Product Overview

Summary: This Loading and Unloading Vehicle Safe Operating Procedure sets out safe, step-by-step methods for moving goods on and off vehicles in Australian workplaces. It helps businesses control high-risk activities such as working around moving vehicles, operating loading equipment and managing loads, while supporting compliance with WHS obligations and chain of responsibility requirements.

Loading and unloading vehicles is one of the most common – and most hazardous – activities in warehousing, transport, construction and manufacturing environments. Without a clear procedure, workers can be exposed to vehicle movements, falling loads, slips and trips, and crush injuries between vehicles, docks and structures. This SOP provides a structured, easy-to-follow process that covers planning the task, securing the loading area, communicating with drivers, using mechanical aids, and safely managing different load types, from pallets and stillages through to long or oversized items.

Developed specifically for Australian workplaces, this document helps you demonstrate due diligence under WHS legislation and align with chain of responsibility obligations in your supply chain. It supports consistent training for new and existing staff, reduces reliance on informal “work‑arounds”, and gives supervisors a clear reference point for monitoring safe work practices. By implementing this SOP, your business can reduce manual handling injuries, prevent vehicle-related incidents, and minimise damage to stock and equipment – all while maintaining efficient turnaround times for vehicles and deliveries.

Key Benefits

• Reduce the risk of vehicle, pedestrian and load-related incidents during loading and unloading operations.
• Ensure consistent, compliant loading and unloading practices across all shifts, sites and teams.
• Improve communication and coordination between drivers, forklift operators and ground staff.
• Minimise product damage, load shift and equipment impacts through structured loading methods and checks.
• Support WHS and chain of responsibility compliance with documented, defensible procedures.

Who is this for?

• Warehouse Supervisors
• Logistics and Transport Managers
• Storepersons
• Truck Drivers and Delivery Drivers
• Forklift Operators
• Loading Dock Coordinators
• Construction Site Supervisors
• Fleet Managers
• Health and Safety Representatives (HSRs)
• WHS Managers and Advisors

Hazards Addressed

• Vehicle and mobile plant movements in loading areas
• Crush injuries between vehicles, docks, racking and fixed structures
• Falling objects and falling loads during lifting, stacking and unrestraining
• Manual handling strains and sprains from lifting, pushing or pulling loads
• Slips, trips and falls on loading docks, tailgates and vehicle trays
• Load shift during transport due to inadequate restraint or poor load placement
• Contact with forklifts, pallet jacks and other load-handling equipment
• Pinch points and entrapment around tailgate loaders, ramps and doors
• Exposure to adverse weather conditions affecting footing and load stability
• Fatigue and time pressure contributing to unsafe loading practices

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (Drivers, Operators, Supervisors, Spotters)
• 4.0 Required Licences, Training and Competency Requirements
• 5.0 Required PPE and Safety Equipment
• 6.0 Pre‑Task Planning and Risk Assessment
• 7.0 Site and Vehicle Pre‑Use Checks
• 8.0 Traffic Management and Exclusion Zones for Loading Areas
• 9.0 Communication Protocols with Drivers and Spotters
• 10.0 Safe Procedure for Loading Vehicles
• 11.0 Safe Procedure for Unloading Vehicles
• 12.0 Load Restraint, Stability and Verification Checks
• 13.0 Manual Handling Controls and Use of Mechanical Aids
• 14.0 Managing Different Load Types (Pallets, Bulk, Oversized, Loose Items)
• 15.0 Working at Heights on Vehicles and Use of Access Equipment
• 16.0 Handling Adverse Weather and Environmental Conditions
• 17.0 Emergency Procedures and Incident Response
• 18.0 Housekeeping, Post‑Task Inspection and Securing the Area
• 19.0 Recordkeeping, Documentation and Audit Requirements
• 20.0 Review, Consultation 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)
• Heavy Vehicle National Law (HVNL) – Chain of Responsibility provisions
• Load Restraint Guide for Light Vehicles 2018 (National Transport Commission, Australia)
• Load Restraint Guide 2018 (National Transport Commission, Australia)
• Code of Practice: Managing the Risks of Plant in the Workplace (Safe Work Australia)
• Code of Practice: Work Health and Safety Consultation, Cooperation and Coordination (Safe Work Australia)
• AS 2359 series: Powered industrial trucks
• AS/NZS 4380: Cargo restraint systems – Transport webbing and components
• AS/NZS 4801: Occupational health and safety management systems (superseded but still widely referenced)