Product Overview

Summary: This Soil Compaction and Testing Safe Operating Procedure sets out a clear, step-by-step method for carrying out compaction works and associated testing safely, consistently and in line with Australian standards. It helps civil and construction businesses control geotechnical risks, protect workers around heavy plant and excavation, and deliver compliant, verifiable ground conditions for long-term asset performance.

Soil compaction and testing are critical activities in civil construction, roadworks, subdivisions and infrastructure projects, where the long-term performance of pavements, slabs, foundations and services depends on achieving the specified ground conditions. At the same time, these tasks introduce significant WHS risks due to the use of rollers, compactors and testing equipment in and around excavations, live traffic, services and other trades. This Safe Operating Procedure provides a structured, end-to-end approach to planning, carrying out and verifying soil compaction and testing in a way that is both technically robust and safety-focused.

The procedure covers the full lifecycle of the activity: pre-start planning and geotechnical review, service locating and ground assessment, selection and inspection of compaction equipment, safe operation of rollers and compactors, management of exclusion zones and traffic interfaces, and coordination with NATA-accredited testing providers. It also sets out standard methods for in-situ density testing, moisture content checks and acceptance criteria aligned with common Australian specifications. By adopting this SOP, organisations can reduce rework and failures, demonstrate compliance with WHS and technical standards, and provide clear, practical guidance to supervisors and crews working on sites across Australia.

Key Benefits

• Ensure soil compaction and testing activities are carried out in line with Australian WHS and geotechnical requirements.
• Reduce the risk of plant–person interaction, ground collapse and struck-by incidents around rollers, compactors and test equipment.
• Standardise compaction and testing methods across projects, improving quality, traceability and audit readiness.
• Minimise costly rework, pavement failures and structural defects caused by inadequate or inconsistent compaction.
• Support clear communication between site teams, geotechnical consultants and testing laboratories using common procedures and terminology.

Who is this for?

• Site Supervisors
• Civil Engineers
• Geotechnical Engineers
• Plant Operators
• Construction Project Managers
• WHS Advisors and Safety Officers
• Laboratory Technicians (Soils Testing)
• Quality Assurance Managers
• Forepersons and Leading Hands
• Local Government Infrastructure Officers

Hazards Addressed

• Plant–person interaction and run-over risks from rollers and compaction equipment
• Vibration-related injuries from prolonged use of hand-operated compactors and rammers
• Ground instability, trench collapse and edge failure during compaction near excavations
• Struck-by and crush injuries from moving plant, tippers and support vehicles in work zones
• Exposure to noise, dust and airborne contaminants generated during compaction and testing
• Musculoskeletal injuries from manual handling of testing equipment, sand cones and nuclear gauges
• Radiation exposure risks associated with the use, transport and storage of nuclear density gauges
• Contact with underground services (gas, power, communications, water) during compaction and testing operations
• Slips, trips and falls on uneven, loose or sloped work surfaces
• Fatigue and reduced situational awareness during repetitive compaction and testing activities

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations (including geotechnical and testing terminology)
• 3.0 Roles and Responsibilities (Supervisors, Operators, Testers, WHS Personnel)
• 4.0 Applicable Legislation, Standards and Reference Documents
• 5.0 Pre-Start Planning and Risk Assessment (SWMS, JSEA, geotechnical review)
• 6.0 Service Locating, Site Access and Ground Condition Assessment
• 7.0 Required Competencies, Training and Licensing (plant operators and testers)
• 8.0 Plant, Tools and Equipment Requirements (rollers, compactors, testing apparatus)
• 9.0 Personal Protective Equipment (PPE) Requirements
• 10.0 Safe Work Zones, Traffic Management and Exclusion Areas
• 11.0 Step-by-Step Procedure – Soil Preparation and Moisture Conditioning
• 12.0 Step-by-Step Procedure – Compaction Operations (layering, passes, verification)
• 13.0 Step-by-Step Procedure – In-Situ Density and Moisture Testing (e.g. sand replacement, nuclear gauge, plate load tests)
• 14.0 Quality Control, Acceptance Criteria and Non-Conformance Management
• 15.0 Hazard Identification and Control Measures (plant, vibration, noise, radiation, excavation)
• 16.0 Environmental Considerations (dust, noise, vibration impacts on surroundings)
• 17.0 Emergency Procedures (plant incidents, ground collapse, radiation incident response)
• 18.0 Inspection, Maintenance and Pre-Use Checks for Compaction and Testing Equipment
• 19.0 Documentation, Records and Reporting Requirements (test reports, compaction registers, calibration certificates)
• 20.0 Review, Audit and Continuous Improvement of the Procedure

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) and state/territory equivalents
• Safe Work Australia – Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – Code of Practice: Excavation Work
• AS 1289 – Methods of testing soils for engineering purposes
• AS 3798 – Guidelines on earthworks for commercial and residential developments
• AS 2159 – Piling – Design and installation (for interface with ground improvement and foundation works)
• AS/NZS 3012 – Electrical installations – Construction and demolition sites (for temporary power to plant and testing equipment)
• AS/NZS 4801 – Occupational health and safety management systems (superseded but still commonly referenced)
• ISO 45001 – Occupational health and safety management systems – Requirements with guidance for use