Product Overview

Summary: This SOP provides clear, step-by-step guidance for loading and unloading timbers safely using vehicles, forklifts, cranes and manual handling techniques. It helps Australian businesses control high-risk activities such as falling loads, crush injuries and musculoskeletal strain, while demonstrating compliance with WHS obligations and chain of responsibility requirements.

Loading and unloading timbers is a routine task in timber yards, hardware stores, transport depots and construction sites across Australia, but it carries a high risk of serious injury if not tightly controlled. Long, heavy and sometimes unstable timber packs can shift unexpectedly, fall from height, or cause crush and impact injuries during handling. This SOP sets out a structured, easy-to-follow process to ensure that every timber movement – from vehicle arrival through to final placement – is carried out safely, consistently and in line with Australian WHS requirements.

The procedure addresses the full lifecycle of timber handling activities, including traffic management in yards, pre-start equipment checks, load restraint, use of forklifts and cranes, working around trucks, and safe manual handling of individual lengths. It clarifies who does what, when and how, reducing the risk of miscommunication between drivers, yard staff and site personnel. By implementing this SOP, businesses can significantly reduce incidents such as falls of load, struck-by injuries, musculoskeletal disorders and property damage, while also supporting compliance with chain of responsibility laws and demonstrating due diligence during regulator inspections or incident investigations.

Key Benefits

• Reduce the risk of crush, struck-by and fall-of-load incidents during timber loading and unloading.
• Ensure consistent, defensible work practices that align with Australian WHS legislation and chain of responsibility obligations.
• Improve coordination and communication between drivers, forklift operators, spotters and yard staff.
• Minimise manual handling strain by standardising safer lifting, carrying and stacking techniques for timber products.
• Streamline induction and refresher training with a clear, documented procedure that is easy for workers to follow on site.

Who is this for?

• Yard Supervisors
• Warehouse Managers
• Timber Yard Workers
• Forklift Operators
• Truck Drivers and Delivery Drivers
• Construction Site Supervisors
• WHS Managers and Advisors
• Logistics and Transport Coordinators
• Small Business Owners in Timber and Building Supply
• Crane and Hiab Operators

Hazards Addressed

• Falling timber packs or individual lengths during loading, unloading or stacking
• Crush injuries between vehicles, loads, racking and fixed structures
• Struck-by incidents from moving forklifts, trucks or swinging loads
• Load shift due to inadequate or incorrect load restraint on vehicles
• Musculoskeletal injuries from repetitive or heavy manual handling of timber
• Slips, trips and falls in loading areas, truck trays and storage zones
• Pinch and entanglement points when using slings, chains, binders and load restraint equipment
• Poor visibility and communication in busy yards and loading zones
• Falling from height when accessing or working on truck trays or elevated loads
• Noise and dust exposure in high-traffic timber handling areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (Timber Types, Packs, Dunnage, Load Restraint)
• 3.0 Roles and Responsibilities (Drivers, Forklift Operators, Spotters, Supervisors)
• 4.0 Required Training, Competency and Licensing
• 5.0 Required PPE and Safety Equipment
• 6.0 Pre-Start Checks (Plant, Vehicles, Slings, Load Restraint Devices)
• 7.0 Site and Traffic Management Requirements for Loading Areas
• 8.0 Assessing the Load and Work Area (Weather, Ground Conditions, Overhead Hazards)
• 9.0 Safe Loading Procedure – Forklifts, Cranes and Manual Handling
• 10.0 Safe Unloading Procedure – On-Site and at Customer Locations
• 11.0 Load Restraint Requirements for Timber on Vehicles
• 12.0 Manual Handling of Individual Timbers and Small Bundles
• 13.0 Working at Height on Truck Trays and Elevated Loads
• 14.0 Hazard Identification and Risk Control Measures
• 15.0 Communication, Signalling and Use of Spotters
• 16.0 Emergency Procedures and Incident Response
• 17.0 Housekeeping, Storage and Stacking of Timbers
• 18.0 Inspection, Maintenance and Tag-Out of Equipment
• 19.0 Training, Induction and Competency Verification
• 20.0 Document Control and Review History

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (and state/territory equivalents)
• Heavy Vehicle National Law (HVNL) – Chain of Responsibility provisions
• National Transport Commission – Load Restraint Guide (Latest Edition)
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – General Guide for Workplace Traffic Management
• AS 2359: Powered industrial trucks (series)
• AS/NZS 4380: Cargo restraint systems – Transport webbing and components
• AS 4991: Lifting devices
• AS 1891 (series): Industrial fall-arrest systems and devices (where working at height is involved)