Comprehensive SWMS for Walk-Behind and Pedestrian-Controlled Forklift Operations

Forklift - Pedestrian Operated Safe Work Method Statement

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Pedestrian operated forklifts, also known as walk-behind forklifts, electric pallet jacks, or walkie stackers, are material handling equipment controlled by an operator walking alongside or behind the machine rather than riding on it. These machines are commonly used in warehouses, construction sites, manufacturing facilities, and retail environments for moving palletised goods, building materials, and heavy loads across short to medium distances. This SWMS addresses the specific safety requirements for pedestrian forklift operations in accordance with Australian WHS legislation, providing detailed hazard controls, pre-operational inspection procedures, and safe operating methods to protect operators and surrounding workers from crushing injuries, tip-over incidents, and struck-by hazards.

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Overview

What this SWMS covers

Pedestrian operated forklifts encompass a range of powered material handling equipment where the operator controls the machine while walking alongside or behind it, maintaining constant proximity to the load and equipment. These machines include electric pallet jacks (also called walkie pallet trucks or power jacks), walkie stackers with lifting masts capable of elevating loads to heights of 3-5 metres, walkie reach trucks for racking applications, and electric tuggers or tow tractors used to pull wheeled cages or multiple pallets in train configurations. Electric pallet jacks represent the most common type, designed primarily for horizontal transport of palletised loads across warehouse floors, construction sites, and loading docks. These machines typically have load capacities ranging from 1,500kg to 3,000kg and use electric motors powered by onboard batteries to drive hydraulic systems that raise forks slightly off the ground for transport. The operator walks behind the machine, controlling direction and speed through a tiller handle that also houses the control buttons for raising and lowering forks. Walkie stackers extend the functionality of pallet jacks by incorporating a vertical mast allowing loads to be lifted to stacking heights typically between 1.5 metres and 5 metres. These machines enable operators to stack pallets in racking systems or onto elevated storage platforms while maintaining pedestrian operation. The mast may be fixed or reach-type, with reach stackers allowing the forks to extend forward to place loads into racking. Walkie stackers require the operator to stand on a small platform or remain at ground level depending on the model, but the defining characteristic remains that the operator does not ride within an enclosed cabin. The work typically occurs in confined warehouse spaces, busy construction sites with multiple trades operating simultaneously, retail back-of-house areas, and loading docks where trucks are being loaded or unloaded. Operators must navigate around other workers, stationary obstacles, racking systems, and parked vehicles while controlling loads that may obstruct forward visibility. The combination of pedestrian operation, load handling, and congested environments creates specific hazards distinct from ride-on forklift operations, particularly relating to operators being crushed between the machine and fixed objects, loads falling during stacking operations, and struck-by incidents when other workers enter the operating area.

