Product Overview

Summary: This Tyre Replacement and Rotation Safe Operating Procedure sets out a clear, step-by-step method for safely changing, rotating, and handling vehicle tyres in Australian workplaces. It helps businesses control manual handling, vehicle movement, and equipment risks while extending tyre life and maintaining fleet reliability.

Tyre replacement and rotation work exposes technicians to a range of high-risk activities, from manual handling of heavy tyres and wheels to working around raised vehicles, jacks, and powered tools. This Safe Operating Procedure provides a structured, WHS-aligned approach to planning and carrying out tyre work on cars, light commercials, trucks, buses, and plant equipment. It covers everything from pre-job inspection and vehicle isolation through to correct jacking and support, safe removal and refitting of wheels, torque application, and post-job checks.

For Australian businesses operating workshops, depots, or mobile service vehicles, inconsistent tyre practices can lead to serious incidents such as wheel separations on the road, crush injuries, or long-term musculoskeletal disorders. This SOP helps standardise safe work methods, ensuring that every technician follows the same, clearly documented process. It supports compliance with WHS legislation, reduces rework and warranty claims, and improves tyre performance and fuel efficiency across your fleet. The document is designed to be easily integrated into existing safety management systems, training programs, and toolbox talks.

Key Benefits

• Ensure consistent, safe tyre replacement and rotation practices across all vehicles and sites.
• Reduce the risk of injuries from manual handling, vehicle collapse, and tool misuse.
• Improve compliance with Australian WHS legislation and relevant vehicle maintenance standards.
• Extend tyre life and enhance vehicle handling, braking performance, and fuel efficiency.
• Streamline onboarding and refresher training for new and existing workshop and depot staff.

Who is this for?

• Workshop Managers
• Fleet Managers
• Automotive Technicians
• Tyre Fitters
• Heavy Vehicle Mechanics
• Light Vehicle Mechanics
• Service Advisors
• WHS Managers
• Transport and Logistics Supervisors
• Council Depot Supervisors
• Mining and Construction Maintenance Supervisors

Hazards Addressed

• Crush injuries from vehicle collapse due to incorrect jacking or lack of axle stands
• Manual handling injuries from lifting and manoeuvring heavy tyres and wheel assemblies
• Hand and finger injuries from pinch points when removing and refitting wheels
• Eye and hearing injuries from improper use of rattle guns and other powered tools
• Tyre or rim failure due to incorrect inflation, seating, or matching of components
• Vehicle roll-away from inadequate chocking or failure to isolate the vehicle
• Slips, trips, and falls in cluttered or contaminated workshop and depot areas
• Exposure to hazardous substances such as tyre dust, brake dust, and lubricants
• On-road incidents caused by incorrect wheel nut torque or incomplete tightening

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Applicable Vehicle Types
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Required Tools, Equipment and Personal Protective Equipment (PPE)
• 5.0 Pre-Job Planning and Vehicle Reception
• 6.0 Vehicle Isolation, Parking, Chocking and Jacking Requirements
• 7.0 Tyre and Wheel Inspection Criteria (Wear, Damage, Age and Compliance)
• 8.0 Safe Manual Handling Techniques for Tyres and Wheels
• 9.0 Tyre Replacement Procedure – Step-by-Step
• 10.0 Tyre Rotation Patterns and Vehicle-Specific Requirements
• 11.0 Use of Rattle Guns, Torque Wrenches and Inflation Equipment
• 12.0 Quality Checks, Test Drive and Post-Job Documentation
• 13.0 Hazard Identification and Risk Control Measures
• 14.0 Emergency Procedures and Incident Response
• 15.0 Training, Induction and Competency Verification
• 16.0 Inspection, Maintenance and Calibration of Workshop Equipment
• 17.0 Recordkeeping, Review and Continuous Improvement

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 the Risk of Plant in the Workplace
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• AS/NZS 4024.1: Safety of machinery (for workshop equipment and guarding)
• AS 1210: Pressure vessels and AS/NZS 1596: The storage and handling of LP Gas (as applicable to inflation equipment and workshop gases)
• AS/NZS 1891.1: Industrial fall-arrest systems and devices (where work at height is involved)
• Manufacturer tyre and vehicle service manuals and bulletins