Product Overview

Summary: This Heavy Lifting Safety Safe Operating Procedure sets out clear, practical steps for planning and performing manual and mechanical lifting tasks safely in Australian workplaces. It helps businesses control musculoskeletal injury risks, meet WHS obligations, and embed consistent safe lifting practices across all teams.

Heavy lifting is one of the most common causes of workplace injury in Australia, often resulting in back strains, sprains, hernias and long-term musculoskeletal disorders. This Heavy Lifting Safety Safe Operating Procedure provides a structured, step-by-step method for assessing loads, planning lifts, using mechanical aids, and coordinating team lifts so that workers are not placed at unnecessary risk. It translates WHS legal requirements and best practice guidance into clear, day-to-day instructions that frontline workers and supervisors can easily follow.

The SOP helps businesses move away from informal or ad-hoc lifting practices and towards a consistent, documented system for managing hazardous manual tasks. It covers the full lifecycle of a lift: from initial risk assessment and selection of appropriate equipment (such as trolleys, forklifts, pallet jacks, cranes and hoists) through to communication, traffic management, housekeeping and post-lift review. By implementing this procedure, organisations can significantly reduce manual handling injuries, demonstrate due diligence under WHS legislation, support safer work design, and improve productivity by ensuring that heavy items are moved efficiently and safely the first time.

Key Benefits

• Reduce the incidence and severity of manual handling and musculoskeletal injuries associated with heavy lifting.
• Ensure compliance with Australian WHS legislation and the Hazardous Manual Tasks Code of Practice.
• Standardise lifting practices across sites, shifts and contractors for consistent, defensible safety performance.
• Improve planning and coordination of lifts, minimising delays, damage to goods and equipment, and near misses.
• Support effective training and onboarding by providing clear, visual, step-by-step lifting guidance for workers.

Who is this for?

• WHS Managers
• Health and Safety Representatives (HSRs)
• Site Supervisors
• Warehouse and Logistics Managers
• Construction Supervisors
• Manufacturing Team Leaders
• Facilities and Maintenance Managers
• Transport and Distribution Coordinators
• Labour Hire Providers
• Return-to-Work and Injury Management Coordinators

Hazards Addressed

• Musculoskeletal disorders from lifting, lowering, pushing, pulling or carrying heavy loads
• Back, shoulder and neck strains from awkward postures or sudden movements during lifts
• Crush injuries from dropped loads or load instability
• Foot and hand injuries from impacts, pinch points and uncontrolled movement of loads
• Slips, trips and falls while carrying or moving heavy objects
• Overexertion and fatigue from repetitive or prolonged heavy lifting tasks
• Collision risks between pedestrians, lifting equipment and vehicles in shared work areas
• Equipment failure or misuse of mechanical lifting aids such as hoists, cranes, pallet jacks and forklifts

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Key Terms (Heavy Lifting, Hazardous Manual Task, Mechanical Aid)
• 3.0 Roles and Responsibilities (PCBU, Officers, Supervisors, Workers, Contractors)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for Heavy Lifting Tasks
• 6.0 Load Assessment (Weight, Size, Shape, Stability and Centre of Gravity)
• 7.0 Environmental and Task Assessment (Space, Floor Condition, Slopes, Weather, Lighting)
• 8.0 Hierarchy of Controls for Heavy Lifting (Elimination, Substitution, Engineering, Administrative, PPE)
• 9.0 Use of Mechanical Aids (Trolleys, Pallet Jacks, Forklifts, Cranes, Hoists and Lift Tables)
• 10.0 Safe Manual Lifting Techniques (One-Person Lifts, Team Lifts, Pushing vs Pulling)
• 11.0 Planning and Conducting Team Lifts (Communication, Roles, Command Signals)
• 12.0 Traffic Management and Segregation of Pedestrians and Mobile Plant
• 13.0 Personal Protective Equipment (PPE) Requirements for Heavy Lifting Tasks
• 14.0 Pre-Lift Checks and Housekeeping Requirements
• 15.0 Step-by-Step Heavy Lifting Procedure (From Planning to Completion)
• 16.0 Managing High-Risk or Non-Routine Lifts (Permits, Lift Plans, Spotters)
• 17.0 Incident, Near Miss and Hazard Reporting Related to Heavy Lifting
• 18.0 Training, Competency and Induction Requirements
• 19.0 Monitoring, Review and Continuous Improvement of Heavy Lifting Practices
• 20.0 Recordkeeping and Documentation (Risk Assessments, Training, Maintenance Logs)

Legislation & References

• Work Health and Safety Act 2011 (Cth and harmonised state/territory legislation)
• Work Health and Safety Regulations 2011 (hazardous manual tasks and plant)
• Safe Work Australia - Code of Practice: Hazardous Manual Tasks
• Safe Work Australia - Code of Practice: Managing the Risk of Plant in the Workplace
• AS/NZS ISO 45001:2018 Occupational health and safety management systems
• AS 2550 series: Cranes, hoists and winches – Safe use (where mechanical lifting devices are used)
• AS 2359 series: Powered industrial trucks (forklifts) – Safety and operation