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Why this SWMS matters

Pedestrian operated forklift incidents account for significant workplace injuries in Australian warehousing, construction, and logistics industries. The most serious hazard is operator crushing, which occurs when the pedestrian operator becomes trapped between the forklift's rear end (tiller handle area) and a fixed object such as a wall, column, racking upright, parked vehicle, or another forklift. Unlike ride-on forklifts where the operator is protected within a cabin structure, pedestrian operators are vulnerable to being struck by the machine they are controlling, particularly when reversing or turning in confined spaces. Safe Work Australia data indicates crushing injuries from pedestrian forklifts result in serious outcomes including fractured pelvis, crushed legs, rib fractures, and internal organ damage. The Work Health and Safety Regulations 2011 classify certain powered mobile plant operations as high-risk construction work requiring specific licensing. While basic pallet jack operation (machines limited to raising loads to 200mm height) may not require forklift licensing in some jurisdictions, walkie stackers capable of lifting loads above this height typically require operators to hold High Risk Work Licences for forklift operation. Employers must verify operator competency through licence verification and provide site-specific training on the particular equipment model, work environment hazards, and traffic management protocols applicable to the workplace. This SWMS forms a critical component of the documented safe operating procedures required under WHS legislation. Load stability hazards create serious risks during stacking operations when walkie stackers lift pallets to elevated heights. Loads may shift or topple if poorly stacked, unevenly distributed, or raised too quickly. The pedestrian operator, standing directly beneath or adjacent to the elevated load, faces falling object hazards that can cause head injuries, crush injuries, or fatalities. Inadequate load assessment, exceeding rated capacity, operating on sloped surfaces, or attempting to stack damaged pallets all contribute to load instability incidents. The consequences extend beyond the operator to surrounding workers who may be struck by falling loads or toppling pallets from inadequately secured racking. Visibility limitations inherent in pedestrian forklift operation create struck-by hazards for other workers and collision risks with stationary objects. When transporting loads, particularly bulky or tall pallets, the operator's forward view may be completely obscured, requiring reverse travel or reliance on a spotter. In busy construction sites or warehouses with multiple vehicles and pedestrians, the interaction between pedestrian forklifts and ground workers creates complex hazards. Workers stepping into the travel path, reversing forklifts entering blind corners, and operators distracted by navigating obstacles while controlling the machine all contribute to struck-by incidents. Effective traffic management, designated travel routes, speed limits, and exclusion zones are essential controls. From an operational perspective, comprehensive SWMS documentation for pedestrian forklift operations establishes clear pre-start inspection requirements ensuring machines are maintained in safe condition with functional brakes, steering, hydraulics, and safety devices. It defines load capacity limits and load assessment procedures preventing overloading. It specifies traffic management requirements including one-way travel routes, speed limits (typically walking pace, approximately 5 km/h), and pedestrian separation protocols. The documentation supports structured operator induction, provides supervisors with monitoring checklists, and demonstrates due diligence in managing material handling risks. Projects with effective pedestrian forklift safety programs experience fewer lost-time injuries, reduced equipment damage from collisions, and improved coordination in shared work areas.

Reinforce licensing, insurance, and regulator expectations for Forklift - Pedestrian Operated Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Operator Crushing Between Forklift and Fixed Objects

High

The most serious hazard in pedestrian forklift operation is the operator being crushed between the rear of the machine (tiller handle area) and a fixed obstacle when reversing or turning. This occurs when operators lose awareness of their surroundings, reverse too quickly, or turn in confined spaces without adequate clearance. The forklift's rear counterweight section swings wide during turns, reducing the clearance between the machine and nearby walls, columns, racking, or parked vehicles. Operators can become pinned against these objects, suffering crush injuries to the pelvis, legs, chest, or abdomen. The risk is heightened in congested warehouses and construction sites where working space is limited and multiple obstacles exist.

Consequence: Severe crush injuries including fractured pelvis, broken legs, crushed torso, rib fractures, internal organ damage, and potentially fatal injuries. Survivors often face extended recovery periods, permanent disability, and inability to return to physical work roles.

Loads Falling from Forks During Stacking Operations

High

When operating walkie stackers to stack pallets at elevated heights (1.5m to 5m), loads can fall if they are unstable, poorly stacked, unevenly distributed, or exceed the machine's rated capacity. Raising loads too quickly, operating on sloped ground, or sudden stops can cause loads to shift and topple. Damaged pallets may collapse when lifted, or loads may slide off forks if not properly positioned. The pedestrian operator standing adjacent to or beneath the raised load faces direct falling object hazards. Surrounding workers in the stacking area are also at risk from falling pallets, boxes, or construction materials.

Consequence: Serious head injuries, crush injuries from falling pallets or materials, fractures, and potentially fatal injuries if heavy loads strike workers. Falling materials can also cause secondary hazards by blocking egress routes or damaging other stored goods.

Struck-By Incidents Involving Other Workers

High

Pedestrian forklifts operating in shared work areas create struck-by hazards when workers on foot enter the forklift's travel path or operating radius. Visibility is often compromised when transporting loads that obstruct the operator's forward view, requiring reverse travel or reliance on mirrors. Workers may not hear electric forklifts approaching due to quiet operation compared to combustion engine equipment. In congested environments with multiple workers and machines, communication failures, inadequate separation between pedestrians and vehicles, and workers stepping backwards into forklift paths all contribute to struck-by incidents. The forklift's load, forks, or counterweight can strike workers causing serious injuries.

Consequence: Impact injuries ranging from bruising and lacerations to fractures, crush injuries, and head trauma depending on impact force and struck body area. Workers struck by forks face puncture wound risks and crush injuries to limbs.

Tip-Over of Pedestrian Forklift During Operations

Medium

Walkie stackers can tip forward or sideways if operated outside their stability limits. Forward tip-over occurs when lifting loads exceeding rated capacity, lifting loads with the centre of gravity too far from the mast, or tilting the mast forward excessively while carrying elevated loads. Sideways tip-over can result from turning too sharply while carrying elevated loads, operating on sloped or uneven surfaces with raised loads, or travelling across ramps at unsafe angles. Tip-over events can crush the pedestrian operator if the machine falls toward them, or cause the load to fall striking the operator or nearby workers.

Consequence: Operator crushed beneath tipping machine, falling loads striking operator or surrounding workers, equipment damage, and potential secondary incidents if tipped machine blocks egress routes or strikes racking systems.

Collision with Racking, Doorways, and Structures

Medium

Pedestrian forklifts operating in warehouses with narrow aisles, construction sites with temporary structures, or facilities with low doorways face collision hazards. Operators misjudging clearances, traveling too fast for conditions, or operating in poorly lit areas may strike racking uprights, door frames, overhead pipes, or temporary barriers. Collisions can dislodge stored items from racking causing falling object hazards, damage building structures, or damage the forklift's mast, forks, or hydraulic components. Struck racking uprights may be weakened even if damage is not immediately visible, creating future collapse risks.

Consequence: Stored materials falling from damaged racking onto workers below, structural damage to buildings or racking systems, costly forklift repairs, and disruption to operations during equipment inspection and repair.

Battery Charging and Electrical Hazards

Medium

Electric pedestrian forklifts require regular battery charging creating electrical and chemical hazards. Lead-acid batteries used in many machines require connection to charging stations rated for the battery voltage and capacity. Incorrect charging procedures, damaged charging leads, or faulty charging equipment can cause electrical shocks, short circuits, or battery explosions due to hydrogen gas accumulation during charging. Handling batteries during changeout operations (in machines with removable battery packs) creates manual handling and acid spill risks. Batteries can weigh 200-400kg requiring mechanical lifting equipment for safe handling.

Consequence: Electrical shock injuries potentially fatal depending on voltage and current, battery acid burns to skin and eyes, inhalation of acid vapours or hydrogen gas, explosion hazards from hydrogen accumulation in poorly ventilated charging areas, and manual handling injuries during battery changeout.

Repetitive Strain from Prolonged Tiller Handle Operation

Low

Operating pedestrian forklifts for extended periods requires workers to maintain grip on the tiller handle while walking behind the machine, often in awkward postures. The tiller handle controls steering and is also used to activate drive and hydraulic functions. Prolonged operation can cause hand and wrist fatigue, particularly if operators grip too tightly or operate machines with poorly maintained controls requiring excessive force. Walking behind the machine for full shifts on hard concrete surfaces contributes to foot and lower back fatigue. Operators who perform these tasks repetitively over months or years face cumulative musculoskeletal disorder risks.

Consequence: Hand and wrist pain, repetitive strain injuries affecting fingers and forearms, chronic lower back pain from prolonged standing and walking on hard surfaces, and foot pain from inadequate footwear or prolonged weight-bearing on concrete.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Operator Clearance Zones and Traffic Management

Engineering Control

Implement physical traffic management measures creating separation between pedestrian forklift operating areas and other workers. Install fixed barriers, bollards, or safety gates defining forklift-only zones in loading docks and material staging areas. Use floor marking (typically yellow or white lines) to designate forklift travel routes separate from pedestrian walkways. Ensure minimum clearances of 500mm between forklift travel paths and fixed obstacles such as walls, columns, and racking to prevent operator crushing. Install convex mirrors at blind corners and intersections to improve visibility. These engineering controls physically separate operators and pedestrians reducing struck-by and crushing hazards.

