Product Overview

Summary: This Load Handling and Lifting Safe Operating Procedure sets out clear, step-by-step requirements for planning, performing and supervising lifting tasks in Australian workplaces. It helps businesses control the high-risk hazards associated with manual handling, cranes, forklifts and lifting accessories, while demonstrating strong compliance with WHS obligations.

Load handling and lifting activities are among the most common—and most hazardous—tasks in Australian workplaces, from construction sites and warehouses to manufacturing plants and maintenance workshops. Poorly planned lifts, incorrect use of lifting gear, and unsafe manual handling practices can result in serious musculoskeletal injuries, dropped loads, plant damage and major WHS breaches. This Load Handling and Lifting SOP provides a structured, practical framework to ensure every lift is assessed, controlled and executed safely, whether using mechanical lifting equipment or manual techniques.

The procedure guides your team through risk assessment, lift planning, equipment selection, pre-use inspections, communication protocols and safe operating techniques. It clearly defines who can authorise lifts, when a lift plan or lift study is required, and how to manage complex or non-routine lifts. By standardising your approach across sites and shifts, this SOP reduces variability, supports effective training and supervision, and helps you evidence due diligence to regulators, clients and insurers. It is written specifically with Australian WHS legislation and guidance in mind, making it suitable for businesses of all sizes looking to strengthen their lifting and load handling controls.

Key Benefits

• Reduce the risk of musculoskeletal injuries, crush incidents and dropped loads through a structured, risk-based approach to all lifting activities.
• Ensure compliance with Australian WHS legislation, relevant Codes of Practice and Australian Standards for manual tasks and lifting equipment.
• Standardise lifting and load handling practices across sites, shifts and contractors, improving consistency and reducing reliance on informal methods.
• Improve equipment reliability and lifespan by embedding routine pre-use inspections and defect reporting for lifting gear and plant.
• Enhance communication and coordination between operators, doggers, riggers and supervisors through clear roles, signals and escalation pathways.

Who is this for?

• Site Supervisors
• Warehouse and Distribution Managers
• Construction Project Managers
• Crane Operators and Doggers
• Forklift Operators
• Riggers
• Maintenance Supervisors
• WHS Advisors and Safety Officers
• Manufacturing and Production Managers
• Logistics and Transport Coordinators

Hazards Addressed

• Musculoskeletal disorders from unsafe manual handling and repetitive lifting
• Crush injuries from uncontrolled or swinging loads
• Struck-by incidents from falling or dropped loads
• Equipment failure due to damaged or incorrectly selected lifting gear (slings, chains, shackles, hooks)
• Tip-over or loss of stability of forklifts, cranes or other lifting plant
• Pinch and entanglement injuries around lifting points and attachment areas
• Over-exertion and fatigue from excessive load weight or poor task design
• Poor visibility and communication leading to misdirected or unexpected load movement
• Slips, trips and falls in congested or obstructed lifting areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (Loads, Lifting Equipment, High-Risk Work, Competent Person)
• 3.0 Roles and Responsibilities (PCBU, Officers, Supervisors, Operators, Doggers/Riggers)
• 4.0 Regulatory and Standards References
• 5.0 Hazard Identification and Risk Assessment for Lifting Tasks
• 6.0 Planning Lifting Operations (Routine, Non-Routine and Complex Lifts)
• 7.0 Manual Handling and Team Lifting Requirements
• 8.0 Selection and Use of Lifting Equipment (Cranes, Forklifts, Hoists, Jacks, Slings and Attachments)
• 9.0 Pre-use Inspection and Tagging of Lifting Gear
• 10.0 Load Assessment (Weight, Centre of Gravity, Stability and Load Integrity)
• 11.0 Rigging and Slinging Practices
• 12.0 Establishing Exclusion Zones and Traffic Management Around Lifting Areas
• 13.0 Communication Methods and Standard Signals (Spotters, Doggers and Operators)
• 14.0 Step-by-Step Safe Lifting Procedure (Set-up, Lift, Travel, Placement and Demobilisation)
• 15.0 Working Near Services, Structures and Other Hazards
• 16.0 Managing Adverse Weather and Environmental Conditions
• 17.0 Incident Response, Near Miss Reporting and Emergency Procedures
• 18.0 Training, Competency and High-Risk Work Licensing Requirements
• 19.0 Inspection, Maintenance and Recordkeeping
• 20.0 Review, Audit and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth and harmonised state and 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 Risks of Plant in the Workplace
• Safe Work Australia – General Guide for Working in the Vicinity of Overhead and Underground Electric Lines
• AS 2550 series: Cranes, hoists and winches – Safe use
• AS 1418 series: Cranes, hoists and winches – Design and construction
• AS 4991: Lifting devices
• AS 1891 series: Industrial fall-arrest systems and devices (where working at height during lifting operations)
• AS/NZS ISO 31000: Risk management – Guidelines