Product Overview

Summary: This Loading and Unloading Materials Safe Operating Procedure sets out safe, step-by-step requirements for receiving, handling and dispatching materials on Australian worksites. It helps businesses control high-risk activities involving vehicles, forklifts, cranes and manual handling, reducing the likelihood of crush injuries, falls and property damage while supporting WHS compliance.

Loading and unloading is one of the most hazardous routine activities on Australian worksites, particularly where trucks, forklifts, cranes and pedestrians interact in tight spaces. This SOP provides a clear, practical framework for planning and carrying out loading and unloading tasks so that everyone on site understands the safe sequence of work, communication protocols and exclusion zones. It is designed to be applied across warehouses, construction sites, manufacturing plants, transport depots and any workplace where goods are regularly moved on and off vehicles.

The procedure addresses common problem areas such as poorly controlled traffic movement, unstable loads, inadequate use of load restraints, and unsafe manual handling practices. It helps businesses demonstrate that they have systematically identified the hazards, implemented control measures and trained workers, in line with Australian WHS legislation and relevant Codes of Practice. By standardising how materials are loaded and unloaded, this SOP reduces the risk of serious injury, near misses, product damage and costly downtime, while making it easier for supervisors to monitor compliance and for new workers to be inducted quickly and safely.

Key Benefits

• Reduce the risk of crush, struck-by and fall-from-height incidents during loading and unloading activities.
• Ensure consistent application of traffic management, exclusion zones and communication protocols across all shifts and crews.
• Improve compliance with Australian WHS laws and transport-related Codes of Practice for load restraint and vehicle loading.
• Streamline training and induction for new drivers, operators and yard staff with a clear, step-by-step process.
• Minimise product damage, rework and delays by standardising how materials are prepared, secured and inspected before movement.

Who is this for?

• Warehouse Managers
• Yard Supervisors
• Logistics and Dispatch Coordinators
• Truck Drivers and Delivery Drivers
• Forklift Operators
• Crane and Hoist Operators
• Construction Site Supervisors
• Manufacturing Production Managers
• WHS Advisors and Safety Officers
• Small Business Owners managing loading docks or yards

Hazards Addressed

• Vehicle and mobile plant collisions between trucks, forklifts and pedestrians
• Crush injuries from moving vehicles, reversing trucks and forklifts
• Falling objects from poorly secured or unstable loads
• Falls from height when accessing truck trays, trailers or elevated loads
• Manual handling injuries from lifting, pushing, pulling or carrying materials
• Pinch and entanglement injuries when using slings, chains, hooks and lifting attachments
• Slips, trips and falls on loading docks, ramps and around vehicles
• Exposure to hazardous atmospheres (e.g. exhaust fumes) in enclosed loading areas
• Strains and sprains from repetitive handling or awkward postures
• Property damage and equipment impact incidents during tight manoeuvring

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Key Terms
• 3.0 Roles and Responsibilities (Drivers, Operators, Spotters, Supervisors)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required Competencies, Licences and Training
• 6.0 Required PPE and Safety Equipment
• 7.0 Pre-Operation Planning and Risk Assessment
• 8.0 Site and Traffic Management Requirements
• 9.0 Vehicle Arrival, Parking and Docking Procedures
• 10.0 Load Assessment and Stability Checks
• 11.0 Safe Use of Forklifts, Cranes and Other Mobile Plant for Loading/Unloading
• 12.0 Manual Handling Controls and Use of Mechanical Aids
• 13.0 Load Restraint, Securing and Verification Prior to Departure
• 14.0 Communication Protocols, Spotters and Exclusion Zones
• 15.0 Working at Height and Fall Prevention During Loading/Unloading
• 16.0 Housekeeping and Post-Operation Inspection
• 17.0 Incident, Near Miss and Damage Reporting Requirements
• 18.0 Emergency Procedures (Injury, Load Shift, Equipment Failure)
• 19.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and corresponding state/territory legislation)
• Work Health and Safety Regulation 2011 (Cth and corresponding state/territory regulations)
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• National Transport Commission – Load Restraint Guide (Australia) – current edition
• AS 2359 Forklift trucks – Safe use
• AS/NZS 4801 Occupational health and safety management systems (superseded but still referenced in many systems)
• AS 4991 Lifting devices
• AS/NZS 1891 Industrial fall-arrest systems and devices (where working at height is involved)