Implementation

1. Map all pedestrian forklift travel routes and work areas within the site layout plan 2. Mark dedicated forklift lanes using high-visibility yellow floor paint or tape with minimum 1.2m lane width 3. Install bollards or barriers at least 500mm from walls and columns in forklift operating areas to prevent crushing 4. Position convex safety mirrors at all blind corners and aisle intersections at 2.5m height for optimal viewing 5. Install physical barriers (safety gates or bollards) separating pedestrian walkways from forklift zones in high-traffic areas 6. Mark load/unload zones with designated boundaries and 'Forklift Operating Area - Keep Clear' signage 7. Ensure adequate clearance under doorways and overhead structures - minimum 200mm greater than loaded forklift height

Pre-Operational Inspection and Maintenance Protocols

Administrative Control

Require documented pre-start inspections before each shift or use period. Operators must complete a checklist covering brakes, steering, hydraulic lift function, forks, battery charge level, tiller handle controls, emergency stop function, and visual/audible warning devices. Any defects must be reported immediately with the machine tagged 'DO NOT USE' and withdrawn from service until repairs are completed by qualified technicians. Establish preventative maintenance schedules according to manufacturer specifications including brake adjustments, hydraulic system inspection, battery maintenance, and load wheel/caster replacement when worn.

Implementation

1. Provide laminated pre-start inspection checklist attached to each pedestrian forklift for easy reference 2. Operators complete checklist covering: battery charge level, brakes, steering response, hydraulic lift/lower function, fork condition, tyre condition, tiller handle controls, horn/warning devices 3. Test emergency stop function by activating button and verifying machine immediately stops all movement 4. Check battery charge level - minimum 40% required to complete shift; recharge if below this threshold 5. Inspect forks for cracks, bends, or damage; measure fork thickness ensuring meets minimum safe dimension 6. Document inspection on checklist with operator signature and date; report defects to supervisor immediately 7. Tag defective equipment with red 'DO NOT USE' tag and remove from service area 8. Maintain service records showing inspection dates, repairs completed, and next scheduled maintenance

Load Assessment and Capacity Compliance

Administrative Control

Implement mandatory load assessment procedures before lifting any load. Operators must verify the load weight does not exceed the forklift's rated capacity as shown on the data plate. For walkie stackers, the rated capacity typically decreases as lift height increases - operators must consult the load chart posted on the machine. Loads must be assessed for stability - reject damaged pallets, loads with overhang, or unevenly distributed materials. Establish a load refusal protocol empowering operators to refuse unsafe loads without repercussion. Document load capacity limits in site induction and post warning signs near stacking areas.

Implementation

1. Display load capacity data plate clearly on all pedestrian forklifts showing maximum capacity at various heights 2. Require operators to visually inspect every load before lifting checking for: pallet damage, unstable stacking, load overhang, and uneven distribution 3. Estimate or verify load weight against forklift rated capacity - if weight uncertain, use weighing system or refuse load 4. For walkie stackers, cross-reference intended lift height with load chart to verify capacity at that height 5. Position forks fully under the load with even weight distribution on both forks before lifting 6. Lift load slowly to approximately 150mm height and verify stability before proceeding with transport 7. Lower and re-position any load showing instability or tipping tendency 8. Document load refusals in daily log including reason and corrective action taken

Operator Licensing, Training, and Competency Verification

Administrative Control

Verify all operators of walkie stackers and pedestrian forklifts capable of raising loads above 200mm hold current High Risk Work Licences (HRWL) for Forklift Operation as required by WHS Regulations. Sight original licences and maintain photocopies in worker induction records. Provide site-specific familiarisation training covering the specific forklift model, site traffic management requirements, load types commonly handled, and emergency procedures. Conduct competency assessments for new operators before authorising unsupervised operation. Refresher training is required when incidents occur, new equipment is introduced, or work procedures change.

