Product Overview

Summary: This SOP sets out clear, practical steps for the safe set‑up and operation of remotely controlled plant and equipment in Australian workplaces. It helps businesses manage the unique risks of remote operation, protect workers both in and outside exclusion zones, and demonstrate compliance with WHS obligations when using modern control technologies.

Remote control technology is increasingly used across construction, mining, manufacturing and maintenance activities to remove operators from high‑risk areas. While it can significantly reduce exposure to hazards such as falling objects, entrapment and hazardous atmospheres, it also introduces new risks related to signal loss, equipment runaway, poor line‑of‑sight and confusion over who is in control. This Remote Control Equipment Operation Safe Operating Procedure provides a structured, step‑by‑step framework for planning, setting up and operating remote‑controlled plant in a way that is both safe and compliant with Australian WHS requirements.

The SOP addresses the full lifecycle of remote operations – from pre‑start inspections, pairing and functional testing of transmitters and receivers, through to establishing exclusion zones, communication protocols, and controlled shutdown procedures. It clarifies roles and responsibilities, including spotters and controllers, and sets minimum requirements for training, supervision and emergency response. By adopting this procedure, businesses can standardise how remote control equipment is used across sites, reduce the likelihood of serious incidents, and provide documented evidence of a “reasonably practicable” approach to risk management under WHS law.

Key Benefits

• Reduce the risk of crush injuries, collisions and runaways by defining strict operating boundaries and control checks for remote equipment.
• Ensure compliance with Australian WHS legislation and relevant standards when deploying remote‑controlled plant and machinery.
• Standardise training and competency expectations for operators, spotters and supervisors involved in remote operations.
• Improve on‑site communication and coordination through clear protocols for hand signals, radio use and transfer of control.
• Minimise equipment damage and unplanned downtime by embedding robust pre‑start inspections, signal testing and fault‑response steps.

Who is this for?

• Plant Operators
• Remote Control Equipment Operators
• Site Supervisors
• WHS Managers
• Project Managers
• Maintenance Supervisors
• Mining and Quarrying Supervisors
• Construction Managers
• Manufacturing and Processing Supervisors
• Fleet and Asset Managers

Hazards Addressed

• Unintended movement or runaway of remotely controlled plant
• Loss of control due to signal interference, range issues or battery failure
• Collisions with people, vehicles, structures or other plant
• Crush and entrapment injuries within the equipment’s operating envelope
• Struck‑by incidents from moving or swinging loads
• Poor line‑of‑sight leading to blind‑spot incidents
• Miscommunication between operator, spotter and other workers
• Unauthorised use or activation of remote control equipment
• Slips, trips and falls affecting operators moving to maintain visibility
• Electrical and fire hazards associated with batteries, chargers and control units

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Remote Control Equipment
• 3.0 Roles, Responsibilities and Required Competencies
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for Remote Operations
• 6.0 Pre‑Operational Requirements and Authorisations
• 7.0 Equipment Inspection, Pairing and Functional Testing
• 8.0 Site Set‑Up, Exclusion Zones and Traffic Management
• 9.0 Communication Protocols (Spotters, Radios and Hand Signals)
• 10.0 Step‑by‑Step Remote Operation Procedure
• 11.0 Transfer of Control, Multiple Operators and Handover Rules
• 12.0 Emergency Stop, Fault Conditions and Incident Response
• 13.0 Post‑Operation Shutdown, Isolation and Housekeeping
• 14.0 Maintenance, Battery Management and Storage of Control Units
• 15.0 Training, Induction and Competency Verification
• 16.0 Monitoring, Review and Continuous Improvement of the Procedure
• 17.0 Document Control and Recordkeeping Requirements

Legislation & References

• Work Health and Safety Act 2011 (Cth and corresponding state and territory legislation)
• Work Health and Safety Regulations 2011 (Cth and corresponding state and territory regulations)
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: Managing the work environment and facilities
• AS 4024.1 Series: Safety of machinery
• AS/NZS 3000: Electrical installations (Wiring Rules) – for charging and electrical interfaces where relevant
• AS/NZS 4801: Occupational health and safety management systems (superseded but still referenced in many systems)
• ISO 45001: Occupational health and safety management systems (for organisations aligned with current best practice)