Product Overview

Summary: This Manual Handling Safety Safe Operating Procedure provides a clear, step-by-step approach to lifting, carrying, pushing, pulling and handling loads safely in Australian workplaces. It helps businesses significantly reduce musculoskeletal injuries, standardise safe work practices, and demonstrate compliance with WHS duties relating to hazardous manual tasks.

Manual handling is one of the most common sources of workplace injury in Australia, driving workers’ compensation claims, lost time, and long-term musculoskeletal disorders. This Manual Handling Safety Safe Operating Procedure sets out a practical, repeatable system for identifying hazardous manual tasks, assessing the risks, and implementing safe methods of work across a wide range of industries—from warehouses and construction sites to healthcare, hospitality and offices. It translates WHS obligations into clear actions that frontline workers and supervisors can understand and apply in day-to-day tasks.

The procedure goes beyond generic “lift with your legs” advice. It provides structured guidance on task design, use of mechanical aids, team lifting, safe handling of awkward or unstable loads, and job planning to avoid unnecessary strain. It also addresses consultation, training and supervision requirements so that businesses can embed safe manual handling into their broader WHS management system. By implementing this SOP, organisations can reduce the frequency and severity of sprains and strains, improve productivity, and show regulators and insurers that manual handling risks are being systematically controlled.

Developed specifically for the Australian regulatory context, this SOP aligns with the Hazardous Manual Tasks Code of Practice and relevant Australian Standards. It is ideal for businesses looking to standardise their approach across multiple sites, support new worker inductions, and provide clear evidence of due diligence during audits, incident investigations and regulatory inspections.

Key Benefits

• Reduce the incidence and severity of musculoskeletal injuries caused by lifting, carrying, pushing, pulling and repetitive tasks.
• Ensure alignment with Australian WHS legislation and the Hazardous Manual Tasks Code of Practice, supporting compliance and audit readiness.
• Standardise manual handling practices across sites, shifts and teams to improve consistency and reduce unsafe shortcuts.
• Improve productivity by planning tasks, using mechanical aids effectively, and minimising unnecessary physical effort.
• Support effective training, induction and refresher programs with clear, documented procedures and 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
• Logistics and Distribution Managers
• Return-to-Work and Injury Management Coordinators
• Human Resources Managers
• Training and Induction Coordinators

Hazards Addressed

• Musculoskeletal disorders (MSDs) from repetitive or sustained movements
• Back, neck and shoulder strains from lifting or lowering heavy loads
• Injuries from handling awkward, bulky or unstable items
• Sprains and strains from pushing, pulling or sliding loads
• Overexertion due to sudden or unexpected forces
• Slips, trips and falls associated with carrying loads that obstruct vision
• Crush and pinch injuries to fingers, hands and feet during manual handling
• Fatigue-related errors when performing high-exertion manual tasks

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Key Terms (Manual Tasks, Hazardous Manual Tasks, MSDs)
• 3.0 Roles and Responsibilities (PCBUs, Officers, Supervisors, Workers, HSRs)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification – Recognising Hazardous Manual Tasks
• 6.0 Risk Assessment for Manual Handling Activities
• 7.0 Hierarchy of Control Measures for Manual Handling Risks
• 8.0 Task and Workplace Design to Eliminate or Minimise Manual Handling
• 9.0 Use of Mechanical Aids and Handling Equipment (trolleys, pallet jacks, hoists, lifters)
• 10.0 Safe Lifting, Carrying, Pushing and Pulling Techniques
• 11.0 Team Lifting and Coordination Procedures
• 12.0 Handling Specific Load Types (awkward, hot/cold, fragile, unstable, patient handling where applicable)
• 13.0 Planning Workflows, Breaks and Job Rotation to Reduce Fatigue
• 14.0 Personal Protective Equipment (PPE) Requirements and Limitations
• 15.0 Training, Induction and Competency Requirements
• 16.0 Consultation, Communication and Worker Participation
• 17.0 Reporting of Discomfort, Near Misses and Manual Handling Incidents
• 18.0 Incident Response and Early Intervention for Musculoskeletal Symptoms
• 19.0 Monitoring, Review and Continuous Improvement of Manual Handling Controls
• 20.0 Document Control, Recordkeeping and Audit Trail

Legislation & References

• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Model Work Health and Safety Act
• Model Work Health and Safety Regulations (Hazardous Manual Tasks provisions)
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• AS/NZS ISO 45001: Occupational health and safety management systems
• Safe Work Australia – Guide for Preventing Musculoskeletal Disorders in the Workplace