Product Overview

Summary: This SOP sets out a clear, step‑by‑step process for conducting roadworthiness checks when replacing tyres on fleet and work vehicles in Australia. It helps businesses verify that every tyre change restores the vehicle to a safe, compliant condition, reducing the risk of on‑road failures, enforcement action, and serious incidents.

Tyre replacement is one of the most frequent maintenance tasks carried out on work vehicles, yet it is also a common source of preventable incidents, defects and roadside non‑compliances. This Safe Operating Procedure provides a structured process for conducting roadworthiness checks before, during and after tyre replacement on cars, utes, trucks, trailers and mobile plant used for work. It goes beyond basic tyre fitting to ensure that load ratings, inflation pressures, wheel fixings, tread depth, sidewall condition and matching across axles are all verified against Australian road rules and manufacturer specifications.

By implementing this SOP, businesses can demonstrate that each tyre change returns the vehicle to a safe operating state and that reasonable steps have been taken to manage risks associated with blowouts, loss of control, wheel separation and breakdowns. The procedure supports compliance with WHS duties of care and chain of responsibility obligations, while giving mechanics and tyre fitters a consistent checklist to follow. It is particularly valuable for organisations running mixed fleets or subcontractor vehicles, where variable practices can otherwise lead to gaps in safety, recordkeeping and legal defensibility.

The document also clarifies roles and responsibilities between drivers, supervisors and maintenance personnel, and embeds simple documentation requirements so that roadworthiness checks are recorded and auditable. This helps organisations reduce downtime, avoid defect notices and fines, and build a safety culture where vehicle roadworthiness is treated as a critical control, not an afterthought.

Key Benefits

• Ensure every tyre replacement returns the vehicle to a roadworthy, legally compliant condition.
• Reduce the risk of tyre‑related incidents such as blowouts, loss of control and wheel separation.
• Standardise roadworthiness checks across workshops, sites and subcontractors.
• Demonstrate due diligence under WHS and chain of responsibility obligations through clear records.
• Minimise costly roadside defects, enforcement actions and unplanned vehicle downtime.

Who is this for?

• Fleet Managers
• Workshop Supervisors
• Heavy Vehicle Mechanics
• Light Vehicle Mechanics
• Tyre Fitters and Technicians
• Transport and Logistics Managers
• Mining and Civil Operations Managers
• Construction Site Supervisors
• WHS Managers and Advisors
• Owner‑Drivers and Small Transport Business Owners

Hazards Addressed

• Tyre blowouts due to incorrect pressure, damage or unsuitable load rating
• Loss of vehicle control from uneven tread, mismatched tyres or poor wheel alignment indicators
• Wheel separation caused by incorrect wheel nut torque or missing/damaged studs
• Vehicle instability when loaded due to under‑rated or incorrectly specified tyres
• On‑road breakdowns in high‑traffic or remote environments
• Manual handling and crush injuries during tyre and wheel handling if not managed within the process
• Exposure to adverse weather and traffic when conducting roadside or onsite tyre changes

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Vehicle Categories
• 3.0 Roles and Responsibilities (Drivers, Fitters, Supervisors, WHS)
• 4.0 Applicable Legislation, Standards and Manufacturer Requirements
• 5.0 Required Tools, Equipment and Personal Protective Equipment (PPE)
• 6.0 Pre‑Job Planning and Risk Assessment
• 7.0 Vehicle Isolation, Parking and Traffic Management Controls
• 8.0 Pre‑Replacement Roadworthiness Assessment (Tyres, Rims and Wheel Assemblies)
• 9.0 Tyre Selection and Verification (Size, Load/Speed Rating, Application Suitability)
• 10.0 Tyre Replacement Procedure (Removal, Inspection, Fitting and Inflation)
• 11.0 Post‑Replacement Roadworthiness Checks and Inspection Criteria
• 12.0 Wheel Nut Torqueing, Re‑torque Intervals and Wheel Security Checks
• 13.0 Documentation, Checklists and Maintenance Records
• 14.0 Non‑Conformance Management (Defects, Out‑of‑Service Decisions and Escalation)
• 15.0 Training, Competency and Authorisation Requirements
• 16.0 Monitoring, Review and Continuous Improvement

Legislation & References

• Heavy Vehicle (Vehicle Standards) National Regulation under the Heavy Vehicle National Law (HVNL)
• Australian Design Rules (ADRs) relating to tyres, rims and vehicle safety
• State and Territory Road Rules and Vehicle Standards (e.g. NSW Road Transport (Vehicle Registration) Regulation)
• Work Health and Safety Act 2011 (Cth and State/Territory equivalents)
• Work Health and Safety Regulation 2011 (Cth and State/Territory equivalents)
• National Heavy Vehicle Regulator (NHVR) – National Heavy Vehicle Inspection Manual
• Safe Work Australia – General Guide for Workplace Traffic Management
• AS 1973: Pneumatic tyres – Passenger car, light truck and truck/bus – New
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)
• ISO 45001: Occupational health and safety management systems (as adopted in Australia)