Product Overview

Summary: This Tool Usage and Safety Safe Operating Procedure sets out clear, practical steps for selecting, using and maintaining hand and power tools safely in Australian workplaces. It helps organisations control common tool-related hazards, improve productivity, and demonstrate due diligence under WHS legislation across construction, manufacturing, maintenance and facility operations.

Hand and power tools are used every day across Australian workplaces, yet they remain one of the most common sources of preventable injuries – from minor cuts and eye injuries through to serious lacerations, amputations and electric shock. This Tool Usage and Safety Safe Operating Procedure provides a structured, easy-to-follow framework for how tools are selected, inspected, used, transported and stored, ensuring that every worker follows the same safe system of work on every job. It is written specifically for Australian conditions and WHS expectations, supporting PCBU obligations and reinforcing a strong safety culture on site and in the workshop.

The procedure covers both manual and powered tools, including corded and cordless equipment, with a strong focus on pre-use checks, guarding, correct body positioning, safe cutting and drilling practices, and effective use of personal protective equipment (PPE). It also addresses common issues such as using the wrong tool for the job, makeshift repairs, working at heights with tools, and managing noise and vibration exposure. By implementing this SOP, businesses can reduce incident rates, standardise training for new and young workers, and provide clear evidence of risk management and consultation in the event of an audit, client prequalification, or regulator inspection.

Key Benefits

• Reduce tool-related injuries such as cuts, eye injuries, electric shock and strains through consistent safe work practices.
• Ensure compliance with Australian WHS legislation and relevant Codes of Practice for managing plant and equipment.
• Standardise training and competency expectations for all workers and apprentices using hand and power tools.
• Improve productivity by minimising downtime caused by tool failure, misuse and unplanned maintenance.
• Demonstrate due diligence to clients, insurers and regulators with a documented, auditable safe system of work.

Who is this for?

• Site Supervisors
• Workshop Supervisors
• Maintenance Managers
• Health and Safety Representatives (HSRs)
• WHS Managers and Advisors
• Construction Forepersons
• Facility Managers
• Apprentice Coordinators
• Tradespeople (e.g. carpenters, electricians, plumbers, fitters)
• General Maintenance Workers

Hazards Addressed

• Lacerations, puncture wounds and amputations from contact with cutting edges, blades and moving parts
• Eye and facial injuries from flying particles, swarf, dust and debris
• Electric shock and burns from damaged cords, plugs, insulation or incorrect use of electrical tools
• Hearing damage from prolonged exposure to noisy power tools
• Hand-arm vibration syndrome and musculoskeletal disorders from excessive vibration or poor handling technique
• Slips, trips and falls caused by poorly stored tools, leads and accessories on walkways
• Impact injuries from dropped tools, particularly when working at heights or on scaffolds
• Fire and ignition risks from sparks generated near flammable materials
• Strains and sprains from incorrect manual handling of heavy or awkward tools and toolboxes

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Tool Categories (Hand Tools, Power Tools, Portable Plant)
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Workers, Contractors)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for Tool Use
• 6.0 Selection of the Right Tool for the Task
• 7.0 Pre-use Inspection and Tagging Requirements
• 8.0 Safe Operating Procedures for Hand Tools
• 9.0 Safe Operating Procedures for Power Tools (corded and cordless)
• 10.0 Electrical Safety, Isolation and Residual Current Devices (RCDs)
• 11.0 Use of Personal Protective Equipment (PPE) for Tool Tasks
• 12.0 Noise and Vibration Management
• 13.0 Working at Heights and Dropped Object Prevention with Tools
• 14.0 Manual Handling of Tools, Toolboxes and Equipment
• 15.0 Maintenance, Repair, Storage and Housekeeping Requirements
• 16.0 Contractor and Visitor Management for Tool Usage
• 17.0 Training, Competency and Supervision (including apprentices and young workers)
• 18.0 Incident, Near Miss and Defect Reporting Procedures
• 19.0 Emergency Response (Eye Injuries, Lacerations, Electric Shock)
• 20.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and state/territory equivalents)
• Work Health and Safety Regulations 2011 (Cth and state/territory equivalents)
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• AS/NZS 3760: In-service safety inspection and testing of electrical equipment
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 1270: Acoustics – Hearing protectors
• AS/NZS 45001: Occupational health and safety management systems (ISO 45001 as adopted in Australia)