Product Overview

Summary: This Manual Handling and Lifting Safe Operating Procedure sets out clear, practical steps for safely lifting, carrying, pushing, pulling and moving loads in Australian workplaces. It helps businesses significantly reduce musculoskeletal injuries while demonstrating due diligence under WHS legislation and supporting safer, more sustainable work practices.

Manual handling is one of the leading causes of work-related injury in Australia, particularly soft tissue and musculoskeletal disorders affecting the back, shoulders and upper limbs. This Manual Handling and Lifting Safe Operating Procedure provides a structured, step-by-step approach for planning and completing manual tasks safely, from simple lifts and carries through to more complex team lifts and use of mechanical aids. It translates legislative requirements and best practice guidance into clear, practical instructions that frontline workers and supervisors can easily follow.

By implementing this SOP, businesses can systematically assess manual handling tasks, identify hazardous movements or postures, and apply effective control measures such as task redesign, use of trolleys and lifting equipment, or team-based handling. The procedure supports consistent training and onboarding, reduces reliance on informal “workarounds”, and creates a documented, defensible process that demonstrates compliance with Australian WHS duties. It is suitable for a wide range of industries, including warehousing, construction, healthcare, hospitality, manufacturing and local government operations, and can be readily adapted to site-specific tasks and equipment.

The document is written in plain, worker-friendly language, with an emphasis on risk assessment, correct lifting technique, communication during team lifts, and early reporting of discomfort or symptoms. When used as part of a broader manual handling risk management program, this SOP helps organisations cut injury rates, minimise workers compensation costs, and maintain productivity by keeping experienced staff at work and safe.

Key Benefits

• Reduce the incidence and severity of manual handling-related musculoskeletal injuries across your workforce.
• Ensure compliance with Safe Work Australia guidance and state or territory WHS legislation on hazardous manual tasks.
• Standardise safe lifting, carrying and handling practices across sites, shifts and teams.
• Support effective training, induction and refresher programs with clear, step-by-step instructions.
• Minimise disruption, absenteeism and workers compensation costs associated with manual handling injuries.

Who is this for?

• WHS Managers
• Health and Safety Representatives (HSRs)
• Site Supervisors
• Operations Managers
• Warehouse and Storepersons
• Construction Workers and Labourers
• Aged Care and Disability Support Workers
• Nurses and Allied Health Staff
• Facilities and Maintenance Teams
• Logistics and Distribution Coordinators
• Manufacturing and Production Workers
• Human Resources Managers
• Training and Induction Coordinators

Hazards Addressed

• Musculoskeletal disorders from repetitive lifting, bending, twisting and reaching
• Back strain and spinal injuries from lifting or carrying heavy or awkward loads
• Shoulder, neck and upper limb injuries from sustained or awkward postures
• Crush and impact injuries from dropped or shifting loads
• Slips, trips and falls while carrying or moving items that obstruct vision or limit balance
• Overexertion injuries from pushing, pulling or manoeuvring trolleys and equipment
• Hand and finger injuries from poor grip, sharp edges or unstable loads
• Fatigue-related incidents during prolonged or high-force manual tasks

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Key Terms (Manual Task, Hazardous Manual Task, Load, Team Lift, Mechanical Aid)
• 3.0 Roles and Responsibilities (PCBU, Officers, Supervisors, Workers, HSRs)
• 4.0 Legislative and Standards References
• 5.0 Hazard Identification and Risk Assessment for Manual Handling Tasks
• 6.0 Hierarchy of Control for Manual Handling Risks
• 7.0 Planning a Lift or Manual Task (Assessing Load, Path, Environment and Individual Capability)
• 8.0 Safe Lifting Techniques (One-person Lifts)
• 9.0 Team Lifting Procedures and Communication Protocols
• 10.0 Use of Mechanical Aids (Trolleys, Pallet Jacks, Hoists, Patient Lifters and Handling Equipment)
• 11.0 Task-specific Guidance (e.g. Stacking and Destacking, Loading Vehicles, Handling Patients or Clients, Handling Long or Bulky Items)
• 12.0 Environmental Considerations (Housekeeping, Lighting, Slopes, Weather and Surface Conditions)
• 13.0 Personal Protective Equipment (PPE) Requirements and Limitations
• 14.0 Training, Induction and Competency Requirements
• 15.0 Early Reporting of Discomfort, Pain and Near Misses
• 16.0 Incident Response and Injury Management Overview
• 17.0 Monitoring, Review and Continuous Improvement of Manual Handling Controls
• 18.0 Document Control, Version History and Recordkeeping

Legislation & References

• Safe Work Australia – Hazardous Manual Tasks Code of Practice
• Model Work Health and Safety Act 2011
• Model Work Health and Safety Regulations 2011 – Part 4.2 Hazardous Manual Tasks
• AS/NZS ISO 45001:2018 Occupational health and safety management systems
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• Relevant state and territory WHS Acts and Regulations (e.g. Work Health and Safety Regulation 2017 (NSW))