Implementation

1. Verify operator holds valid HRWL for forklift operation by sighting original licence; maintain photocopy in site records 2. Provide site induction covering specific forklift models used, traffic routes, speed limits, and load handling procedures 3. Assign experienced operator as trainer to demonstrate pre-start checks, safe operating techniques, and load handling 4. New operators complete supervised practice period (minimum 2 hours) before competency assessment 5. Conduct competency assessment including pre-start inspection, load pickup, travel with load, stacking/placing load, and parking procedures 6. Document competency assessment outcome and authorise operator for unsupervised work only after successful assessment 7. Provide refresher training annually or when incidents occur, new equipment introduced, or procedures change 8. Maintain training records showing dates, topics covered, trainer details, and competency assessment results

Speed Limits and Safe Operating Procedures

Administrative Control

Establish and enforce speed limits for pedestrian forklift operation - typically walking pace (approximately 5 km/h) in general areas, and reduced speed (slow walking pace, 3 km/h) in congested areas, near pedestrians, at intersections, and when approaching blind corners. Mandate travel with forks lowered to 150mm maximum height off the ground for stability. Require operators to travel in reverse when loads obstruct forward vision, using mirrors and turning head to maintain awareness of travel path. Prohibit riding on pedestrian forklifts except on models specifically designed with rider platforms and safety features.

Implementation

1. Post speed limit signs at entry points to forklift operating areas: '5 km/h Maximum - Walking Pace Only' 2. Brief operators that speed must never exceed comfortable walking pace; reduce to slow walk near pedestrians 3. Require forks to be lowered to 150mm maximum height during travel for stability and visibility 4. When transporting loads that obstruct forward vision, travel in reverse while watching travel path 5. Use horn or audible warning device when approaching intersections, blind corners, or doorways 6. Come to complete stop at intersections and verify clear path before proceeding 7. Never allow passengers or ride-on use unless machine is specifically designed and fitted with rider platform 8. Supervisors monitor forklift speeds during site walks; provide immediate correction if excessive speed observed

Battery Charging Safety Protocols

Engineering Control

Designate specific battery charging areas with adequate ventilation to disperse hydrogen gas generated during charging. Install charging stations with appropriate electrical ratings matching battery specifications. Provide eye wash stations and spill kits in charging areas for acid exposure incidents. Use mechanical lifting equipment for battery changeout operations eliminating manual lifting of heavy battery packs. Ensure charging areas are separated from general work areas with clear signage identifying electrical hazards and restricted access.

Implementation

1. Establish designated battery charging area separated from general work areas with 'Authorised Personnel Only' signage 2. Ensure charging area has natural or mechanical ventilation providing minimum 4 air changes per hour to disperse hydrogen gas 3. Install charging stations rated for battery voltage (typically 24V or 48V) with appropriate circuit protection 4. Position emergency eye wash station within 10 metres of charging area for acid exposure incidents 5. Provide spill kit containing acid neutraliser, absorbent material, and disposal bags near charging area 6. For battery changeout operations, use mechanical hoist or battery changing trolley rated for battery weight 7. Post electrical safety signage and battery safety procedures in charging area visible to all users 8. Prohibit smoking, open flames, and spark-producing activities within 5 metres of charging area due to hydrogen gas

Personal Protective Equipment for Pedestrian Forklift Operations

Personal Protective Equipment

Require operators to wear high-visibility clothing ensuring visibility to other forklift operators and vehicle drivers in shared work areas. Mandate steel-capped safety boots protecting feet from crush injuries if loads or forks strike feet. Provide and require hearing protection if operating in high-noise environments (warehouses with multiple machines). For battery maintenance activities, require chemical-resistant gloves, face shields, and aprons when handling batteries or acid. Ensure PPE is maintained in serviceable condition and replaced when damaged.

Implementation

1. Issue high-visibility vest or shirt (Class D Day/Night per AS/NZS 1906.4) to all pedestrian forklift operators 2. Require steel-capped safety boots rated to 200 joules impact protection (AS/NZS 2210.3) for all forklift work 3. Provide hearing protection (Class 3 per AS/NZS 1270) for operators working in areas exceeding 85dB(A) 4. For battery maintenance, issue chemical-resistant gloves (nitrile or rubber per AS/NZS 2161), face shield, and acid-resistant apron 5. Ensure operators wear close-fitting clothing to prevent snagging on controls or forks 6. Inspect PPE during pre-start meetings; replace worn high-visibility clothing losing reflective properties 7. Brief operators on PPE requirements during induction; verify compliance through regular site observations

