Product Overview

Summary: This Puncture Repair Safe Operating Procedure sets out a clear, safe and compliant method for inspecting, repairing and reinstating tyres and tubes in Australian workplaces. It helps control the significant risks associated with working on pressurised tyres, jacks and lifting equipment, while supporting consistent, high-quality repairs that keep vehicles and plant safely on the road.

Tyre puncture repair work is often treated as a quick, routine task, yet it involves serious hazards such as explosive tyre failure, vehicle collapse from incorrect jacking, and exposure to traffic in roadside environments. This Puncture Repair Safe Operating Procedure provides a structured, step-by-step method for safely assessing tyre damage, selecting the correct repair method, using jacks and stands, and re‑inflating and reinstating tyres on a wide range of vehicles and plant. It is designed for workshops, mobile service vehicles, depots and on-site maintenance teams across transport, construction, agriculture, mining and local government operations.

By implementing this SOP, businesses create a consistent and defensible process that aligns with Australian WHS expectations for managing risks associated with plant and vehicle maintenance. The procedure addresses common pain points such as ad‑hoc repair decisions, inconsistent use of wheel chocks and stands, poor inflation practices, and inadequate documentation of repairs. It supports safer work environments, better tyre life, reduced unplanned downtime and clearer training pathways for new and existing technicians, while demonstrating due diligence in the event of an incident or regulator inspection.

Key Benefits

• Reduce the risk of serious injury from tyre burst, vehicle collapse and uncontrolled movement during puncture repairs.
• Ensure consistent, high-quality puncture repairs that extend tyre life and minimise repeat failures.
• Standardise training for technicians and apprentices with a clear, step-by-step repair method.
• Demonstrate compliance with WHS duties for safe plant maintenance and roadside work activities.
• Improve fleet reliability and reduce downtime through structured inspection and repair decision criteria.

Who is this for?

• Workshop Managers
• Tyre Technicians
• Fleet Maintenance Supervisors
• Light and Heavy Vehicle Mechanics
• Agricultural Machinery Operators
• Mining and Civil Plant Operators
• Service Station and Roadside Assistance Staff
• WHS Managers and Safety Advisors

Hazards Addressed

• Tyre explosion or rapid air release during inflation or bead seating
• Vehicle or plant collapse due to incorrect jacking or lack of axle stands
• Crush injuries from uncontrolled vehicle movement or rolling wheels
• Manual handling injuries from lifting and manoeuvring wheels and tyres
• Exposure to traffic during roadside puncture repairs
• Hand and eye injuries from tyre levers, bead breakers and sharp objects
• Noise exposure from compressed air tools and impact wrenches
• Slips, trips and falls in workshop or roadside environments
• Contact with hazardous substances such as tyre sealants, lubricants and cleaning agents

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Applicable Tyre Types
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Required Tools, Equipment and Materials
• 5.0 Personal Protective Equipment (PPE) Requirements
• 6.0 Pre-Job Planning and Risk Assessment
• 7.0 Vehicle Securing, Jacking and Support Procedures
• 8.0 Tyre and Wheel Removal and Handling
• 9.0 Inspection, Damage Assessment and Repair Decision Criteria
• 10.0 Approved Puncture Repair Methods (Plug, Patch, Combination) and Limitations
• 11.0 Step-by-Step Puncture Repair Procedure
• 12.0 Tyre Refitting, Torque Settings and Re-Inflation Controls
• 13.0 Post-Repair Checks, Testing and Documentation
• 14.0 Hazard Identification and Control Measures
• 15.0 Roadside and Remote Location Repair Considerations
• 16.0 Emergency Procedures (Tyre Burst, Vehicle Instability, Injury)
• 17.0 Equipment Maintenance, Inspection and Storage
• 18.0 Training, Induction and Competency Verification
• 19.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulations 2011 (Cth and relevant state/territory variants) – Part 4.5 Plant and Part 3.1 Managing Risks of Hazardous Work
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• AS 4457.1: Earth-moving machinery – Tyre assemblies – Part 1: Rim selection and rim matching
• AS 4457.2: Earth-moving machinery – Tyre assemblies – Part 2: Maintenance and repair
• AS/NZS 4024 series: Safety of machinery (for general guarding and safety principles)
• AS/NZS 1891 series: Industrial fall-arrest systems and devices (where work at height is involved)
• AS/NZS 2161 series: Occupational protective gloves (for hand protection selection)