Product Overview

Summary: This SOP sets out clear, practical requirements for the safe selection, use, inspection and storage of chains and straps used for lifting, securing and load restraint. It helps Australian businesses control the risk of equipment failure, dropped loads and transport incidents, while demonstrating due diligence under WHS and road transport laws.

Chains and straps are critical items of load‑bearing and load‑restraint equipment, yet they are often misused, overloaded or left in service long after they should have been removed. This Chain and Strap Usage and Inspection Safe Operating Procedure provides a clear, step‑by‑step framework for how workers must select, inspect, use and store chains, webbing straps, ratchet assemblies and associated fittings. It is written specifically for Australian workplaces and aligns with WHS legislation and recognised load restraint and lifting standards.

By implementing this SOP, organisations can significantly reduce the risk of equipment failure, falling or shifting loads, vehicle rollovers and serious crush injuries. The document clearly defines responsibilities, inspection criteria, tagging and rejection rules, and practical control measures such as working load limit (WLL) compliance, angle factors, protection from sharp edges and correct tensioning methods. It also supports consistent training across sites, helping supervisors and PCBU duty holders demonstrate that they have implemented a systematic approach to plant and equipment safety, as required under Australian WHS law and the Heavy Vehicle National Law.

Key Benefits

• Reduce the risk of dropped loads, shifting cargo and transport incidents caused by chain or strap failure.
• Ensure chains, straps and associated hardware are inspected, tagged and removed from service in line with Australian standards and manufacturer guidance.
• Standardise how workers select the correct chain or strap for the task, including WLL, angle, length and environmental considerations.
• Demonstrate compliance with WHS obligations and load restraint requirements under Australian legislation and industry codes.
• Improve worker competence and confidence through a clear, easy‑to‑train procedure for safe usage, inspection and storage.

Who is this for?

• Site Supervisors
• Workshop Supervisors
• Transport and Logistics Managers
• Truck Drivers and Load Restraint Operators
• Forklift Operators
• Dogmen and Riggers
• Warehouse and Storepersons
• Maintenance Coordinators
• WHS Managers and Safety Advisors
• Construction Project Managers

Hazards Addressed

• Failure of chains, straps, hooks or ratchet mechanisms under load
• Dropped or shifting loads during lifting, loading, unloading and transport
• Vehicle instability and rollovers due to inadequate load restraint
• Crush injuries and struck‑by incidents during tensioning, release or failure of restraints
• Hand and finger injuries from pinch points, recoil or snap‑back of chains and straps
• Musculoskeletal injuries from incorrect manual handling of heavy chains and equipment
• Damage to loads and plant from incorrect use, routing or protection of chains and straps
• Environmental degradation of equipment (corrosion, UV damage, chemical attack) leading to hidden weakness

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (Chains, Webbing Straps, WLL, SWL, Tagging, etc.)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Guidance Material
• 5.0 Equipment Types and Approved Uses (Chains, Webbing Straps, Ratchets, Hooks and Fittings)
• 6.0 Pre‑Use Inspection Requirements and Rejection Criteria
• 7.0 Formal Inspection Intervals, Tagging and Record‑Keeping
• 8.0 Selection of Chains and Straps (WLL, Load Type, Angles and Environmental Conditions)
• 9.0 Safe Usage Procedure – Lifting Applications (if applicable)
• 10.0 Safe Usage Procedure – Load Restraint and Transport
• 11.0 Tensioning, Re‑tensioning and Safe Release of Chains and Straps
• 12.0 Protection from Sharp Edges, Abrasion and Environmental Damage
• 13.0 Manual Handling and Storage of Chains, Straps and Hardware
• 14.0 Hazard Identification, Risk Controls and PPE Requirements
• 15.0 Out‑of‑Service, Quarantine and Disposal of Defective Equipment
• 16.0 Emergency Response and Incident Reporting (Equipment Failure or Load Shift)
• 17.0 Training, Induction and Competency Assessment
• 18.0 Document Review, Audit and Continuous Improvement

Legislation & References

• Heavy Vehicle National Law (HVNL) and associated Load Restraint requirements
• National Transport Commission – Load Restraint Guide (latest edition)
• Model Work Health and Safety Act and Regulations (as implemented in each state and territory)
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• AS/NZS 4380: Cargo restraint systems – Transport webbing and components
• AS/NZS 4344: Cargo restraint systems – Transport chains and components
• AS 3775: Chain slings for lifting purposes (where chains are used for lifting)
• AS 4991: Lifting devices (where applicable to associated lifting hardware)