Product Overview

Summary: This Safe Operating Procedure sets out a clear, compliant method for assessing, handling and incorporating recycled materials into roadworks across Australia. It supports WHS, environmental and quality obligations by controlling contamination, stability and handling risks while helping organisations meet sustainability targets without compromising worker safety or road performance.

The use of recycled materials in road construction is rapidly becoming standard practice across Australian jurisdictions, driven by sustainability targets, landfill diversion policies and community expectations. However, recycled aggregates, reclaimed asphalt pavement (RAP), crushed glass, and other recovered materials introduce unique safety, quality and environmental risks if they are not assessed and managed systematically. This SOP provides a structured, step-by-step approach for selecting, testing, transporting, storing and incorporating recycled materials into roadworks in a way that protects workers, the public and the environment while achieving consistent pavement performance.

Developed for Australian civil and roadwork environments, the procedure aligns with WHS duties, environmental approvals and relevant transport and road authority specifications. It addresses practical issues such as controlling dust and contamination, managing variable material properties, safe loading and unloading, and ensuring traceability from source to site. By implementing this SOP, organisations can confidently expand their use of recycled content, reduce project costs and waste to landfill, and demonstrate due diligence to regulators and clients. It helps standardise practices across crews and contractors, reducing rework, defects and incident risk on both urban and regional road projects.

Key Benefits

• Ensure safe handling, transport and placement of recycled materials in line with Australian WHS and environmental requirements.
• Reduce variability and defects in road pavements by standardising material assessment, testing and acceptance criteria.
• Demonstrate compliance and due diligence to road authorities, regulators and clients when using recycled content.
• Support organisational sustainability goals by increasing recycled material use without compromising safety or performance.
• Streamline coordination between engineers, site crews, recyclers and transport providers through clear, documented procedures.

Who is this for?

• Civil Engineers
• Road Construction Supervisors
• Project Managers – Civil and Infrastructure
• WHS Managers and Advisors
• Environmental and Sustainability Managers
• Quality Assurance Managers
• Local Government Infrastructure Officers
• Plant and Quarry Managers
• Site Forepersons
• Contract Administrators

Hazards Addressed

• Exposure to dust, respirable crystalline silica and other airborne contaminants from recycled aggregates and crushed materials
• Manual handling injuries during loading, unloading and spreading of recycled materials
• Contact with sharp, protruding or foreign objects (e.g. metal, glass, debris) within recycled stockpiles
• Vehicle and mobile plant interactions during haulage, tipping and placement operations
• Noise exposure from crushing, screening, loading and compaction activities
• Environmental contamination from improperly stored or unsuitable recycled materials (leachate, runoff, spills)
• Slips, trips and falls around uneven stockpiles, soft ground and unstable working surfaces
• Fire or ignition risks associated with contaminated or incorrectly stored recycled materials (e.g. oily rags, flammable waste)
• Traffic management risks when delivering and placing recycled materials in live traffic environments

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Recycled Materials
• 3.0 Legislative, Standards and Specification Requirements
• 4.0 Roles and Responsibilities
• 5.0 Pre‑Use Assessment and Supplier Approval
• 6.0 Material Testing, Acceptance Criteria and Traceability
• 7.0 Planning and Risk Assessment (including SWMS/JSA)
• 8.0 Transport, Delivery and Traffic Management Requirements
• 9.0 Safe Handling, Storage and Stockpile Management
• 10.0 On‑Site Use and Placement Procedures
• 11.0 Hazard Identification and Control Measures
• 12.0 Environmental Management and Waste Controls
• 13.0 Personal Protective Equipment (PPE) Requirements
• 14.0 Quality Control, Inspection and Non‑Conformance Management
• 15.0 Emergency Procedures and Incident Reporting
• 16.0 Training, Competency and Communication
• 17.0 Document Control and Review

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS legislation
• Work Health and Safety Regulation 2011 and state/territory equivalents
• Safe Work Australia – Model Code of Practice: How to Manage Work Health and Safety Risks
• Safe Work Australia – Model Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Model Code of Practice: Managing the Work Environment and Facilities
• AS/NZS 4801:2001 Occupational health and safety management systems (noting transition to ISO 45001)
• ISO 45001:2018 Occupational health and safety management systems – Requirements with guidance for use
• AS 2758 series: Aggregates and rock for engineering purposes (including road construction applications)
• Austroads Guides and Technical Specifications for use of recycled materials in roadworks (as applicable in each jurisdiction)
• State and territory road authority specifications for recycled materials (e.g. Transport for NSW, Department of Transport and Main Roads QLD, VicRoads)
• Environment Protection Acts and waste classification guidelines applicable in the relevant state or territory