Product Overview

Summary: This SOP provides a structured process for selecting, positioning and managing plant and equipment on Australian worksites to minimise risk and maximise productivity. It helps businesses control mobile and fixed plant hazards, protect workers and the public, and demonstrate compliance with WHS duties for safe design, traffic management and site layout.

Plant and equipment are often the highest-risk elements on any worksite, particularly where mobile plant interacts with pedestrians, other vehicles and fixed structures. This Plant Selection and Placement Safe Operating Procedure establishes a clear, repeatable method for choosing the right plant for the task and positioning it so that risks are eliminated or minimised so far as is reasonably practicable. It guides supervisors and planners through assessing the work environment, understanding task requirements, reviewing plant capabilities and limitations, and designing safe layouts that separate people from plant.

The SOP is designed for Australian workplaces that use mobile and fixed plant in construction, civil works, manufacturing, warehousing, utilities and maintenance operations. It addresses common pain points such as poorly planned site layouts, ad‑hoc plant selection, conflicting work activities and inadequate exclusion zones. By implementing this procedure, businesses can reduce near misses and collisions, improve traffic flow, protect critical underground and overhead services, and provide a documented, defensible approach to plant risk management aligned with WHS legislation and regulator expectations across all states and territories.

Key Benefits

• Ensure plant is selected based on task risk, site conditions and WHS requirements rather than convenience or availability.
• Reduce the likelihood of collisions, struck-by incidents and service strikes through planned placement and clearly defined exclusion zones.
• Improve site productivity by optimising plant positioning, traffic routes and material flow while maintaining safe separation from pedestrians.
• Standardise decision-making around plant selection and layout across projects, supporting consistent training and supervision.
• Demonstrate due diligence and compliance with WHS laws through a documented, risk-based process for plant planning and deployment.

Who is this for?

• Project Managers
• Site Supervisors
• WHS Managers
• Construction Managers
• Civil Works Supervisors
• Maintenance Managers
• Plant Coordinators / Allocators
• Fleet Managers
• Health and Safety Representatives (HSRs)

Hazards Addressed

• Mobile plant and vehicle collisions with workers, other vehicles or structures
• Contact with overhead powerlines or underground services during plant operation
• Crushing and trapping between plant and fixed objects due to poor positioning
• Reversing and blind-spot incidents in congested work areas
• Unauthorised access to operating zones due to inadequate exclusion areas or signage
• Instability, overturning or collapse of plant due to unsuitable ground conditions or gradients
• Noise and dust exposure from poorly located plant relative to work areas and amenities
• Traffic congestion and conflicting movement paths between pedestrians and plant

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Plant Covered
• 3.0 Roles and Responsibilities (PCBU, Officers, Supervisors, Operators, HSRs)
• 4.0 Pre-Planning and Risk Assessment Requirements
• 5.0 Criteria for Plant Selection (task, environment, load, access, WHS controls)
• 6.0 Verification of Plant Compliance, Licensing and Competency
• 7.0 Site Assessment for Plant Placement (ground conditions, gradients, services, access)
• 8.0 Design of Plant Layout and Traffic Management (routes, crossings, parking, laydown areas)
• 9.0 Establishing Exclusion Zones, Barriers and Signage
• 10.0 Controls for Interaction Between Plant and Pedestrians
• 11.0 Controls for Overhead and Underground Services
• 12.0 Environmental and Amenity Considerations (noise, dust, vibration, lighting)
• 13.0 Step-by-Step Procedure for Implementing Plant Selection and Placement on Site
• 14.0 Monitoring, Inspection and Adjustment of Plant Layout During Works
• 15.0 Emergency Access, Egress and Incident Response Considerations
• 16.0 Training, Communication and Consultation Requirements
• 17.0 Documentation, Record Keeping and Review
• 18.0 References and Related Documents

Legislation & References

• Model Work Health and Safety Regulations (Safe Work Australia), Part 4.5 – Plant and Structures
• Safe Work Australia – Code of Practice: Managing the Risks of Plant in the Workplace
• Safe Work Australia – General Guide for Workplace Traffic Management
• Safe Work Australia – Code of Practice: Construction Work
• AS/NZS 4801:2001 Occupational health and safety management systems (superseded but still referenced in many systems)
• AS 2359.2: Powered industrial trucks – Operations
• AS 2550 series: Cranes, hoists and winches – Safe use (where applicable to lifting plant)
• AS 1319: Safety signs for the occupational environment