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General Logistics Delivery and Goods Handling Risk Assessment

General Logistics Delivery and Goods Handling Risk Assessment

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General Logistics Delivery and Goods Handling Risk Assessment

Product Overview

Identify and control organisational risks associated with General Logistics Delivery and Goods Handling at a management and systems level, ensuring your logistics operations are planned, resourced and governed in a consistent, defensible way. This Risk Assessment supports WHS Act compliance, demonstrates Due Diligence, and helps protect your business from operational, legal and reputational exposure.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, WHS Duties and Consultation: Assessment of officer due diligence, PCBU obligations, consultation arrangements, and the integration of WHS into corporate governance for logistics operations.
  • Logistics Planning, Scheduling and Workload Management: Management of route planning, delivery timeframes, peak periods, and workload allocation to minimise time pressure, shortcuts and fatigue-related risk.
  • Vehicle and Equipment Procurement and Fleet Standards: Assessment of specifications, safety features, selection criteria and lifecycle management for trucks, vans, forklifts, pallet jacks and associated handling equipment.
  • Preventive Maintenance, Inspection and Pre‑Start Systems: Protocols for scheduled servicing, defect reporting, pre‑start checks and withdrawal-from-service criteria for vehicles, plant and lifting equipment.
  • Driver, Storeperson and Operator Competency and Training: Management of licensing, verification of competency, induction, refresher training and supervision for all personnel involved in delivery and goods handling.
  • Traffic and Site Access Management (Including Multi‑Storey Buildings): Assessment of vehicle movements, loading zones, shared pedestrian areas, dock operations, multi‑storey access, and interaction with public traffic.
  • Load Planning, Packaging and Restraint Systems: Controls for pallet configuration, stacking, wrapping, tie-down methods, load distribution, and compliance with load restraint requirements.
  • Manual Handling and Ergonomic Risk Management: Management of lifting, carrying, pushing, pulling, repetitive tasks and awkward postures during loading, unloading and internal goods movement.
  • High‑Risk Load Types and Special Handling: Assessment of fragile, sensitive, high-value, temperature‑controlled and oversized loads, including specialised equipment, procedures and training needs.
  • Fatigue, Health and Fitness for Work Management: Systems for monitoring work hours, rest breaks, shift patterns, medical fitness, and the management of fatigue, drugs and alcohol in logistics operations.
  • Contractor, Subcontractor and Third‑Party Interface Management: Protocols for prequalification, onboarding, information sharing, and performance monitoring of transport providers, labour hire and warehouse service partners.
  • On‑Site Delivery, Distribution and Internal Transport Systems: Assessment of loading docks, warehouses, goods lifts, trolleys, conveyors and internal traffic routes within customer and depot sites.
  • Dangerous Goods, Dusts and Hazardous Materials in Logistics: Management of classification, segregation, labelling, SDS access, spill response and exposure controls for dangerous goods and hazardous substances.
  • Communication, Technology and Documentation Systems: Assessment of dispatch systems, in‑vehicle technology, GPS and telematics, delivery documentation, permits and record‑keeping for WHS compliance.
  • Emergency Preparedness, Incident Management and Continuous Improvement: Protocols for emergency response, first aid, incident reporting, investigation, corrective actions and ongoing review of logistics risk controls.

Who is this for?

