Product Overview

Summary: This Tyre Replacement Safety Safe Operating Procedure sets out a clear, step-by-step method for changing tyres safely on light vehicles, trucks, plant and equipment. It helps Australian businesses control high-risk hazards such as vehicle movement, jacking failures and manual handling injuries while demonstrating compliance with WHS obligations and manufacturer requirements.

Tyre replacement is one of the most common maintenance tasks in transport, construction, agriculture and service businesses, yet it remains a significant source of serious workplace injuries. Jack failure, poorly secured vehicles, incorrect wheel nut torque and unsafe manual handling can all lead to crush injuries, vehicle roll-away, musculoskeletal disorders and costly downtime. This Tyre Replacement Safety SOP provides a structured, repeatable process that guides workers through safe preparation, isolation, jacking, wheel removal, installation and final checks for a wide range of vehicles and equipment used in Australian workplaces.

Developed with Australian WHS expectations in mind, the procedure clarifies who is responsible for each step, what tools and PPE are required, and how to control key risks such as working on road shoulders, dealing with heavy truck tyres or operating in busy yards and workshops. It helps businesses move away from informal “this is how we’ve always done it” practices and towards a documented, defensible system of work. By implementing this SOP, organisations can improve safety performance, standardise training for new and existing staff, and reduce the likelihood of incidents that lead to injuries, vehicle damage, schedule delays and regulatory scrutiny.

Key Benefits

• Reduce the risk of crush, impact and roll-away incidents during tyre replacement activities.
• Ensure consistent, manufacturer-aligned tyre replacement practices across all vehicles and sites.
• Demonstrate compliance with Australian WHS legislation and duty of care requirements for vehicle maintenance tasks.
• Improve training efficiency by providing clear, step-by-step guidance for new and existing workers.
• Minimise equipment damage, wheel loss events and rework through correct jacking, torqueing and inspection processes.

Who is this for?

• Workshop Managers
• Fleet Managers
• Mechanics and Tyre Technicians
• Heavy Vehicle Operators
• Mobile Service Technicians
• Maintenance Supervisors
• WHS Managers and Advisors
• Construction and Mining Supervisors
• Agricultural Equipment Operators

Hazards Addressed

• Vehicle roll-away or unexpected movement during tyre replacement
• Jack or support stand failure leading to crush injuries
• Struck-by injuries from falling wheels or tools
• Manual handling injuries from lifting, rolling or positioning heavy tyres and wheels
• Slips, trips and falls in and around the work area
• Exposure to traffic when changing tyres on road shoulders or in car parks
• Pinch and shear points around wheel studs, nuts and hub assemblies
• Noise and vibration from rattle guns and other powered tools
• Eye injuries from flying particles, rust, dirt or metal fragments
• Burns or contact injuries from hot brake components or wheels

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-Task Planning and Site Risk Assessment
• 6.0 Vehicle Positioning, Isolation and Securing (Chocking and Parking Brake)
• 7.0 Jack and Support Stand Selection, Inspection and Setup
• 8.0 Safe Tyre and Wheel Removal Procedure
• 9.0 Safe Tyre and Wheel Installation Procedure
• 10.0 Torqueing, Re-Torque and Post-Task Inspection Requirements
• 11.0 Managing Roadside and High-Traffic Tyre Changes
• 12.0 Hazard Identification and Control Measures (JSA/SWMS Linkage)
• 13.0 Manual Handling Techniques for Tyres and Wheels
• 14.0 Use of Powered Tools (Rattle Guns, Impact Wrenches and Compressors)
• 15.0 Housekeeping, Waste Tyre Handling and Environmental Considerations
• 16.0 Emergency Procedures and Incident Response
• 17.0 Training, Induction and Competency Verification
• 18.0 Inspection, Maintenance and Storage of Jacks and Associated Equipment
• 19.0 Review, Audit and Continuous Improvement of the SOP
• 20.0 Document Control and Recordkeeping

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (Cth and relevant state/territory variants)
• Safe Work Australia – Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• AS 2550 series: Cranes, hoists and winches – Safe use (for related lifting equipment where applicable)
• AS/NZS 1892: Portable ladders (where access to elevated wheels is required)
• AS/NZS 2210.1: Safety, protective and occupational footwear
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161 series: Occupational protective gloves
• Manufacturer tyre, wheel, jack and vehicle manuals and specifications