-climbing work platforms provide the best combination of access coverage and stability. On buildings where MCWPs cannot be used due to site constraints, suspended access equipment or IRATA rope access may be appropriate. Your RAMS should justify the access method chosen and provide full risk controls specific to that method.

Q: Do curtain walling RAMS need to address the Building Safety Act?
A: For HRBs (over 18 metres, residential), yes. Your RAMS should reference the approved facade specification, include fire compliance confirmations, and specify documentation requirements for the Golden Thread. For commercial buildings, CDM 2015 applies as normal.

Q: How should we handle structural silicone COSHH in the RAMS?
A: Your RAMS should list all silicone and sealant products used and confirm that individual COSHH assessments have been prepared for each hazardous product. The COSHH assessment should specify RPE requirements, skin protection, ventilation, and emergency procedures for skin or eye contact.

Next Steps

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