Product Overview

Summary: This Tyre Recycling Safe Operating Procedure provides a clear, step-by-step framework for safely handling, processing and storing waste tyres in Australian workplaces. It helps you control fire risk, plant and traffic hazards, and environmental exposures while maintaining compliance with WHS and waste management requirements.

Tyre recycling operations combine high fire loads, mobile plant, cutting and shredding equipment, and significant manual handling – a mix that can quickly lead to serious incidents if not tightly controlled. This Tyre Recycling Safe Operating Procedure sets out a practical, WHS-focused method for receiving, sorting, storing, processing and dispatching tyres and tyre-derived products in a way that protects workers, visitors and the environment. It provides a consistent, defendable process that aligns day‑to‑day activities with your legal duties under Australian WHS and waste legislation.

The SOP addresses the full lifecycle of tyre handling, from vehicle arrival and unloading controls through to operation of shredders and granulators, dust and noise management, hot work controls, and emergency response for fires and spills. It clarifies roles and responsibilities, embeds risk controls such as safe stacking heights, exclusion zones and guarding, and integrates PPE, pre-start checks and lock-out/tag-out steps. By implementing this procedure, organisations can reduce incident rates, minimise downtime, support contractor management, and demonstrate due diligence during audits, regulator inspections and insurance reviews.

Key Benefits

• Ensure consistent, safe practices for receiving, storing and processing tyres across all shifts and sites.
• Reduce the risk of fires, crush injuries and plant-related incidents in high-risk tyre recycling environments.
• Demonstrate compliance with Australian WHS, waste and environmental obligations during audits and inspections.
• Streamline induction and refresher training for operators, contractors and supervisors with clear, step-by-step guidance.
• Improve operational efficiency by minimising unplanned downtime, equipment damage and near-miss events.

Who is this for?

• Tyre Recycling Plant Managers
• Operations Managers
• WHS Managers and Advisors
• Recycling Facility Supervisors
• Waste Management Coordinators
• Forklift and Mobile Plant Operators
• Maintenance Technicians
• Environmental and Sustainability Managers
• Logistics and Yard Supervisors

Hazards Addressed

• Fire and explosion risk from large volumes of combustible tyres and rubber dust
• Crush and impact injuries from mobile plant (forklifts, loaders, telehandlers)
• Entanglement, cutting and amputation hazards from shredders, conveyors and cutting equipment
• Manual handling injuries from lifting, rolling and stacking heavy tyres
• Slips, trips and falls in cluttered yards, around stockpiles and near processing lines
• Exposure to noise, dust, fumes and potential contaminants in tyres and residues
• Traffic management risks from trucks, delivery vehicles and internal yard movements
• Struck-by hazards from unstable stacks, falling tyres or shifting stockpiles
• Electrical hazards during maintenance, cleaning and unjamming activities
• Heat stress and environmental exposure for outdoor yard and processing work

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Legislation and Definitions
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Required Plant, Tools and Personal Protective Equipment (PPE)
• 5.0 Pre-Start Checks and Site Preparation
• 6.0 Vehicle Arrival, Traffic Management and Unloading Procedures
• 7.0 Tyre Sorting, Inspection and Segregation (by size, condition and type)
• 8.0 Safe Tyre Handling, Lifting and Manual Handling Controls
• 9.0 Tyre Storage, Stacking and Stockpile Management (including fire separation distances)
• 10.0 Operation of Shredders, Granulators, Conveyors and Ancillary Equipment
• 11.0 Guarding, Lock-Out/Tag-Out and Isolation Procedures
• 12.0 Dust, Noise and Airborne Contaminant Control Measures
• 13.0 Housekeeping, Waste Streams and Environmental Controls
• 14.0 Contractor Management and Visitor Controls in Recycling Areas
• 15.0 Incident, Near Miss and Equipment Fault Reporting
• 16.0 Emergency Preparedness and Response (fire, spills, plant failure)
• 17.0 Training, Induction and Competency Verification
• 18.0 Inspection, Monitoring, Recordkeeping and Continuous Improvement

Legislation & References

• Model Work Health and Safety Act and Regulations (as implemented in each state and territory)
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• AS 4839: The safe use of portable and mobile tyre equipment for mining and earthmoving industries (principles applicable to large tyre handling)
• AS 1940: The storage and handling of flammable and combustible liquids (for fuel, oils and associated products on site)
• AS/NZS 1269 series: Occupational noise management
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 45001 (ISO 45001): Occupational health and safety management systems
• Relevant state and territory waste and environmental protection legislation and tyre storage/recycling guidelines (e.g. EPA tyre stockpile and fire risk guidelines)