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Vehicle Lifting Jacking and Hoisting Risk Assessment

Vehicle Lifting Jacking and Hoisting Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
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  • • Includes 2 Years of Free Compliance Updates

Vehicle Lifting Jacking and Hoisting Risk Assessment

Product Overview

Identify and control organisational risks associated with Vehicle Lifting, Jacking and Hoisting through a structured, management-level WHS Risk Management approach. This Risk Assessment supports compliance with the WHS Act, demonstrates Due Diligence, and helps protect your business from operational and legal liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Policy & Legal Compliance: Assessment of organisational WHS responsibilities, safety policy frameworks, consultation arrangements and alignment with statutory obligations for vehicle lifting and hoisting activities.
  • Plant Procurement & Equipment Suitability: Management of selection, specification and purchasing processes for jacks, hoists, stands and lifting accessories to ensure design suitability, capacity and compatibility with vehicle types and workshop operations.
  • Workshop Layout, Pits & Traffic Engineering: Evaluation of workshop design, hoist positioning, vehicle access routes, pit guarding, segregation of pedestrians and mobile plant, and controls to minimise collision and crush risks.
  • Plant Registration, Commissioning & Verification: Protocols for statutory registration (where required), installation verification, load testing, commissioning checks and documentation for all vehicle lifting systems.
  • Inspection, Maintenance & Testing Systems: Development of preventative maintenance schedules, inspection checklists, third‑party testing arrangements and records management for jacks, hoists, stands and lifting attachments.
  • Vehicle Assessment, Load Rating & Jacking Configuration: Controls for verifying vehicle weight and configuration, jacking points, lifting plans, load distribution, and ensuring appropriate stands and support systems are used.
  • Worker Competency, Licensing & Training: Assessment of competency requirements, licensing obligations, induction content and refresher training for staff involved in lifting, hoist operation and pit work.
  • Supervision, Authorisation & Permit‑to‑Work: Management of supervision levels, authority to operate lifting equipment, and permit‑to‑work systems for high‑risk lifts, pit entry and non‑routine tasks.
  • Pre‑Use Checks, Tagging & Defect Reporting: Systems for pre‑start inspections, colour tagging, out‑of‑service labelling, escalation of defects and follow‑up actions to control equipment failure risks.
  • Safe Systems for Working Under Raised Vehicles & in Pits: Development of procedural controls, exclusion zones, secondary supports, access/egress arrangements and monitoring for people working beneath vehicles and in pits.
  • Ergonomics, Manual Handling & Work Organisation: Assessment of postures, underbody access methods, tool selection, task rotation and work scheduling to minimise musculoskeletal and fatigue‑related risks.
  • Environmental Conditions, Ventilation & Hazardous Substances: Management of air quality, exhaust extraction, lighting, noise, slips/trips, and exposure to fuels, oils and cleaning chemicals in and around pits and hoist areas.
  • Isolation, Energy Control & Interaction with Other Systems: Protocols for lock‑out/tag‑out, control of hydraulic, pneumatic and electrical energy, and coordination with other work such as welding, diagnostics or mobile plant movements.
  • Emergency Preparedness, Rescue & Incident Management: Planning for vehicle or hoist failure scenarios, pit rescue, first aid, emergency equipment, drills, and post‑incident investigation and corrective action processes.
  • Contractor & Visitor Management: Controls for induction, supervision, access restrictions and coordination of contractors, customers and visitors in vehicle lifting and pit work areas.

Who is this for?

