Product Overview

Summary: This Safety Operating Procedure sets out clear, practical steps for the safe use of moving trolleys in Australian workplaces. It helps reduce manual handling injuries, protects pedestrians and property, and supports compliance with WHS obligations when transporting loads by hand across warehouses, retail floors, healthcare facilities and offices.

Moving trolleys are used in almost every industry to shift stock, equipment and supplies, yet they are a frequent source of strains, crush injuries and collisions when not used correctly. This Safe Operating Procedure provides a clear, step‑by‑step framework for selecting the right trolley for the task, conducting pre‑use checks, moving loads safely, and parking and storing trolleys to avoid creating new hazards. It is designed specifically for Australian workplaces and aligns with national WHS legislation and manual handling best practice.

By implementing this SOP, businesses can significantly reduce musculoskeletal injuries, foot and hand crush incidents, and slip, trip and fall events linked to poorly managed trolleys. The document supports duty holders in demonstrating due diligence by standardising how workers assess routes, handle ramps and kerbs, share pedestrian spaces, and manage loads on vehicles or in confined spaces like lifts and storerooms. It also provides a consistent training tool so new and existing workers understand not just what to do, but why each control is important for their own safety and that of others.

Key Benefits

• Reduce manual handling injuries such as back strains and shoulder injuries by defining safe pushing, pulling and load‑handling techniques.
• Minimise collision and crush risks to workers, visitors and customers through clear rules for shared pedestrian areas and visibility.
• Ensure consistent pre‑use inspection and maintenance of trolleys to prevent equipment failure, wheel jams and instability.
• Demonstrate compliance with Australian WHS duties relating to hazardous manual tasks and plant, supporting incident investigations and audits.
• Standardise training and induction content across sites, improving worker competence and confidence when using different types of trolleys.

Who is this for?

• Warehouse Supervisors
• Storepersons and Pick Packers
• Retail Managers
• Facilities Managers
• Hospital and Aged Care Support Staff
• Office Services and Mailroom Staff
• Logistics and Distribution Coordinators
• WHS Managers and Advisors
• Health and Safety Representatives (HSRs)

Hazards Addressed

• Musculoskeletal disorders from excessive pushing, pulling or twisting while moving trolleys
• Crush injuries to feet, hands and lower legs from uncontrolled or poorly guided trolleys
• Slips, trips and falls due to obstructed routes, uneven surfaces, ramps or cluttered walkways
• Load instability leading to falling objects, tip‑overs or runaway trolleys on slopes
• Struck‑by incidents involving pedestrians, customers, patients or visitors in shared spaces
• Pinch and shear points around wheels, castors and folding mechanisms
• Vehicle loading and unloading hazards when using trolleys at docks, tail‑lifts or kerbs

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Moving Trolleys
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and References
• 5.0 Hazard Identification and Risk Assessment for Trolley Use
• 6.0 Selection of the Appropriate Trolley for the Task
• 7.0 Pre-use Inspection and Tag-out Requirements
• 8.0 Safe Loading Practices and Load Limits
• 9.0 Safe Pushing, Pulling and Manoeuvring Techniques
• 10.0 Use of Trolleys on Ramps, Kerbs, Lifts and Vehicles
• 11.0 Working in Shared Pedestrian Areas and Traffic Management
• 12.0 Personal Protective Equipment (PPE) Requirements
• 13.0 Parking, Storage and Housekeeping Controls
• 14.0 Maintenance, Fault Reporting and Repairs
• 15.0 Training, Competency and Supervision
• 16.0 Incident Reporting and Corrective Actions
• 17.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and State/Territory variants)
• Work Health and Safety Regulations 2011 (hazardous manual tasks and plant)
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• AS/NZS 3760: In-service safety inspection and testing of electrical equipment (for powered trolleys, if applicable)
• AS 4024.1: Safety of machinery (general principles applicable to trolley design and guarding, where relevant)