Product Overview

Summary: This Dent Removal Safe Operating Procedure sets out a clear, safe and consistent method for removing dents from vehicles and metal components in Australian workplaces. It helps technicians complete repairs efficiently while controlling WHS risks associated with panel beating tools, lifting, noise, and hazardous substances.

Dent removal work is routine in automotive and metal fabrication workshops, yet it involves a combination of force, heat, chemicals and powered tools that can create significant WHS risks if not managed properly. This Dent Removal Safe Operating Procedure provides a structured, step‑by‑step method for assessing damage, preparing the work area, selecting the appropriate dent removal technique (including panel beating, glue pulling, stud welding and paintless dent removal), and carrying out repairs in a controlled and compliant manner.

Developed for Australian conditions, the SOP integrates WHS obligations with practical workshop realities. It addresses common pain points such as inconsistent repair quality, ad‑hoc tool use, poor housekeeping around vehicles, and exposure to noise, vibration and hazardous substances. By implementing this SOP, businesses can standardise how dent removal is planned and executed, demonstrate due diligence under WHS legislation, and support safer, faster and more professional repairs across light vehicles, heavy vehicles and fleet operations.

Key Benefits

• Ensure dent removal activities are carried out in line with Australian WHS legislation and industry best practice.
• Reduce the likelihood of injuries from impact tools, sharp metal edges, hot surfaces and hazardous substances.
• Standardise dent assessment and repair methods, improving consistency and quality of finished work.
• Streamline training and onboarding for new technicians, apprentices and labour hire workers.
• Minimise rework, customer complaints and downtime caused by poor repair practices or equipment damage.

Who is this for?

• Panel Beaters
• Automotive Body Repair Technicians
• Spray Painting and Panel Workshop Managers
• Automotive Workshop Owners
• Fleet Maintenance Supervisors
• WHS Managers and Advisors in Automotive Repair
• Apprentice Panel Beaters and Trainees
• Heavy Vehicle Body Repair Technicians

Hazards Addressed

• Manual handling injuries from pushing, pulling and awkward postures around vehicles
• Impact and crush injuries from hammers, dollies, slide hammers and pulling devices
• Cuts and lacerations from sharp metal edges and burrs on damaged panels
• Burns and fire risk from heat guns, stud welders and nearby flammable materials
• Exposure to hazardous substances such as solvents, cleaners, body fillers and dusts
• Noise-induced hearing loss from repeated hammering and powered tools
• Hand–arm vibration exposure from extended use of power tools and sanders
• Eye injuries from flying metal fragments, dust, glue tabs or broken studs
• Trips and slips caused by hoses, leads, tools and components around the vehicle
• Electrical hazards from damaged leads, portable equipment and stud welding units
• Vehicle movement hazards when working on or around unrestrained vehicles

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Dent Types (including paintless vs conventional repair)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Required Tools, Equipment and Materials
• 5.0 Personal Protective Equipment (PPE) Requirements
• 6.0 Pre-Start Checks and Work Area Preparation
• 7.0 Vehicle Securing and Isolation Procedures
• 8.0 Dent Assessment and Repair Method Selection
• 9.0 Step-by-Step Procedure – Paintless Dent Removal (PDR)
• 10.0 Step-by-Step Procedure – Conventional Dent Repair (panel beating and filling)
• 11.0 Step-by-Step Procedure – Glue Pulling and Stud Welding Techniques
• 12.0 Hazard Identification and Risk Control Measures
• 13.0 Safe Use of Heat, Chemicals and Powered Tools
• 14.0 Housekeeping, Waste Management and Environmental Considerations
• 15.0 Quality Checks, Tolerances and Documentation
• 16.0 Emergency Procedures and Incident Reporting
• 17.0 Training, Induction and Competency Verification
• 18.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 and state/territory equivalents
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• AS/NZS 4024.1: Safety of machinery (series)
• AS/NZS 3760: In-service safety inspection and testing of electrical equipment
• AS/NZS 2161: Occupational protective gloves (series)
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 1270: Acoustics – Hearing protectors