Product Overview

Summary: This Tubular Handling and Storage Safe Operating Procedure provides clear, step‑by‑step guidance for safely receiving, moving, stacking and storing tubular products such as pipe, casing and drill pipe. It is designed for Australian worksites where heavy tubulars are handled, helping to prevent crush injuries, dropped loads, equipment damage and costly downtime while supporting WHS compliance.

Handling and storing tubular products such as drill pipe, casing, line pipe and structural tube presents significant safety risks if not tightly controlled. The combination of heavy loads, round surfaces and lifting equipment such as cranes, forklifts and telehandlers creates a high potential for roll‑away incidents, crush injuries, dropped loads, and damage to expensive tubular assets. This Tubular Handling and Storage Safe Operating Procedure sets out a practical, worksite-ready method for planning, lifting, moving, stacking and storing tubulars in yards, laydown areas and on rigs in line with Australian WHS expectations.

The SOP provides a structured, repeatable process that supervisors and crews can follow to manage risk at every stage – from pre‑job planning and inspection of lifting gear, through to safe slinging, chocking, dunnage selection, stack design, segregation of grades, and housekeeping. It helps businesses demonstrate due diligence by clearly documenting how hazards such as pinch points, unstable loads, line‑of‑fire exposure and vehicle–pedestrian interaction are controlled. By implementing this procedure, organisations can reduce manual handling injuries, protect high‑value tubular inventory from damage, and show regulators, clients and auditors that tubular operations are being conducted to a consistent, defensible standard across all sites.

Key Benefits

• Reduce the risk of crush, pinch and line‑of‑fire injuries during tubular lifting and stacking activities.
• Ensure consistent, best‑practice methods for chocking, dunnage placement and stack layout across all yards and sites.
• Protect expensive tubular assets from bending, thread damage and coating loss caused by poor handling or storage.
• Demonstrate compliance with Australian WHS legislation and relevant industry standards for high‑risk work and plant use.
• Streamline training and onboarding by providing clear, visual and step‑by‑step guidance for operators and supervisors.

Who is this for?

• Operations Managers
• Yard Supervisors
• Rig Managers
• Drilling Supervisors
• Warehouse and Stores Coordinators
• Dogmen and Riggers
• Forklift and Telehandler Operators
• Crane Operators
• WHS Managers and Advisors
• Logistics and Materials Coordinators

Hazards Addressed

• Crush and pinch injuries from moving or rolling tubulars
• Dropped loads during crane, forklift or telehandler operations
• Roll‑away incidents due to inadequate chocking or dunnage
• Struck‑by incidents involving mobile plant and pedestrians in laydown areas
• Musculoskeletal injuries from manual handling and repositioning tubulars
• Equipment failure from incorrect use of slings, spreader bars and lifting gear
• Instability and collapse of tubular stacks
• Damage to tubular threads, bodies and coatings leading to integrity failures
• Slips, trips and falls around poorly organised tubular storage areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Operators, Dogmen/Riggers)
• 4.0 Competency, Licensing and Training Requirements
• 5.0 Required PPE, Tools, Lifting Equipment and Attachments
• 6.0 Pre‑Start Planning and Risk Assessment (JSA/SWMS)
• 7.0 Yard Layout, Traffic Management and Exclusion Zones for Tubular Areas
• 8.0 Inspection and Acceptance of Tubular Deliveries
• 9.0 Safe Lifting and Handling of Tubulars (Cranes, Forklifts, Telehandlers)
• 10.0 Use of Slings, Spreaders, Clamps, Racks and Specialized Tubular Handling Equipment
• 11.0 Chocking, Dunnage Selection and Stack Design Requirements
• 12.0 Safe Storage Practices (Segregation, Height Limits, Stability and Environmental Considerations)
• 13.0 Manual Handling Controls for Small Tubulars and Accessories
• 14.0 Housekeeping, Walkways and Pedestrian Safety in Tubular Storage Areas
• 15.0 Hazard Identification, Incident Reporting and Corrective Actions
• 16.0 Emergency Procedures for Dropped Loads, Unstable Stacks and Injuries
• 17.0 Inspection, Maintenance and Tagging of Lifting Gear and Racks
• 18.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Parts relating to Hazardous Manual Tasks, Plant and High Risk Work
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – General Guide for Cranes
• AS 2550 series: Cranes, hoists and winches – Safe use
• AS 4991: Lifting devices
• AS 1418 series: Cranes, hoists and winches
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)
• Relevant state and territory Codes of Practice for Traffic Management in Workplaces and Construction Work