Product Overview

Summary: This Manual Handling Safe Operating Procedure sets out clear, practical steps for lifting, carrying, pushing, pulling and moving loads safely in Australian workplaces. It helps you control one of the most common causes of workers’ compensation claims—musculoskeletal injuries—while demonstrating due diligence under WHS legislation.

Manual tasks are performed in almost every Australian workplace, from offices and warehouses to construction sites, healthcare facilities and hospitality venues. Poorly planned or ad‑hoc manual handling exposes workers to sprains, strains, back injuries and long-term musculoskeletal disorders that can quietly erode productivity and morale. This Manual Handling Safe Operating Procedure provides a structured, step-by-step approach to identifying hazardous manual tasks, assessing risk, and applying effective controls before the job starts.

Developed with Australian WHS requirements in mind, this SOP gives your workers clear guidance on when and how to lift, when to use mechanical aids, how to work in teams, and when to stop and reassess a task. It supports businesses to move beyond generic “lift with your legs” messages and instead embed a consistent, defendable system for planning and performing manual tasks. By implementing this SOP, you reduce the likelihood of manual handling injuries, cut workers’ compensation costs, and demonstrate that your organisation takes its duty of care seriously.

Key Benefits

• Reduce the incidence and severity of musculoskeletal injuries arising from lifting, carrying, pushing and pulling tasks.
• Ensure consistent, compliant manual handling practices across different sites, shifts and teams.
• Support legal compliance with Australian WHS legislation and the Hazardous Manual Tasks Code of Practice.
• Improve productivity by planning tasks, using mechanical aids effectively and minimising unnecessary double-handling.
• Strengthen worker engagement through clear instructions, practical examples and defined responsibilities.

Who is this for?

• WHS Managers
• Health and Safety Representatives (HSRs)
• Operations Managers
• Warehouse and Store Supervisors
• Construction Site Supervisors
• Aged Care and Disability Support Coordinators
• Manufacturing Team Leaders
• Facilities and Maintenance Managers
• HR and Training Managers
• Small Business Owners and Directors

Hazards Addressed

• Musculoskeletal disorders (MSDs) from repetitive or sustained movements
• Back, neck and shoulder injuries from heavy or awkward lifting
• Strains and sprains from sudden or unexpected loads
• Crush and impact injuries from dropped or unstable loads
• Slips, trips and falls while carrying or moving items
• Fatigue-related incidents due to prolonged or high-force manual tasks

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (Manual Tasks, Hazardous Manual Tasks, MSDs)
• 3.0 Roles and Responsibilities (PCBUs, Managers, Supervisors, Workers, HSRs)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification for Manual Tasks
• 6.0 Risk Assessment of Manual Handling Activities
• 7.0 Hierarchy of Control for Hazardous Manual Tasks
• 8.0 Planning Manual Handling Tasks (Job Design and Work Organisation)
• 9.0 Use of Mechanical Aids and Handling Equipment
• 10.0 Safe Lifting, Carrying, Pushing and Pulling Techniques
• 11.0 Team Lifting and Communication Requirements
• 12.0 Environmental Considerations (Housekeeping, Lighting, Slopes, Weather)
• 13.0 Training, Competency and Supervision
• 14.0 Pre-Task Checks and Take 5 / Stop-Think-Act Assessments
• 15.0 Incident, Near Miss and Discomfort Reporting
• 16.0 Monitoring, Review and Continuous Improvement
• 17.0 Recordkeeping and Document Control
• 18.0 Appendices – Sample Risk Assessment Checklist, Manual Task Planning Form, Training Record Template

Legislation & References

• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Model Work Health and Safety Act
• Model Work Health and Safety Regulations – Part 4.2 Hazardous Manual Tasks
• Safe Work Australia – Guide for Preventing Musculoskeletal Disorders in the Workplace
• AS/NZS ISO 45001:2018 Occupational health and safety management systems