Download complete control procedures

Personal protective equipment

Requirement: Class D Day/Night vest or shirt per AS/NZS 1906.4

When: Required at all times during pedestrian forklift operation to ensure visibility to other operators and vehicle drivers

Requirement: 200 joules impact protection per AS/NZS 2210.3

When: Required throughout all pedestrian forklift operations to protect feet from crush injuries from loads or forks

Requirement: Class 3 protection per AS/NZS 1270

When: Required when operating in environments with noise levels exceeding 85dB(A) over 8-hour period

Requirement: Nitrile or rubber construction per AS/NZS 2161

When: Required during battery maintenance, electrolyte level checks, or any activity involving potential contact with battery acid

Requirement: Full face coverage per AS/NZS 1337

When: Required when performing battery maintenance, adding distilled water to batteries, or cleaning battery terminals

Requirement: PVC or rubber construction

When: Required during battery changeout operations or when performing maintenance on battery systems

Inspections & checks

Before work starts

✓Verify battery charge level meets minimum 40% for planned work duration; charge battery if below threshold
✓Test brakes by activating brake control and attempting to move forklift; brakes must hold machine stationary
✓Check steering response by turning tiller handle full left and right; steering must respond smoothly without binding
✓Operate hydraulic lift controls to raise and lower forks through full range; verify smooth operation without jerking or fluid leaks
✓Inspect forks for cracks, bends, or damage; measure fork thickness to verify meets minimum safe dimension per manufacturer specification
✓Test emergency stop button by activating while machine is moving; verify immediate stop of all functions
✓Check tyre condition for cuts, excessive wear, or damage affecting stability; verify load wheels rotate freely
✓Test horn or warning device to verify audible signal functioning; confirm adequate volume for work environment

During work

✓Monitor battery charge level throughout shift; cease operation and recharge if level drops below 20%
✓Verify each load is within rated capacity before lifting; refuse loads exceeding capacity or unstable loads
✓Assess load stability after raising to 150mm height; lower and reposition any shifting or tipping loads
✓Maintain awareness of surroundings during operation; watch for pedestrians, other vehicles, and obstacles in travel path
✓Verify adequate clearance exists when entering narrow aisles or passing through doorways; measure if uncertain
✓Monitor forklift performance for unusual sounds, vibrations, or handling changes indicating developing faults
✓Check load remains secure and stable during transport; reduce speed if load shows any movement or shifting
✓Ensure operators maintain safe walking pace (5 km/h maximum) and reduce speed in congested areas or near pedestrians

After work

✓Park forklift in designated area away from doorways, exits, and high-traffic zones
✓Lower forks fully to ground level and activate parking brake before leaving machine
✓Disconnect battery charging lead if connected; verify charging station is switched off
✓Report any defects, unusual performance, or safety concerns identified during operation in daily log
✓Clean any spills of hydraulic fluid or battery electrolyte from forklift and surrounding floor area
✓Document operating hours and battery charging cycles in maintenance log book
✓Note any near-miss incidents or safety observations in daily briefing log for team awareness
✓Verify forklift keys are secured in designated location preventing unauthorised use overnight

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Pre-Operational Inspection and Equipment Verification

Before commencing work, conduct comprehensive pre-start inspection using the documented checklist. Begin by verifying battery charge level on the gauge located on the tiller handle or dashboard - minimum 40% charge is required to complete a standard shift. If charge level is below 40%, connect the forklift to the battery charging station before use. Inspect the battery compartment for corrosion on terminals or electrolyte leaks indicating maintenance is required. Test brakes by activating the brake control and attempting to push the forklift - brakes must hold the machine completely stationary. Check steering by turning the tiller handle through its full range of motion; steering should respond smoothly without binding, excessive play, or unusual resistance. Operate the hydraulic lift controls to raise and lower the forks through their complete travel range, observing for smooth operation, unusual noises, or visible hydraulic fluid leaks from hoses or cylinders. Carefully inspect both forks along their entire length for cracks, bends, or deformation; measure fork thickness at the heel (thickest point) to verify it meets the manufacturer's minimum safe dimension - forks worn below this limit must be replaced. Test the emergency stop button by pressing it while the forklift is powered on; all functions should immediately cease. Inspect tyres for cuts, punctures, excessive wear, or damage that could affect stability or cause sudden deflation during operation. Verify the horn or audible warning device produces adequate sound volume. Check for hydraulic oil level in the reservoir, and visually inspect the mast for damage, bent sections, or missing components. Document the inspection on the checklist, noting any defects, and report immediately to the supervisor. Tag defective equipment with a red 'DO NOT USE' tag and withdraw it from service until qualified technicians complete repairs and sign off the equipment as safe to use.

