Product Overview

Summary: This Elevator Load Testing Safe Operating Procedure provides a clear, step-by-step framework for planning, conducting, and documenting elevator load tests in line with Australian WHS and building safety requirements. It helps duty holders verify lift performance, manage critical risks, and maintain a defensible record of compliance for inspections, certifications, and insurance purposes.

Elevator load testing is a critical control measure for ensuring that passenger and goods lifts operate safely under their rated capacity. In Australia’s highly regulated building and WHS environment, building owners and PCBU’s must be able to demonstrate that elevators are tested, inspected, and maintained in accordance with recognised standards and manufacturer specifications. This Safe Operating Procedure sets out a practical, repeatable method for planning, conducting, and recording elevator load tests so that the lift’s braking, hoisting, safety gear, and control systems can be verified under real-world loading conditions.

The procedure addresses the full lifecycle of a load test: pre-test planning and risk assessment, isolations and controls, correct selection and placement of test weights, step-by-step test sequences, performance criteria, and post-test inspection and sign-off. It clarifies who is responsible for each task (from lift technicians to building management), what documentation is required, and how to manage tenants, visitors, and contractors during testing to minimise disruption and risk. By implementing this SOP, organisations can reduce the likelihood of lift failures, entrapments, and serious incidents, while also supporting compliance with Australian Standards, WHS legislation, and insurance requirements.

This SOP is particularly valuable for organisations managing multiple sites or high-traffic facilities such as hospitals, shopping centres, commercial towers, and industrial buildings, where elevator reliability and safety are business-critical. It supports consistent contractor performance, simplifies auditing, and provides a clear reference point for training new technicians and maintenance staff.

Key Benefits

• Ensure elevator load testing is conducted safely and consistently in line with Australian Standards and WHS duties.
• Reduce the risk of lift failures, entrapments, and catastrophic mechanical incidents under load.
• Demonstrate due diligence and compliance to regulators, certifiers, insurers, and building owners through structured documentation.
• Standardise contractor and in-house maintenance practices across multiple buildings and portfolios.
• Minimise disruption to building occupants by clearly planning, scheduling, and communicating testing activities.

Who is this for?

• Lift Technicians
• Elevator Maintenance Contractors
• Facilities Managers
• Building Managers
• WHS Managers
• Strata Managers
• Asset and Property Managers
• Engineering Managers
• Compliance and Risk Managers
• Construction Project Managers (for new installations and commissioning)

Hazards Addressed

• Uncontrolled elevator movement during testing
• Mechanical failure of hoisting and braking systems under load
• Failure of safety gear or overspeed protection devices
• Crush and shear hazards at lift doors and landing thresholds
• Falls into lift shafts during inspection or weight placement
• Manual handling injuries from lifting and positioning test weights
• Electrical shock or arc flash from working near control panels and drive systems
• Entrapment of passengers or workers in the lift car during testing
• Slips, trips and falls in plant rooms, machine rooms, and lift lobbies
• Unauthorised access to lift machinery spaces or test areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (Lift Types, Rated Load, Test Load, Dynamic vs Static Testing)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Manufacturer Requirements
• 5.0 Pre-Test Planning and Scheduling
• 6.0 Risk Assessment and Permit-to-Work Requirements
• 7.0 Communication with Building Occupants and Stakeholders
• 8.0 Required Tools, Test Weights and Equipment Specifications
• 9.0 Personal Protective Equipment (PPE) Requirements
• 10.0 Site Preparation, Isolation and Barricading of Test Area
• 11.0 Pre-Test Inspection of Lift Components and Safety Systems
• 12.0 Step-by-Step Load Testing Procedure (Static and Dynamic)
• 13.0 Test Acceptance Criteria and Performance Measurements
• 14.0 Post-Test Inspection, Fault Identification and Rectification
• 15.0 Documentation, Test Reports and Record Keeping
• 16.0 Reinstatement of Normal Operation and Handover to Building Management
• 17.0 Emergency Procedures and Incident Response During Testing
• 18.0 Training, Competency and Induction Requirements
• 19.0 Review, Audit and Continuous Improvement of the Procedure

Legislation & References

• AS 1735 series – Lifts, escalators and moving walks (particularly AS 1735.2 and AS 1735.10 as applicable)
• AS 1735.3: Lifts, escalators and moving walks – Passenger lifts
• AS 1735.5: Lifts, escalators and moving walks – Electric lifts
• AS 1735.10: Lifts, escalators and moving walks – Goods lifts
• AS/NZS 3000: Electrical installations (Wiring Rules)
• AS/NZS 4801: Occupational health and safety management systems (superseded but still referenced in many systems)
• ISO 45001: Occupational health and safety management systems – Requirements with guidance for use
• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulations 2011 (and state/territory equivalents) – Plant and structures, registration of lifts
• Safe Work Australia – Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks