Vehicle lifting is performed dozens of times daily in auto body workshops, and complacency with this routine activity is the primary cause of crush fatalities in the automotive repair industry. Hoist failures, incorrect lift point selection, inadequate secondary support, and uncontrolled vehicle movement on tilted ramps all create life-threatening crush scenarios. The WHS Regulation 2025 requires PCBUs to manage risks of plant including hoists, jacks, and support stands through systematic inspection, maintenance, and operator competency verification. This template covers all vehicle lifting operations with controls mapped to the binding Managing Risks of Plant code effective 1 July 2026.
WHS Regulation 2025 Part 5.1 — Plant; AS 1418 Cranes and Hoists; AS 2550 Mobile Equipment
Work involving powered mobile plant
Managing Risks of Plant in the Workplace (binding 1 July 2026 under Section 26A)
Yes — Plant code binding July 2026. Non-compliance is a standalone offence.
| Hazard | Consequence | Likelihood |
|---|---|---|
| Vehicle crush from hoist failure or hydraulic line burst | Fatality, crush injuries, spinal cord injury | Unlikely |
| Vehicle falling from jack stands due to incorrect placement | Fatality, crush injuries | Possible |
| Uncontrolled vehicle movement on tilted ramp hoist | Crush, vehicle running over worker | Possible |
| Component falling from raised vehicle during repair | Head injuries, crush injuries to hands and feet | Possible |
| Ergonomic strain from working overhead on raised vehicles | Shoulder and neck musculoskeletal injuries | Likely |
Worker crushed when vehicle fell from hoist that had not been serviced in three years. Hydraulic seal failure caused uncontrolled descent. No mechanical locking device was engaged.
2024 — WorkSafe Victoria Prosecution Database
Our WHS consultants develop vehicle lifting SWMS with hoist inspection protocols and crush prevention controls for your workshop.
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