Product Overview

Summary: This Loading and Unloading Procedures SOP sets out clear, safe and compliant methods for moving goods on and off vehicles, docks and storage areas. It helps Australian businesses control high‑risk activities such as vehicle movements, working around forklifts and manual handling, reducing the likelihood of injuries, product damage and costly disruptions.

Loading and unloading is one of the highest-risk activities in warehousing, logistics, construction and manufacturing, with workers routinely exposed to moving vehicles, suspended loads, uneven surfaces and time pressure. This Safe Operating Procedure provides a structured, step-by-step approach for managing these tasks safely, from pre-arrival planning and vehicle marshalling through to load restraint, unloading, inspection and sign-off. It clarifies who does what on the loading dock or worksite, how communication is managed between drivers and ground staff, and the controls required when using forklifts, pallet jacks, cranes, tail lifts and loading ramps.

Developed for Australian workplaces, the SOP is aligned with WHS legislation and recognised industry guidance for load restraint, traffic management and manual handling. It helps businesses demonstrate due diligence by documenting how loading and unloading risks are identified, controlled and monitored in day-to-day operations. By implementing this procedure, organisations can significantly reduce the risk of crush injuries, falls, musculoskeletal disorders and product damage, while also improving turnaround times, consistency across shifts and the professionalism of their logistics operations.

Key Benefits

• Reduce the risk of serious injuries arising from vehicle movements, falling loads and unsafe manual handling.
• Ensure compliance with Australian WHS obligations and National Transport Commission load restraint guidance.
• Standardise loading and unloading practices across all sites, shifts and contractors for consistent, repeatable outcomes.
• Improve communication and coordination between drivers, forklift operators and dock staff to minimise delays and confusion.
• Minimise product damage, rework and insurance claims through controlled handling and verification steps.

Who is this for?

• Warehouse Managers
• Logistics and Transport Managers
• Dispatch Supervisors
• Loading Dock Supervisors
• Truck and Delivery Drivers
• Forklift Operators
• Storepersons and Pick-Packers
• WHS Managers and Advisors
• Operations Managers
• Construction Site Supervisors

Hazards Addressed

• Being struck by moving vehicles, forklifts or mobile plant in loading areas
• Crush injuries between vehicles, docks, racking and loads
• Falling loads from pallets, tines, tail lifts, cranes or unsecured stacks
• Falls from trucks, trailers, docks, ramps and elevated work areas
• Manual handling injuries from lifting, pushing, pulling or carrying loads
• Slips, trips and falls on uneven, wet or cluttered loading surfaces
• Load shift during transport due to inadequate or incorrect load restraint
• Pinch and entanglement points around tail lifts, dock levellers and loading equipment
• Exposure to adverse weather conditions affecting footing and equipment operation
• Fatigue and time pressure leading to shortcuts and unsafe practices

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology
• 3.0 Roles and Responsibilities (Drivers, Supervisors, Operators, Spotters)
• 4.0 Applicable Legislation, Standards and Guidance
• 5.0 Required Training, Competency and Authorisation
• 6.0 Required PPE and Safety Equipment
• 7.0 Pre-Loading and Pre-Unloading Checks (Vehicle, Dock and Work Area)
• 8.0 Traffic Management and Vehicle Movement Controls
• 9.0 Communication Protocols Between Drivers and Loading Personnel
• 10.0 Safe Loading Procedure (Palletised, Loose, Oversized and Hazardous Loads)
• 11.0 Safe Unloading Procedure (Including Verification and Inspection)
• 12.0 Use of Forklifts, Pallet Jacks, Cranes, Tail Lifts and Ramps
• 13.0 Load Restraint Requirements and Verification
• 14.0 Managing Hazardous Manual Tasks During Loading and Unloading
• 15.0 Working at Height on Vehicles, Docks and Platforms
• 16.0 Housekeeping and Management of Slips, Trips and Falls
• 17.0 Managing Adverse Weather and Environmental Conditions
• 18.0 Contractor and Visitor Management in Loading Areas
• 19.0 Incident, Near Miss and Damage Reporting
• 20.0 Emergency Procedures and Response (Injuries, Spills, Load Failure)
• 21.0 Inspection, Monitoring and Audit of Loading/Unloading Activities
• 22.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (Cth and relevant state/territory variants)
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• National Transport Commission – Load Restraint Guide for Light and Heavy Vehicles
• AS/NZS 4801: Occupational health and safety management systems (superseded but still widely referenced)
• AS 2359 series: Powered industrial trucks
• AS 4991: Lifting devices
• AS 1891 series: Industrial fall-arrest systems and devices