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Safety Protocol 001: Cold Glass Cutting and Assembly Hazards

Protocol ID: U12M2-SAFE-001

Potential Hazards

1. Laceration from Sharp Glass Edges and Fragments

Severity: High - Freshly scored and broken glass edges are razor-sharp - Tiny glass slivers are nearly invisible on work surfaces and skin - Cuts are typically deep, clean incisions that bleed heavily - Glass fragments can embed in skin without immediate sensation

2. Silica Dust from Grinding

Severity: High (chronic, cumulative) - Dry grinding produces respirable silica particles - No acute symptoms — damage accumulates over years - Chronic exposure causes silicosis (irreversible lung fibrosis) - Even brief dry grinding produces hazardous dust levels

3. Lead Exposure from Solder and Came

Severity: High (cumulative) - 60/40 solder contains 40% lead - Lead came is nearly pure lead - Exposure routes: skin contact, ingestion (hand-to-mouth), inhalation of fumes during soldering - Lead is neurotoxic and bioaccumulative — no safe threshold for chronic exposure

4. Thermal Burns from Soldering Iron

Severity: Medium - Soldering irons operate at 700-800°F (370-425°C) - Contact burns are instant and deep - Solder splatter can cause point burns to skin and eyes - Iron tips remain hot for several minutes after power-off

5. Chemical Irritation from Flux

Severity: Low to Medium - Oleic acid flux causes skin irritation with prolonged contact - Flux fumes irritate eyes and respiratory tract during soldering - Accidental eye contact causes significant irritation

Required Precautions

Glass Handling

  1. Wear safety glasses at ALL times when cutting, breaking, or handling glass
  2. Use cut-resistant gloves when handling large sheets or broken pieces
  3. Never wipe glass fragments from surfaces with bare hands — use whisk broom and dustpan
  4. Dispose of all glass fragments in dedicated glass waste container (rigid-walled, labeled)
  5. Keep work surface clean — sweep regularly during cutting sessions
  6. Carry glass sheets vertically, gripped at the edges, never flat overhead

Grinding

  1. Wet grinding only — never grind glass dry under any circumstances
  2. Maintain water level in grinder reservoir at all times
  3. Stop grinding immediately if water runs low
  4. If emergency dry grinding is unavoidable: P100 respirator mandatory, HEPA-filtered dust collection required
  5. Clean grinder and work area with wet methods (damp cloth), not dry sweeping

Lead Safety

  1. Wash hands thoroughly with soap and water after handling solder or lead came
  2. Never eat, drink, or touch face during soldering or came work
  3. Use fume extractor or work in well-ventilated area during soldering
  4. Wear nitrile gloves when handling lead came for extended periods
  5. Store food and beverages outside the glass work area
  6. Change clothing after extended lead came sessions before going home

Soldering

  1. Keep soldering iron in stand when not actively in use
  2. Never leave a heated iron unattended
  3. Ensure iron cord is secured and will not be tripped over or pulled
  4. Clean iron tip on wet sponge, not dry cloth
  5. Allow soldered pieces to cool before handling — solder remains hot for 30+ seconds after application

Emergency Response

Glass Cut

  1. Apply direct pressure with clean cloth or gauze
  2. If bleeding is heavy or does not stop within 5 minutes, seek medical attention
  3. If glass fragment is embedded, do NOT remove it — stabilize and seek medical attention
  4. Clean minor cuts thoroughly — glass fragments may remain in wound
  5. Report all cuts to instructor, no matter how minor

Thermal Burn from Soldering Iron

  1. Remove from heat source immediately
  2. Run cool water over burn for 10 minutes
  3. Do not apply ice, butter, or ointments
  4. Cover with clean, non-adhesive dressing
  5. Seek medical attention for burns larger than 1 inch or on face/hands

Flux in Eyes

  1. Flush eyes immediately with clean water for 15 minutes
  2. Use eyewash station if available
  3. Do not rub eyes
  4. Seek medical attention if irritation persists

PPE Requirements

Hazard PPE Specification When Required
Glass cuts Safety glasses ANSI Z87.1 rated All cutting, breaking, grinding, and handling
Glass cuts Cut-resistant gloves ANSI A4+ rating Handling large sheets, broken pieces
Silica dust Water (wet grinding) Maintained at contact point All grinding operations
Lead exposure Nitrile gloves Disposable, powder-free Extended soldering and came work
Solder fumes Fume extractor or ventilation Activated carbon or HEPA filter All soldering operations
Thermal burns Heat awareness Soldering iron in stand protocol All soldering operations

Last Updated: 2026-03-19