Product Overview

Summary: This Safe Operating Procedure provides a clear, step‑by‑step method for safely measuring and cutting drywall on Australian construction and fit‑out sites. It focuses on accurate layout, safe use of cutting tools, and effective dust control to protect workers while improving productivity and finish quality.

Measuring and cutting drywall (plasterboard) is a routine task on almost every building and fit‑out project in Australia, yet it is also a common source of injuries, rework and costly delays. Poor technique can lead to cuts and lacerations, exposure to nuisance dust, musculoskeletal strain, and a high volume of offcuts that blow out material budgets. This SOP sets out a consistent, WHS‑aligned method for planning, measuring, marking and cutting drywall, including safe handling of full sheets, correct use of knives, saws and power tools, and practical dust minimisation strategies.

Developed for the Australian construction environment, the procedure helps businesses demonstrate due diligence under WHS legislation while lifting workmanship standards. It clarifies who does what on site, what pre‑start checks are required, how to set up a safe cutting area, and how to manage offcuts and waste in line with environmental and housekeeping expectations. By embedding this SOP into your induction, toolbox talks and on‑the‑job training, you can reduce incidents, improve installation accuracy, and create a safer, cleaner and more efficient work front for your teams and subcontractors.

Key Benefits

• Reduce the risk of cuts, eye injuries and dust exposure when handling and cutting drywall.
• Ensure consistent measuring and cutting practices that minimise rework and material wastage.
• Support compliance with Australian WHS duties for safe plant use, manual handling and airborne contaminants.
• Standardise training for apprentices and new workers with a clear, repeatable method.
• Improve site housekeeping and workflow by defining safe cutting zones and waste‑handling requirements.

Who is this for?

• Carpenters and Plasterers
• Drywall Installers and Fixers
• Site Supervisors
• Construction Project Managers
• WHS Advisors and Safety Officers
• Apprentices and Trade Assistants
• Facilities Maintenance Teams
• Shopfitting and Fit‑out Contractors

Hazards Addressed

• Lacerations and puncture wounds from utility knives, hand saws and power cutting tools
• Eye injuries from flying fragments and dust during scoring, snapping and sawing
• Inhalation of drywall and jointing compound dust, including respirable particles
• Musculoskeletal strain from lifting, carrying and positioning large drywall sheets
• Trips and slips due to offcuts, packaging and tools obstructing walkways
• Noise exposure from power saws and cutting equipment
• Electric shock risk when cutting near concealed electrical services
• Hand–arm vibration exposure from prolonged use of powered cutting tools

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Standards and Legal Requirements
• 3.0 Definitions (Drywall/Plasterboard, Score and Snap, Cut‑Outs, Offcuts)
• 4.0 Roles and Responsibilities (PCBU, Supervisors, Workers, Contractors)
• 5.0 Required Competencies and Training
• 6.0 Tools, Equipment and Materials
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Pre‑Start Checks and Site Preparation
• 9.0 Setting Up a Safe Drywall Cutting Area
• 10.0 Manual Handling and Safe Sheet Handling Techniques
• 11.0 Measuring and Marking Procedures for Drywall
• 12.0 Scoring and Snapping Technique for Straight Cuts
• 13.0 Cutting Openings for Services (Power Points, Switches, Fixtures)
• 14.0 Use of Hand Saws and Power Tools for Curved and Complex Cuts
• 15.0 Dust Control Measures and Ventilation Requirements
• 16.0 Housekeeping, Offcut Management and Waste Disposal
• 17.0 Hazard Identification and Risk Control Measures
• 18.0 Lock‑out and Service Location Considerations (Electrical and Services)
• 19.0 Emergency Procedures (First Aid for Cuts, Eye Injuries and Dust Inhalation)
• 20.0 Inspection, Maintenance and Storage of Tools and Equipment
• 21.0 Training, Induction and Competency Verification
• 22.0 Monitoring, Review and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161: Occupational protective gloves
• AS/NZS 3012: Electrical installations – Construction and demolition sites