This Risk Assessment is designed for Business Owners, Workshop Managers, Fleet Managers and Safety Officers responsible for planning, approving and overseeing Vehicle Lifting, Jacking and Hoisting operations across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Policies and Legal Compliance
  • • Absence of a documented WHS policy specific to vehicle lifting, jacking, hoisting and pit work
  • • Senior management not clearly allocating resources or accountability for safe vehicle lifting systems
  • • Inadequate understanding of duties under the WHS Act 2011 and WHS Regulation (e.g. plant, hazardous manual tasks, falls, confined spaces)
  • • No process to identify and apply relevant Australian Standards (e.g. AS 2615, AS 2538, AS/NZS 2550 series, AS/NZS 1891, AS 2550.9 for vehicle‑loading cranes, applicable hoist and jack standards)
  • • Failure to consult workers and HSRs on changes to lifting equipment, pits or procedures
  • • No formal review of WHS objectives and targets relating to lifting and hoisting incidents
2. Plant Procurement, Design and Suitability of Lifting Equipment
  • • Procurement of low‑quality, non‑compliant or counterfeit jacks, stands, hoists or chains without Australian certification
  • • Lifting equipment not rated or designed for the specific vehicle types, axle loads, motorcycles or heavy vehicles in use
  • • Incompatible interfaces between jacks, axle stands, transmission jacks and vehicle lifting points
  • • Lack of consideration for underbody access requirements when specifying hoists, pits and creepers
  • • No engineering input into layout of pits, hoist columns, clearances and escape routes
  • • Failure to design for additional attachments such as engine cranes, chain falls and under‑hoist transmission jacks
3. Engineering Design of Workshop Layout, Pits and Traffic Flow
  • • Poor workshop layout resulting in vehicles, pedestrians and lifting operations interfering with each other
  • • Inspection pits not designed or guarded to prevent falls, struck‑by or engulfment risks
  • • Insufficient headroom and side clearances around hoists and lifted vehicles for safe movement and escape
  • • Inadequate structural design of pit walls, pit covers, ladders, steps and edge protection
  • • No physical separation between heavy vehicle jacking areas and general workspaces
  • • Inadequate emergency exits from pit areas or underbody work zones
4. Plant Registration, Commissioning and Verification of Lifting Systems
  • • Vehicle hoists or other registrable plant not registered with the regulator as required
  • • New or modified hoists, cranes and chain falls placed into service without commissioning checks
  • • Lack of baseline inspection and test records for jacks, axle stands and lifting accessories
  • • Improper installation of hoists, pit equipment or runway beams leading to structural failure
  • • Commissioning not including load testing under worst‑case vehicle and axle loads
5. Inspection, Maintenance and Testing Systems for Jacks, Hoists and Stands
  • • Failure of jacks, axle stands, hoists, chain falls or engine cranes due to lack of systematic maintenance
  • • Hydraulic leaks or slow lowering not identified before catastrophic failure
  • • Unreported damage or overloading of stands and lifting points remaining in service
  • • Inaccurate or missing inspection tags, logs or calibration records for lifting equipment
  • • Use of lifting devices beyond their service life or inspection interval
6. Procedures for Vehicle Assessment, Load Rating and Jacking Configuration
  • • No standard process to confirm vehicle weight, axle loads, centre of gravity and condition before lifting
  • • Incorrect jack or stand selection for heavy vehicles, motorcycles or modified vehicles
  • • Inadequate consideration of load distribution when raising axles or underbody components
  • • Lack of controls for raised vehicles with removed components (e.g. engine, transmission) altering weight distribution
  • • Unclear instructions for using multiple jacks, stands and hoists in combination
7. Worker Competency, Licensing and Training for Lifting and Pit Operations
  • • Workers performing jacking, hoisting and pit tasks without adequate training or competency assessment
  • • No verification of high risk work licences where required for certain lifting operations
  • • Informal on‑the‑job training leading to inconsistent and unsafe practices
  • • Supervisors lacking competence to oversee complex lifting tasks or mechanical pit work
  • • Insufficient refresher training resulting in knowledge gaps about new plant or procedures
8. Supervision, Authorisation and Permit‑to‑Work for High‑Risk Lifting
  • • Unsupervised high‑risk tasks such as engine removal, transmission hoisting or working under heavy vehicles
  • • Workers bypassing safe systems due to production pressure or lack of enforcement
  • • No formal authorisation or permit for complex or non‑routine lifts
  • • Poor communication between supervisors, mechanics and apprentices about job scope and lifting risks
  • • Supervisory focus on productivity over safety when scheduling hoist and pit usage
9. Pre‑Use Checks, Tagging and Defect Reporting Systems
  • • Jacks, hoists, stands and chains used without basic pre‑use safety checks
