Product Overview

Summary: This Air Freight Handling Safe Operating Procedure sets out clear, step-by-step requirements for safely receiving, screening, loading, unloading and storing air cargo in line with Australian WHS and aviation security obligations. It helps your team manage high-risk manual handling, airside vehicle movements, and dangerous goods while protecting workers, freight integrity and your compliance record.

Air freight operations are fast-paced, high-pressure environments where poor handling practices can quickly lead to serious injuries, damaged cargo, and costly regulatory breaches. This Air Freight Handling Safe Operating Procedure provides a structured, WHS-focused framework for every stage of the cargo handling process, from accepting freight at the dock through to aircraft loading, unloading and transfer to landside transport. It clarifies who does what, when, and how, so that staff can work efficiently while controlling hazards such as vehicle and plant interactions, hazardous manual tasks, slips and trips around aircraft, and exposure to dangerous goods.

Developed for Australian conditions, this SOP aligns with WHS legislation, aviation security requirements and relevant Australian Standards to help you demonstrate due diligence and meet your duty of care. It standardises how your team conducts pre-start checks, verifies documentation, manages unit load devices (ULDs), uses mechanical aids, and responds to incidents or spills. By implementing this procedure, freight and ground handling businesses can reduce incident rates, improve turnaround reliability, and provide consistent onboarding and refresher training for new and existing staff across terminals and shifts.

Key Benefits

• Ensure consistent, safe handling of air freight across all shifts and terminals.
• Reduce manual handling injuries through defined lifting limits, mechanical aids and team lifting practices.
• Minimise damage to cargo, aircraft and ground support equipment through controlled loading and securing methods.
• Demonstrate compliance with Australian WHS, aviation security and dangerous goods obligations during audits and investigations.
• Streamline staff induction and refresher training with a clear, step-by-step reference document.

Who is this for?

• Air Freight Operations Managers
• Warehouse and Freight Supervisors
• Ground Handling Supervisors
• Cargo Handlers and Freight Operators
• WHS Managers and Coordinators
• Dangerous Goods (DG) Coordinators
• Logistics and Supply Chain Managers
• Aviation Security Managers
• Training and Compliance Managers

Hazards Addressed

• Hazardous manual tasks leading to musculoskeletal injuries when lifting, pushing or pulling freight and ULDs
• Vehicle and mobile plant interactions between forklifts, tugs, dollies, trucks and pedestrians on the apron and in warehouses
• Struck-by and crush injuries from moving ULDs, pallets, containers and ground support equipment
• Slips, trips and falls around aircraft stands, loading docks, ramps and uneven apron surfaces
• Exposure to and mishandling of dangerous goods, including leaks, spills and incompatible cargo
• Noise exposure from aircraft engines, ground support equipment and busy freight terminals
• Fatigue-related errors due to shift work and time-critical turnaround pressures
• Weather-related risks such as wind, heat, rain and low visibility on the apron
• Security and tampering risks associated with unattended or unsecured cargo
• Pinch points and entanglement in conveyor systems, roller beds and cargo loading systems

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations (including ULDs, DG, airside/landside areas)
• 3.0 Roles and Responsibilities (operators, supervisors, WHS and DG officers)
• 4.0 Applicable Legislation, Standards and Company Policies
• 5.0 Competency, Training and Authorisation Requirements
• 6.0 Required PPE, Tools and Equipment for Air Freight Handling
• 7.0 Pre-Start Checks and Area Preparation (warehouse, apron and equipment)
• 8.0 Freight Acceptance and Documentation Verification Procedures
• 9.0 Screening, Security and Chain-of-Custody Requirements
• 10.0 Dangerous Goods Identification, Segregation and Handling
• 11.0 Manual Handling Controls and Use of Mechanical Aids
• 12.0 Loading and Unloading of ULDs, Pallets and Loose Freight
• 13.0 Aircraft-side Operations and Interface with Ground Support Equipment
• 14.0 Securing Cargo, Weight Distribution and Load Integrity Checks
• 15.0 Vehicle and Mobile Plant Movement Controls (traffic management, spotters, speed limits)
• 16.0 Housekeeping, Storage and Staging of Freight
• 17.0 Incident, Near Miss, Spill and Damage Reporting Procedures
• 18.0 Emergency Response Procedures (injury, fuel spill, DG leak, fire, security breach)
• 19.0 Environmental Considerations (weather, noise, emissions and waste management)
• 20.0 Monitoring, Inspection, Audit and Continuous Improvement
• 21.0 Document Control and Record Keeping

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts and Regulations
• Civil Aviation Safety Regulations (CASR) and Civil Aviation Safety Authority (CASA) guidance for ground operations
• Safe Work Australia – Model Code of Practice: Manual Tasks
• Safe Work Australia – Model Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Model Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• IATA Dangerous Goods Regulations (as adopted in Australian aviation operations)
• AS 4801 / ISO 45001: Occupational health and safety management systems
• AS 2359 series: Powered industrial trucks – Safety
• AS/NZS 1269 series: Occupational noise management
• Aviation Transport Security Act 2004 and Aviation Transport Security Regulations 2005