Product Overview

Summary: This Safe Operating Procedure sets out safe, practical manual handling techniques for lifting, moving and fitting tyres in Australian workplaces. It helps reduce musculoskeletal injuries, standardises safe work methods, and supports compliance with WHS duties wherever tyres are handled, from workshops and transport yards to mining and agricultural sites.

Handling tyres presents unique manual handling challenges due to their awkward shape, size, and weight, especially for heavy vehicle, mining and agricultural tyres. Poor technique or ad‑hoc practices can quickly lead to back strains, shoulder injuries, crush incidents, and long‑term musculoskeletal disorders. This Manual Handling Techniques for Tyres SOP provides a clear, step‑by‑step framework for assessing the load, planning the task, and using safe body mechanics and mechanical aids to control risk at the source.

Developed for Australian conditions, the procedure covers manual handling of a broad range of tyres – from passenger vehicles through to light truck, bus, earthmoving and agricultural tyres – in workshops, depots, warehouses and roadside environments. It helps businesses translate WHS obligations into practical, repeatable work methods that workers can actually follow on the floor. By implementing this SOP, organisations can reduce injury rates, improve productivity, support consistent training of new and existing staff, and demonstrate due diligence if an incident or regulator inquiry occurs.

Key Benefits

• Reduce the risk of back, shoulder and other musculoskeletal injuries associated with tyre handling tasks.
• Ensure consistent, documented safe work methods across workshops, depots and field operations.
• Support compliance with Australian WHS legislation and manual handling risk management requirements.
• Improve productivity by promoting efficient use of trolleys, jacks, dollies and other tyre handling aids.
• Strengthen induction and refresher training with clear, visual and step-by-step guidance for workers.

Who is this for?

• Tyre Fitters
• Automotive Technicians and Mechanics
• Fleet Maintenance Staff
• Warehouse and Storepersons
• Roadside Assistance Technicians
• Workshop Supervisors
• Depot and Yard Supervisors
• WHS Managers and Advisors
• Fleet and Operations Managers
• Mining and Agricultural Maintenance Teams

Hazards Addressed

• Musculoskeletal disorders from lifting, carrying, pushing and pulling tyres
• Back strains and sprains from poor posture or twisting while handling tyres
• Crush injuries to feet and hands from dropped or rolling tyres and rims
• Pinch and entrapment injuries between tyres, rims, vehicles and equipment
• Overexertion from attempting to manually handle oversized or heavy tyres without mechanical aids
• Slips, trips and falls while moving tyres in congested or poorly maintained areas
• Fatigue-related incidents from repetitive tyre handling tasks

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Tyre Categories (Passenger, Light Truck, Heavy Vehicle, OTR, Agricultural)
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Workers)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for Tyre Handling Tasks
• 6.0 Principles of Safe Manual Handling for Tyres
• 7.0 Pre-Task Planning and Work Area Preparation
• 8.0 Selection and Use of Mechanical Aids (Tyre jacks, dollies, trolleys, hoists, conveyors)
• 9.0 Safe Techniques for Lifting, Lowering and Carrying Tyres
• 10.0 Safe Techniques for Rolling, Tilting and Stacking Tyres
• 11.0 Procedures for Fitting and Removing Tyres from Vehicles and Rims
• 12.0 Handling Oversized, Heavy or Off-the-Road (OTR) Tyres
• 13.0 Roadside and Remote Location Tyre Handling Considerations
• 14.0 Housekeeping and Storage Requirements for Tyres
• 15.0 Personal Protective Equipment (PPE) Requirements
• 16.0 Training, Competency and Supervision
• 17.0 Incident Reporting, Near Misses and Corrective Actions
• 18.0 Monitoring, Review and Continuous Improvement of the Procedure
• 19.0 Document Control and Record Keeping

Legislation & References

• Model Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Model Work Health and Safety Regulations 2011 – Hazardous manual tasks provisions
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• AS/NZS ISO 45001:2018 Occupational health and safety management systems – Requirements with guidance for use