Product Overview

Summary: This Metal Recycling Safe Operating Procedure sets out clear, practical steps for safely receiving, sorting, processing and storing scrap metal in line with Australian WHS requirements. It helps metal recyclers control high‑risk activities such as plant operation, manual handling, fire and environmental exposure, while improving efficiency and traceability across the yard.

Metal recycling operations combine heavy mobile plant, fixed processing equipment, variable scrap quality and high traffic volumes, creating a complex risk profile under Australian WHS law. This Metal Recycling Safe Operating Procedure provides a structured, step‑by‑step framework for managing these risks across the full lifecycle of scrap metal handling – from gatehouse acceptance and load inspection through to sorting, shearing, baling, shredding, stockpiling and despatch. It details how to separate and manage different metal types, identify and isolate prohibited or hazardous items (such as gas cylinders and batteries), and coordinate safe interactions between pedestrians, vehicles and machinery.

By implementing this SOP, metal recycling businesses can demonstrate due diligence and a systematic approach to hazard control, supporting compliance with WHS legislation, environmental obligations and chain of responsibility requirements. The procedure standardises work practices across shifts and sites, clarifies roles and communication protocols, and embeds controls for common industry risks such as entanglement, crush injuries, fires in scrap piles, noise, airborne contaminants and poor housekeeping. The result is a safer, more efficient yard that protects workers, contractors, visitors and the surrounding community while maximising recovery of valuable metals.

This document is designed specifically for the Australian context, aligning with relevant WHS Acts and Regulations in each jurisdiction, Safe Work Australia guidance and applicable Australian Standards. It can be readily integrated into existing safety management systems, toolbox talks, worker induction programs and contractor management processes, providing a clear reference point for day‑to‑day operations and incident investigations.

Key Benefits

• Ensure consistent, safe work practices across all metal recycling activities, shifts and sites.
• Reduce the likelihood of serious injuries from mobile plant, crushing, entanglement and uncontrolled movement of scrap.
• Improve compliance with Australian WHS, environmental and dangerous goods requirements for scrap acceptance and processing.
• Streamline traffic management, load inspection, sorting and stockpile control to minimise congestion and double handling.
• Enhance incident preparedness with clear procedures for fires, spills, equipment failures and discovery of hazardous items.

Who is this for?

• Metal Recycling Facility Managers
• Yard Supervisors
• Scrap Metal Operators
• Plant and Machinery Operators
• WHS Managers and Advisors
• Maintenance Supervisors
• Logistics and Dispatch Coordinators
• Compliance and Environmental Officers

Hazards Addressed

• Struck-by and run-over incidents involving forklifts, loaders, excavators and trucks
• Crush injuries from unstable scrap piles, falling loads and pinch points
• Entanglement in conveyors, shredders, shears and other moving plant
• Manual handling injuries from lifting, pushing and pulling heavy or awkward scrap
• Fire and explosion risks from fuel residues, gas cylinders, aerosols and combustible materials in scrap
• Exposure to sharp edges causing cuts, puncture wounds and lacerations
• Noise-induced hearing loss from shredders, shears, balers and heavy vehicle movements
• Exposure to hazardous substances such as oils, coolants, lead, batteries and contaminated scrap
• Slips, trips and falls due to poor housekeeping, uneven ground and debris
• Electrical hazards from damaged cables, stray live components or contact with overhead services

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Plant, Equipment and PPE Requirements
• 6.0 Site Layout and Traffic Management Controls
• 7.0 Pre-Start Checks and Daily Yard Inspections
• 8.0 Scrap Acceptance, Inspection and Rejection Criteria
• 9.0 Identification and Management of Prohibited or Hazardous Items
• 10.0 Safe Procedures for Sorting, Cutting, Shearing, Baling and Shredding
• 11.0 Manual Handling and Use of Mechanical Aids
• 12.0 Stockpile Management and Stability Controls
• 13.0 Housekeeping, Waste Segregation and Environmental Controls
• 14.0 Lockout/Tagout and Isolation of Plant for Maintenance
• 15.0 Emergency Response Procedures (Fire, Explosion, Spills, Injuries)
• 16.0 Incident Reporting, Investigation and Corrective Actions
• 17.0 Training, Induction and Competency Assessment
• 18.0 Monitoring, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 and corresponding state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: Managing risks of hazardous chemicals in the workplace
• Safe Work Australia – Code of Practice: How to manage work health and safety risks
• Safe Work Australia – Code of Practice: Managing the work environment and facilities
• AS/NZS 4024 series: Safety of machinery
• AS 1940: The storage and handling of flammable and combustible liquids (for contaminated scrap and fuels)
• AS/NZS 4801 / ISO 45001: Occupational health and safety management systems
• Relevant state and territory environmental protection legislation and guidelines for waste and recycling facilities