Product Overview

Summary: This Aluminium Handling Safe Operating Procedure sets out clear, practical steps for safely receiving, storing, moving and working with aluminium in Australian workplaces. It helps control key risks such as cuts, crush injuries, manual handling strains and exposure to fumes or dust, while supporting compliance with WHS duties and consistent, efficient operations.

Aluminium is widely used across Australian construction, manufacturing, transport and fabrication industries due to its strength-to-weight ratio and corrosion resistance. However, handling aluminium sheet, plate, extrusion and offcuts presents a range of WHS risks, including sharp edges, unstable loads, manual handling strains and potential exposure to fumes or dust generated during cutting, grinding or welding. This Aluminium Handling Safe Operating Procedure provides a structured, easy-to-follow method for managing these risks from delivery through to storage, handling, processing and waste disposal.

Developed for Australian workplaces, this SOP supports PCBU obligations under WHS legislation by formalising how aluminium is moved, stacked, secured and handled using appropriate lifting gear, trolleys, racking and personal protective equipment. It helps supervisors and workers adopt consistent safe practices, reduce damage to stock and plant, and minimise the likelihood of injuries, near misses and costly downtime. The document is ready to integrate into your existing WHS management system, toolbox talks and induction processes, giving your teams clear, defensible guidance on how aluminium is to be handled every time.

Key Benefits

• Reduce the risk of lacerations, crush injuries and musculoskeletal disorders when handling aluminium products.
• Ensure consistent, documented handling practices across shifts, sites and contractors.
• Support compliance with Australian WHS legislation and relevant standards for manual tasks and hazardous manual handling.
• Minimise product damage, rework and material wastage through correct storage, stacking and lifting techniques.
• Improve onboarding and refresher training with a clear, step-by-step reference for workers and supervisors.

Who is this for?

• Fabrication Workshop Supervisors
• Production Managers
• Warehouse and Storepersons
• Sheet Metal Workers
• Boilermakers and Fabricators
• WHS Managers and Advisors
• Construction Site Supervisors
• Manufacturing Operations Managers
• Maintenance Supervisors
• Logistics and Dispatch Coordinators

Hazards Addressed

• Manual handling injuries from lifting, carrying or repositioning aluminium sheets, plates and extrusions
• Lacerations and puncture wounds from sharp edges and burrs on aluminium stock and offcuts
• Crush injuries from unstable stacks, falling loads or incorrect use of lifting equipment
• Slips, trips and falls due to poorly stored materials, offcuts and swarf on floors and accessways
• Eye injuries from flying particles during cutting, grinding or deburring of aluminium
• Respiratory irritation from aluminium dust and fumes generated during machining or thermal processes
• Noise exposure from cutting, grinding and material handling operations
• Pinch and entanglement hazards associated with cranes, forklifts, conveyors and material handling equipment

Included Sections

• 1.0 Purpose and Scope
• 2.0 References and Applicable Legislation
• 3.0 Definitions (Aluminium Forms, Loads, Handling Equipment)
• 4.0 Roles and Responsibilities
• 5.0 Required Training and Competency
• 6.0 Required PPE and Safety Equipment
• 7.0 Pre-Start Checks and Work Area Preparation
• 8.0 Receiving and Unloading Aluminium Deliveries
• 9.0 Safe Storage, Stacking and Racking of Aluminium
• 10.0 Manual Handling of Aluminium Sheets, Plates and Extrusions
• 11.0 Mechanical Handling Using Cranes, Forklifts and Lifting Aids
• 12.0 Handling During Cutting, Drilling, Grinding and Fabrication
• 13.0 Housekeeping, Offcut Management and Waste Disposal
• 14.0 Hazard Identification and Risk Control Measures
• 15.0 Emergency Procedures and Incident Response
• 16.0 Inspection, Maintenance and Tag-Out of Handling Equipment
• 17.0 Training, Induction and Toolbox Talk Guidance
• 18.0 Document Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace (where aluminium dust or fumes are present)
• AS/NZS 4801:2001 Occupational health and safety management systems (superseded but still commonly referenced)
• AS/NZS ISO 45001:2018 Occupational health and safety management systems – Requirements with guidance for use
• AS 1891 series: Industrial fall-arrest systems and devices (where work at height is involved in aluminium storage/handling)
• AS 2359 series: Powered industrial trucks (for forklift use in aluminium handling)
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 1337.1: Personal eye protection