This Risk Assessment is designed for Business Owners, Logistics Managers, WHS Managers and Safety Officers responsible for planning, governing and monitoring General Logistics Delivery and Goods Handling operations across their organisation and supply chain.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Consultation
  • • Lack of clearly defined WHS responsibilities for logistics managers, supervisors and schedulers
  • • Inadequate consultation with workers, HSRs and contractors about delivery and goods handling risks
  • • Failure to integrate WHS Act 2011 duties into logistics and supply chain contracts
  • • Poor oversight of third‑party logistics providers leading to uncontrolled system risks
  • • Insufficient WHS resourcing (time, budget, personnel) for delivery and materials handling activities
  • • No structured process to review incidents, near misses and trends in delivery operations
  • • Inadequate involvement of PCBUs with shared duties at multi‑storey and construction sites
2. Logistics Planning, Scheduling and Workload Management
  • • Unrealistic delivery schedules leading to speeding, rushing and unsafe loading practices
  • • Inadequate planning for peak periods and commercial bulk orders causing excessive workload and fatigue
  • • Poor coordination of inbound and outbound shipments leading to congestion and conflict at loading areas
  • • Failure to plan for multi‑storey building access constraints (lift capacity, loading dock hours, height restrictions)
  • • Lack of consideration for manual handling limits when planning bagged materials, plasterboard and heavy load movements
  • • Insufficient time allocated for safe unpacking of sensitive components, fragile items and awkward fixtures
  • • No contingency planning for delays, vehicle breakdowns or restricted access on sites
3. Vehicle and Equipment Procurement and Fleet Standards
  • • Procurement of vehicles not suited to load types (e.g. inadequate restraint points for plasterboard, corry wheels or large fixtures)
  • • Lack of standard safety features across fleet (e.g. no ANCAP 5‑star rating, absence of reversing cameras or sensors)
  • • Inadequate selection of mechanical handling equipment for heavy and awkward loads
  • • Failure to specify safety performance requirements for contractor vehicles and hired equipment
  • • Use of vehicles not appropriate for multi‑storey building loading docks, height restrictions or weight limits
  • • Insufficient consideration of internal materials handling needs between premises (e.g. pallet jacks vs powered tugs)
4. Preventive Maintenance, Inspection and Pre‑Start Systems
  • • Inadequate maintenance of vehicles and handling equipment leading to mechanical failure or loss of load control
  • • No systematic pre‑start inspection process for delivery vehicles, forklifts, tail lifts and cranes
  • • Delayed repair of identified defects due to poor reporting or lack of authority to remove equipment from service
  • • Unmanaged deterioration of packaging equipment and load restraint devices (straps, chains, pallets, crates)
  • • Failure to inspect delivery aids used within multi‑storey buildings (e.g. building hoists, shared dock equipment)
  • • Poor record keeping of inspection, maintenance and defect rectification
5. Driver, Storeperson and Operator Competency and Training
  • • Drivers and handlers not competent in securing mixed loads, including fragile and irregular items
  • • Inadequate training in safe use of forklifts, tail lifts, cranes and specialist handling equipment for corry wheels and heavy fixtures
  • • Limited understanding of site‑specific requirements at construction sites and multi‑storey buildings
  • • Poor knowledge of fatigue risks, journey planning and legal driving hour limits
  • • Insufficient training in handling hazardous or dust‑producing bagged materials and plasterboard
  • • Lack of competency in unpacking sensitive components and high‑value goods without damage
6. Traffic and Site Access Management (Including Multi‑Storey Buildings)
  • • Poorly controlled interaction between delivery vehicles, pedestrians and mobile plant at depots and client sites
  • • Lack of clear access routes, loading zones and exclusion areas at multi‑storey or congested sites
  • • Uncoordinated arrival of multiple deliveries, causing queuing on public roads and unsafe manoeuvring
  • • Inadequate control of reversing, blind spots and loading dock approaches
  • • Failure to manage internal vehicle movements between premises and within large sites
  • • Insufficient planning for height, weight and turning limitations for access to certain buildings
7. Load Planning, Packaging and Restraint Systems
  • • Inadequate load planning resulting in unstable or shifting loads during transport
  • • Poor packaging design for fragile items, sensitive components and finished goods
  • • Inappropriate restraint methods for plasterboard, bagged materials, corry wheels and large fixtures
  • • Failure to segregate incompatible goods or balance weight distribution
  • • Use of damaged pallets, crates or packaging materials
  • • No standard system for labelling heavy, awkward or high‑centre‑of‑gravity items
8. Manual Handling and Ergonomic Risk Management
  • • Excessive manual handling of bagged materials, plasterboard and heavy loads due to inadequate mechanical aids
  • • Awkward postures and overreach when handling goods in multi‑storey buildings, stairs and confined spaces
  • • Repetitive handling of smaller packages during packaging, unpacking and internal transfers
  • • Poor design of workstations and packing benches leading to musculoskeletal strain
  • • Lack of planning for team lifts or mechanical assistance for long or bulky items such as assembled fixtures and corry wheels
