Product Overview

Summary: This Tyre Installation Safe Operating Procedure provides a clear, step-by-step method for safely removing, fitting and inflating tyres in Australian workplaces. It helps control high-risk hazards such as manual handling, vehicle movement and explosive tyre failures, while supporting compliance with WHS duties and manufacturer requirements.

Tyre installation work carries significant risk, particularly when dealing with heavy vehicle tyres, split rims, bead seating and high-pressure inflation equipment. This Tyre Installation Safe Operating Procedure sets out a consistent, safe method for inspecting wheels and tyres, removing and fitting assemblies, using jacks and hoists, and inflating tyres within controlled parameters. It is designed specifically for Australian conditions and aligns with WHS obligations for managing high-risk plant and hazardous manual tasks.

By implementing this SOP, businesses can reduce the likelihood of serious incidents such as tyre explosions, vehicle falls from jacks, crush injuries and musculoskeletal disorders from poor lifting techniques. The document provides clear guidance on pre-use equipment checks, safe work zones, lock-out of vehicles and machinery, and the correct use of cages, restraints and remote inflation devices. It also supports standardised training across workshops and mobile service vehicles, helping employers demonstrate due diligence, improve job quality and extend tyre and wheel life through correct fitment practices.

Key Benefits

• Reduce the risk of serious injury from tyre explosions, vehicle instability and crush incidents during tyre installation tasks.
• Ensure consistent, manufacturer-compliant fitment practices across all technicians and worksites.
• Support compliance with Australian WHS legislation and duty of care for hazardous manual tasks and plant use.
• Improve efficiency and turnaround times by providing a clear, repeatable process for tyre removal, fitting and inflation.
• Extend tyre and wheel service life by standardising inspection, preparation and torque procedures.

Who is this for?

• Tyre Technicians
• Workshop Managers
• Fleet Maintenance Supervisors
• Automotive Service Managers
• Heavy Vehicle Mechanics
• Mining and Civil Maintenance Supervisors
• Agricultural Equipment Technicians
• WHS Advisors and Safety Officers

Hazards Addressed

• Tyre burst or explosion during inflation
• Vehicle or machinery falling from jacks, stands or hoists
• Crush and pinch point injuries to hands, feet and body
• Manual handling injuries from lifting, carrying or levering heavy tyres and wheels
• Eye and face injuries from flying debris or bead seating failures
• Exposure to noise, dust, fumes and chemicals in workshop environments
• Slips, trips and falls around tools, hoses and removed wheels
• Uncontrolled movement of vehicles or mobile plant during tyre work

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Applicable Tyre Types (Light, Heavy, Off-road, Agricultural)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Required Tools, Equipment and Tyre Handling Aids
• 5.0 Personal Protective Equipment (PPE) Requirements
• 6.0 Pre-Job Planning and Risk Assessment (JSA/SWMS Integration)
• 7.0 Vehicle Preparation, Isolation and Securing
• 8.0 Safe Jacking, Lifting and Support of Vehicles and Plant
• 9.0 Tyre and Wheel Inspection, Defect Identification and Rejection Criteria
• 10.0 Tyre Removal Procedure (Light Vehicles)
• 11.0 Tyre Removal Procedure (Heavy Vehicle and Split Rim Assemblies)
• 12.0 Tyre Fitting and Bead Seating Procedure
• 13.0 Safe Inflation Practices, Use of Cages and Remote Inflation Devices
• 14.0 Wheel Refitment, Torque Settings and Re-tensioning Requirements
• 15.0 Post-Installation Checks, Test Drive and Documentation
• 16.0 Hazard Controls and Emergency Response (Tyre Failure, Equipment Collapse, Injury)
• 17.0 Housekeeping, Waste Tyre Handling and Environmental Considerations
• 18.0 Training, Competency Verification and Review of Procedure

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• AS 4457.1: Earth-moving machinery – Tyre wheel systems – Rims, wheels and assemblies
• AS 4457.2: Earth-moving machinery – Tyre wheel systems – Maintenance and repair
• AS/NZS 1891 series: Industrial fall-arrest systems and devices (where work at height is involved)
• AS/NZS 4024 series: Safety of machinery (general plant safety guidance)