Product Overview

Summary: This Structural Modification Safe Operating Procedure provides a clear, step-by-step framework for planning, approving and carrying out structural changes safely and compliantly in Australian workplaces. It helps businesses control engineering, construction and demolition risks while demonstrating due diligence under WHS legislation and the National Construction Code.

Structural modifications – whether cutting new openings, removing load-bearing elements, installing mezzanines, strengthening existing structures or altering foundations – introduce significant safety, structural integrity and compliance risks. This SOP sets out a robust, repeatable process for planning, engineering, approving and executing structural changes so that no modification proceeds without appropriate design, assessment, permits and controls in place. It is designed for use across construction sites, industrial facilities, commercial buildings and infrastructure projects throughout Australia.

The procedure helps organisations manage the full lifecycle of a structural modification: from initial concept, engineering assessment and temporary works design, through to isolations, sequencing of work, monitoring for movement, and final certification. It addresses common failure points such as undocumented on‑site changes, unapproved removal of structural elements, inadequate propping, and poor coordination between designers, contractors and building managers. By implementing this SOP, businesses can reduce the likelihood of structural failure, worker injury, property damage and regulatory enforcement action, while providing clear documentation to demonstrate compliance with WHS duties and building regulations.

This SOP also supports better communication and governance. It clarifies who can authorise modifications, how structural risks are assessed and controlled, and what evidence (drawings, calculations, inspection records and sign‑offs) must be retained. The result is a controlled, auditable process that protects workers, occupants and the public, while enabling structural changes to proceed efficiently and with confidence.

Key Benefits

• Ensure all structural modifications are engineered, reviewed and authorised before work commences.
• Reduce the risk of structural failure, collapse and associated worker injury or fatality.
• Demonstrate compliance with WHS legislation, the National Construction Code and relevant Australian Standards.
• Standardise communication between designers, contractors, site supervisors and building owners.
• Minimise costly rework, delays and disputes arising from undocumented or non-compliant modifications.

Who is this for?

• Project Managers
• Construction Site Supervisors
• Structural Engineers
• Building and Facilities Managers
• WHS Managers and Advisors
• Principal Contractors
• Maintenance Managers
• Civil and Structural Contractors
• Demolition Supervisors
• Local Council and Certifier Liaison Officers

Hazards Addressed

• Partial or full structural collapse during or after modification works
• Uncontrolled movement, deflection or settlement of structural elements
• Failure of temporary works, shoring, propping or bracing systems
• Falls from height during demolition, cutting or installation activities
• Falling objects from unstable or inadequately supported structures
• Struck-by and crush injuries from shifting structural members
• Exposure to hazardous materials (e.g. asbestos, lead paint) uncovered during modification
• Service strikes (electrical, gas, water, communications) when altering structural elements containing services
• Noise, vibration and dust exposure during cutting, coring and demolition
• Confined space risks where structural modifications affect tanks, pits, shafts or plant rooms

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (structural element, temporary works, critical lift, etc.)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Planning and Design Requirements for Structural Modifications
• 5.0 Engineering Assessment, Calculations and Design Verification
• 6.0 Approvals, Permits and Consultation (including certifiers and local authorities)
• 7.0 Risk Assessment and Safe Work Method Statements (SWMS) for Structural Work
• 8.0 Temporary Works, Propping, Shoring and Bracing Controls
• 9.0 Services Identification, Isolation and Make-Safe Requirements
• 10.0 Pre-Start Inspections and Site Preparation
• 11.0 Step-by-Step Procedure for Executing Structural Modifications
• 12.0 Controls for Demolition, Cutting, Coring and Removal of Structural Elements
• 13.0 Monitoring for Movement, Deflection and Structural Stability During Works
• 14.0 Emergency Preparedness and Response for Structural Instability or Collapse
• 15.0 Post-Modification Inspections, Testing and Structural Certification
• 16.0 Handover, As-Built Documentation and Records Management
• 17.0 Training, Induction and Communication Requirements
• 18.0 Review, Audit and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (and state/territory equivalents) – including duties of designers, principal contractors and PCBUs
• National Construction Code (NCC) – Building Code of Australia
• Safe Work Australia – Code of Practice: Construction Work
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• AS 3600: Concrete structures
• AS 4100: Steel structures
• AS 1170 series: Structural design actions
• AS 1684 series: Residential timber-framed construction (where applicable)
• AS/NZS 1170.0: Structural design actions – General principles
• AS 4349.1: Inspection of buildings – Pre-purchase inspections – Residential buildings (as a reference for structural condition assessment)
• AS/NZS ISO 31000: Risk management – Guidelines