  • • Inadequate consideration of handling risks for unpacking shipment cargo at client premises with limited infrastructure
9. High‑Risk Load Types and Special Handling (Fragile, Sensitive and Oversized Goods)
  • • Damage to fragile items and sensitive components during handling and transport leading to financial loss and potential exposure to sharp fragments
  • • Instability of large assembled fixtures, plasterboard stacks or corry wheels during movement and transport
  • • Inadequate special handling instructions for temperature‑ or moisture‑sensitive products
  • • Improvised handling methods for oversized or irregular loads due to lack of documented procedures
  • • High centre‑of‑gravity loads tipping during loading, unloading or internal movement
  • • Uncontrolled unpacking of tightly packed or tensioned goods causing sudden release of energy
10. Fatigue, Health and Fitness for Work Management
  • • Driver fatigue due to long shifts, inadequate rest and demanding schedules
  • • Cumulative physical fatigue in workers repeatedly handling heavy or awkward loads
  • • Lack of systems to manage fitness for work, including impacts of heat, illness, medication or substance use
  • • Insufficient monitoring of night work, early starts and irregular rosters for delivery personnel
  • • Pressure to work excessive overtime during peak delivery periods
  • • No structured system for reporting and managing fatigue‑related concerns
11. Contractor, Subcontractor and Third‑Party Interface Management
  • • Inconsistent safety standards across contracted transport providers and owner‑drivers
  • • Poor communication of site rules, delivery procedures and hazards to external drivers
  • • Lack of clarity over responsibilities for loading, unloading and unpacking at customer sites
  • • Inadequate verification of licences, insurances and competencies for subcontractors
  • • Failure to manage interfaces between multiple PCBUs at complex sites (e.g. large construction or multi‑storey commercial buildings)
  • • Under‑reporting of incidents and near misses involving contractors
12. On‑Site Delivery, Distribution and Internal Transport Systems
  • • Uncontrolled handover of loads at customer sites without agreed processes
  • • Unsafe internal transport routes between premises, floors or buildings (including goods lifts and stairwells)
  • • Poor coordination of on‑site distribution of materials leading to congestion and stacking hazards
  • • Inadequate arrangements for storing delivered materials (e.g. plasterboard, bagged materials, finished goods) at point of use
  • • No system for controlling who operates on‑site equipment such as forklifts or pallet movers
  • • Inconsistent unpacking practices at client sites and project locations
13. Dangerous Goods, Dusts and Hazardous Materials in Logistics
  • • Unidentified or poorly declared hazardous materials within shipments
  • • Dust exposure from bagged materials, plasterboard and certain bulk products during loading, transport and unpacking
  • • Inadequate segregation and labelling of dangerous goods during storage and transport
  • • Lack of emergency response information and equipment for spills or releases in transit
  • • Insufficient training in handling requirements for hazardous products and residues on returned goods
  • • Non‑compliance with relevant dangerous goods and chain of responsibility legislation
14. Communication, Technology and Documentation Systems
  • • Breakdowns in communication between schedulers, drivers, warehouses and clients leading to confusion and unsafe last‑minute changes
  • • Lack of reliable communication for remote or after‑hours deliveries
  • • Inadequate documentation of delivery instructions, load requirements and site hazards
  • • Over‑reliance on informal messaging systems without record keeping
  • • Complex or inaccessible procedures that workers do not consult or understand
  • • Failure of electronic systems used for pre‑starts, journey management or fatigue monitoring
15. Emergency Preparedness, Incident Management and Continuous Improvement
  • • Inadequate preparedness for vehicle accidents, load losses or serious injuries during delivery and handling
  • • Lack of coordination with client sites for emergency response at multi‑storey buildings and construction projects
  • • Poor incident reporting and investigation processes leading to repeat events
  • • No structured review of near misses relating to goods damage, dropped loads or equipment failures
  • • Insufficient drills or testing of emergency procedures involving logistics scenarios
  • • Failure to integrate learnings from incidents into system and management improvements

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • Safe Work Australia – How to Manage Work Health and Safety Risks Code of Practice: Guidance on systematic risk management processes.
  • Safe Work Australia – Traffic Management in Workplaces Guidance Material: Principles for managing vehicle and pedestrian interactions.
  • Load Restraint Guide (National Transport Commission): Requirements and good practice for safe load restraint in road transport.
  • AS 4801 / ISO 45001: Occupational health and safety management systems — Requirements for implementing a structured WHS management framework.
  • AS 2359 series: Powered industrial trucks — Safety requirements for the selection, use and maintenance of forklifts and similar plant.
  • ADG Code (Australian Code for the Transport of Dangerous Goods by Road & Rail): Requirements for classification, packaging, marking and transport of dangerous goods.
  • Chain of Responsibility (Heavy Vehicle National Law): Duties relating to parties in the supply chain for heavy vehicle transport safety.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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