Structural bracket made up on site with poor welding
A support bracket for a glass balustrade installed more than 18 metres above ground level appeared to have been fabricated or modified on site and did not match the approved design. The welded connection showed poor workmanship, an irregular weld profile and significant heat discolouration, with no visible evidence of controlled fabrication or inspection. Failure of this safety-critical bracket could compromise the balustrade, creating a risk of a person falling from height or glass and metal components falling onto areas below. The affected area should be isolated and the bracket urgently assessed by the responsible structural engineer.
- NCQLE reference
- NCQLE-2026-00011
- Quality topic
- Installation quality
- Lesson type
- Failure
- Evidence rating
- Experience
- Published
- 31 July 2026
- Last reviewed
- 31 July 2026
Evidence basis: Supported by relevant professional experience. This learning is provided for professional consideration and does not replace project-specific competent advice, statutory duties or contractual requirements.
Context
During an inspection of a glass balustrade installed more than 18 metres above ground level, the structural support brackets and their connections were reviewed before completion and handover. The inspection focused on whether the brackets matched the approved design and provided a verified load path capable of resisting the specified barrier loads. A site-fabricated bracket with visibly poor welding was identified at a safety-critical balustrade connection. A site-fabricated structural bracket was observed supporting a glass balustrade more than 18 metres above ground level. The bracket arrangement did not appear to match the approved design, and the welded connection showed an irregular profile, poor finishing and significant heat discolouration. No evidence was available at the time of inspection to confirm an approved design change, welding procedure, welder qualification or completed weld inspection.
The transferable lesson
Safety-critical balustrade brackets must not be fabricated, modified or welded on site without an approved design, verified calculations and a controlled welding procedure. Every bracket must match the approved detail and provide a fully traceable load path back to the structure. Any deviation must be reviewed by the responsible structural engineer and inspected before the balustrade is installed or brought into service.
Recommended action
Stop installation and establish an exclusion zone below the affected balustrade. Survey all brackets and compare them with the approved drawings, calculations and material specification. Remove and replace any site-made or modified bracket unless the responsible structural engineer provides a documented assessment and approved remedial detail. Require material certificates, an approved welding procedure, qualified welders, recorded weld inspection and any specified non-destructive or load testing before the glass is installed or the barrier is brought into service. The project should confirm compliance with: BS 6180:2011 for barriers in and about buildings. BS EN 1090-2:2018+A1:2024 for execution of structural steelwork. BS EN ISO 15614-1:2017+A1:2019 for welding-procedure qualification. BS EN ISO 9606-1:2017 for welder qualification. BS EN ISO 5817:2023 for weld-imperfection acceptance criteria.
Limitations and application
he required bracket capacity, weld quality level and testing regime depend on the balustrade height, occupancy, design loads, glass configuration, bracket material, supporting structure and specified execution class. A photograph alone cannot confirm weld penetration, material grade or structural capacity. Final acceptance, repair or replacement must be determined by the responsible structural engineer and competent welding inspector against the project-specific approved design and applicable standards.