Product Overview

Summary: This Composite Materials Handling Safe Operating Procedure provides clear, practical guidance for safely receiving, storing, cutting, shaping and disposing of composite materials in Australian workplaces. It helps control hazards such as airborne fibres, resins, dust, manual handling risks and chemical exposure while supporting compliance with WHS obligations and environmental requirements.

Composite materials such as fibreglass, carbon fibre and advanced resins are now common across Australian manufacturing, construction, marine, automotive and aerospace sectors. While they offer high strength-to-weight performance, they also introduce specific health and safety risks including airborne fibres, hazardous dusts, volatile organic compounds (VOCs), skin and respiratory sensitisation, and complex waste disposal requirements. This Composite Materials Handling SOP sets out a structured, step-by-step method for managing these materials safely from delivery through to final disposal.

The procedure provides clear expectations for supervisors and workers on how to assess hazards, select appropriate PPE, set up local exhaust ventilation, handle pre-preg and cured composites, manage cutting and sanding operations, and segregate and label waste. It supports businesses to demonstrate due diligence under Australian WHS legislation by documenting consistent, defensible work practices. By implementing this SOP, organisations can reduce the risk of acute injuries and long-term health effects, minimise cross-contamination in workshops, and protect equipment and finished products from damage caused by poor handling practices.

Designed specifically for the Australian regulatory environment, this SOP also helps align your operations with relevant standards and industry best practice. It is suitable for both small workshops and large production facilities seeking to standardise training, improve housekeeping, and ensure safe, efficient handling of composite materials across shifts and sites.

Key Benefits

• Reduce worker exposure to composite fibres, dusts and resin vapours through clearly defined control measures.
• Ensure consistent, legally defensible handling practices that support compliance with Australian WHS legislation and relevant standards.
• Minimise manual handling injuries and product damage by standardising lifting, storage and transport of composite materials.
• Improve workshop cleanliness and air quality with structured controls for cutting, sanding, lay-up and clean-up activities.
• Streamline induction and refresher training for workers who handle composite materials across multiple work areas.

Who is this for?

• WHS Managers
• Production Managers
• Workshop Supervisors
• Composite Technicians
• Fabricators and Laminators
• Maintenance Supervisors
• Engineering Managers
• Warehouse and Stores Personnel
• Boatbuilding Supervisors
• Manufacturing Operations Managers

Hazards Addressed

• Inhalation of airborne composite fibres and fine dusts from cutting, grinding and sanding
• Skin and respiratory sensitisation from epoxy, polyester and vinyl ester resins and hardeners
• Exposure to volatile organic compounds (VOCs) and styrene vapours
• Eye and skin irritation from fibreglass and carbon fibre contact
• Manual handling strains and sprains from lifting and moving large or awkward composite components
• Fire and explosion risks associated with flammable resins, solvents and dust accumulation
• Cuts and lacerations from sharp composite edges and offcuts
• Environmental contamination from improper disposal of composite waste and resin-contaminated materials

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Composite Materials
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for Composite Handling
• 6.0 Required PPE and Engineering Controls
• 7.0 Receiving and Inspection of Composite Materials
• 8.0 Safe Storage and Labelling Requirements
• 9.0 Manual Handling and Mechanical Aids for Composite Components
• 10.0 Safe Handling of Resins, Hardeners and Additives
• 11.0 Cutting, Drilling, Grinding and Sanding of Composites
• 12.0 Housekeeping, Dust Control and Ventilation Requirements
• 13.0 Spill Management and Resin Leak Response
• 14.0 Waste Segregation, Disposal and Environmental Controls
• 15.0 Health Monitoring and Exposure Management (where required)
• 16.0 Emergency Procedures and First Aid
• 17.0 Training, Competency and Induction Requirements
• 18.0 Inspection, Monitoring and Continuous Improvement
• 19.0 Document Control and Review

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and corresponding state and territory WHS Regulations
• Safe Work Australia – Managing risks of hazardous chemicals in the workplace: Code of Practice
• Safe Work Australia – Managing the work environment and facilities: Code of Practice
• Safe Work Australia – Hazardous manual tasks: Code of Practice
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 2161: Occupational protective gloves series
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 4501: Occupational protective clothing
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 2985: Workplace atmospheres – Method for sampling and gravimetric determination of respirable dust