  • • Workers not reporting or recording lifting equipment defects or near misses
  • • No standardised checklist for visual inspection of lifting points, pins, locking mechanisms and hydraulics
  • • Defective equipment remaining in circulation due to informal verbal reporting only
  • • Use of incorrect or missing adaptors, saddles or cradle attachments
10. Safe Systems for Working Under Raised Vehicles and in Pits
  • • Collapse of unsupported or inadequately supported vehicles during underbody work
  • • Inadvertent movement of vehicles when in gear, with park brake off or wheels not chocked while raised
  • • Workers trapped, crushed or struck while sliding under low chassis or working in pits
  • • No secondary support system when using jacks for extended tasks under vehicles
  • • Inadequate controls for simultaneous work above and below vehicles in pits
11. Ergonomics, Manual Handling and Work Organisation for Underbody Tasks
  • • Poor body postures when sliding under low chassis leading to musculoskeletal disorders
  • • Excessive manual handling of heavy components such as transmissions, axles and exhaust assemblies
  • • Inadequate planning of staffing levels for heavy tasks, leading to solo lifts
  • • Limited use of mechanical aids (transmission jacks, engine cranes, trolleys) due to availability or layout issues
  • • Time pressure and job‑pushing increasing the likelihood of short‑cuts on handling practices
12. Environmental Conditions, Ventilation and Hazardous Substances in Pits
  • • Accumulation of exhaust fumes, vapours or heavier‑than‑air gases in inspection pits
  • • Poor lighting leading to misplacement of jacks, stands or underbody support points
  • • Oil, coolant or fuel spills increasing slip risk in pits and around hoists
  • • Inadequate control of welding, grinding or hot‑work fumes during underbody repairs
  • • Inappropriate storage of flammable liquids or gas cylinders near pits or hoists
13. Isolation, Energy Control and Interaction with Other Systems of Work
  • • Uncontrolled release of mechanical, hydraulic or electrical energy while vehicles are lifted or in pits
  • • Unplanned movement of vehicles due to remote start, automatic systems or unsecured batteries
  • • Conflicting activities such as tyre fitting, brake testing or diagnostic running while someone is underneath
  • • Failure to coordinate with contractors working on the same vehicle or in the same bay
  • • No formal process to manage concurrent work on raised vehicles and plant in adjacent bays
14. Emergency Preparedness, Rescue and Incident Management
  • • Lack of a practical rescue plan for a person trapped under a vehicle or in a pit
  • • Inadequate emergency equipment such as lifting bags, cribbing or rescue jacks
  • • Workers uncertain about how to safely lower or secure a failed hoist or jack during an emergency
  • • Delayed emergency response due to poor communication systems in pits or remote bays
  • • Failure to capture and learn from lifting‑related incidents and near misses
15. Contractor and Visitor Management in Lifting and Pit Areas
  • • Contractors operating lifting equipment or working in pits without understanding site‑specific procedures
  • • Visitors and non‑essential personnel entering hoist bays or pit areas during lifts
  • • Conflicting safety expectations where contractors follow their own procedures rather than site standards
  • • Inadequate verification of contractors’ lifting equipment, certifications and maintenance records
  • • Language or literacy barriers leading to misunderstanding of lifting and pit hazards
16. Monitoring, Audit, Consultation and Continuous Improvement of Lifting Systems
  • • Drift from safe systems over time due to complacency or production pressures
  • • Lack of systematic monitoring of lifting‑related performance indicators
  • • Worker feedback on jacking, hoisting and pit hazards not being captured or acted upon
  • • Infrequent or superficial safety inspections of lifting equipment and underbody work practices
  • • No structured review after significant changes to vehicles, workloads or workshop layout

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • Safe Work Australia – Managing Risks of Plant in the Workplace Code of Practice: Guidance on controlling risks associated with plant, including vehicle hoists and jacking equipment.
  • Safe Work Australia – Hazardous Manual Tasks Code of Practice: Requirements for managing musculoskeletal risks from under‑vehicle and pit work.
  • Safe Work Australia – Managing the Work Environment and Facilities Code of Practice: Guidance on workshop layout, pits, ventilation, lighting and traffic management.
  • AS 2550 series: Cranes, hoists and winches – Safe use (relevant principles for inspection, maintenance and operation of lifting equipment).
  • AS 1418 series: Cranes, hoists and winches – Design and construction (applicable design and load rating principles for lifting systems).
  • AS/NZS 4801 / ISO 45001: Occupational health and safety management systems – Requirements for systematic WHS management and due diligence.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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