Product Overview

Summary: This Warehousing and Storage Safe Operating Procedure sets out clear, practical steps for safely receiving, handling, storing and dispatching goods in Australian warehouse environments. It helps businesses control key WHS risks, protect workers from common warehouse injuries, and maintain compliant, efficient storage operations that stand up to regulatory scrutiny.

Warehouses and storage areas are high‑risk environments where people, plant and products interact in fast‑paced, often congested spaces. Without a structured, documented way of working, the likelihood of incidents involving forklifts, racking collapse, falling objects or hazardous manual tasks increases dramatically. This Warehousing and Storage Safe Operating Procedure provides a clear, step‑by‑step framework for how goods are to be received, moved, stored, picked and dispatched, with safety built into every stage of the process.

Developed specifically for Australian workplaces, this SOP supports compliance with WHS legislation and relevant codes of practice while also addressing the day‑to‑day realities of running a busy warehouse. It sets expectations for traffic management, racking integrity, load limits, housekeeping, storage of hazardous substances, and safe use of mechanical aids such as forklifts and pallet jacks. By implementing this procedure, businesses can reduce injuries, improve layout and workflow, enhance stock accuracy and provide consistent training material for new and existing staff, regardless of warehouse size or industry sector.

Key Benefits

• Reduce warehouse incidents and injuries by standardising safe methods for receiving, handling and storing goods.
• Ensure compliance with Australian WHS laws, relevant Codes of Practice and industry standards for warehousing operations.
• Improve productivity and accuracy by defining clear workflows for put‑away, picking, replenishment and dispatch.
• Minimise product damage and stock losses through correct stacking, segregation and racking load management.
• Support consistent induction and refresher training with a documented, easy‑to‑follow procedure for all warehouse staff.

Who is this for?

• Warehouse Managers
• Operations Managers
• Inventory Controllers
• Warehouse Team Leaders
• Storepersons and Pick Packers
• Logistics and Supply Chain Managers
• WHS Managers and Advisors
• Facilities and Distribution Centre Managers
• Small Business Owners operating warehouses
• 3PL (Third Party Logistics) Providers

Hazards Addressed

• Forklift and mobile plant collisions with pedestrians or fixed structures
• Racking failure or collapse due to overloading or impact damage
• Falling objects from pallets, shelving or high‑bay storage
• Manual handling injuries from lifting, pushing, pulling or carrying loads
• Slips, trips and falls caused by poor housekeeping or uneven surfaces
• Crush and pinch injuries during pallet handling and stacking
• Exposure to hazardous chemicals or dangerous goods stored incorrectly
• Vehicle and truck loading/unloading risks at docks and dispatch areas
• Fatigue and strain from repetitive picking and packing tasks
• Fire and emergency evacuation issues in high‑density storage areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Officers, Supervisors, Workers, Contractors)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Warehouse Layout and Traffic Management Requirements
• 6.0 Racking Design, Load Limits and Inspection Requirements
• 7.0 Goods Receiving and Unloading Procedures
• 8.0 Put‑away, Stacking and Storage Procedures
• 9.0 Picking, Replenishment and Dispatch Procedures
• 10.0 Manual Handling and Use of Mechanical Aids
• 11.0 Storage of Hazardous Chemicals and Dangerous Goods
• 12.0 Housekeeping, Waste Management and Aisle Clearance
• 13.0 Personal Protective Equipment (PPE) Requirements
• 14.0 Hazard Identification, Risk Assessment and Control Measures
• 15.0 Incident, Near Miss and Damage Reporting
• 16.0 Emergency Preparedness, Fire Safety and Evacuation in Warehouses
• 17.0 Training, Competency and Licence Requirements (e.g. LF/LO high risk work licences)
• 18.0 Inspection, Maintenance and Monitoring of Warehouse Equipment
• 19.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and corresponding state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• AS 4084: Steel storage racking
• AS/NZS 4801: Occupational health and safety management systems (superseded but still widely referenced)
• AS 1940: The storage and handling of flammable and combustible liquids
• AS 1891 series: Industrial fall‑arrest systems and devices (where work at height in racking is required)