Safety considerations

Never operate pedestrian forklifts with known defects even if they seem minor - brake failures, steering malfunctions, and fork failures can cause serious accidents. Ensure battery terminals are not corroded or loose creating electrical hazards. Verify emergency stop functions correctly as this is the primary means to prevent injuries if the machine malfunctions.

Load Assessment and Capacity Verification

Before attempting to pick up any load, conduct a thorough assessment to determine if it is safe to lift. First, visually inspect the pallet or load container for damage including cracked or broken pallet boards, missing boards, protruding nails, or structural weakness that could cause collapse when lifted. Check that the load is stacked uniformly without overhanging the pallet edges, as overhang creates instability and increases tip-over risk. Look for uneven load distribution - all weight should be evenly distributed across the pallet surface. If load weight is unknown, estimate based on material type and volume, or use weighing equipment if available. Compare the estimated or actual weight against the forklift's rated capacity shown on the data plate permanently fixed to the machine. For walkie stackers, remember that rated capacity decreases as lift height increases - consult the load chart displayed on the mast showing maximum capacity at each lift height. If you intend to lift the load to 3 metres height, verify the load weight does not exceed the rated capacity at that height. If there is any uncertainty about whether the load exceeds capacity, refuse to lift it and obtain assistance from supervision to verify weight or arrange appropriate equipment. Assess the approach path to the load ensuring adequate space exists to position the forklift squarely in front of the pallet. Verify the floor surface is level and firm - do not attempt to lift loads on sloped surfaces or soft ground that could cause the forklift to tip. Check overhead clearance if you will be raising the load, ensuring at least 200mm clearance exists between the top of the raised load and any overhead structures such as pipes, cable trays, door frames, or ceiling height restrictions. Document load refusals in the daily log, including the reason (excessive weight, damaged pallet, unstable stacking) and the corrective action taken (load re-stacked, different equipment sourced, load split into smaller units).

Safety considerations

Exceeding rated capacity is a leading cause of forklift tip-overs and structural failures. When in doubt about load weight, always refuse the lift - it is better to delay work than risk a serious incident. Remember that dynamic forces during turning or braking can increase effective load weight beyond static weight.

Load Pickup and Initial Lift Procedure

Position the pedestrian forklift squarely in front of the pallet, approaching from the direction that allows forks to enter the pallet openings fully. Use the tiller handle to steer the machine into alignment, ensuring the forks are centred on the pallet width so weight will be evenly distributed on both forks. Slowly advance the forklift until the fork tips are approximately 100mm from the pallet face. Stop and verify alignment - both forks should enter the pallet openings evenly. If the forklift or pallet is misaligned, reposition before proceeding. Slowly drive forward, inserting the forks fully into the pallet until the load backrest (if fitted) or the heel of the forks is against the pallet face. The forks should extend at least two-thirds the depth of the pallet to properly support the load - forks that only partially enter the pallet create instability. Once positioned, activate the hydraulic lift control to slowly raise the load approximately 150mm off the ground. Pause at this height and assess load stability by observing whether the load tilts, shifts, or shows any signs of instability. Walk around the forklift inspecting the load from all sides. If the load shifts, tilts, or appears unstable, immediately lower it back to the ground and reassess. Check whether the pallet is damaged, the load is unevenly distributed, or the weight exceeds capacity. Correct the issue before attempting to transport the load. If the load is stable, tilt the mast backward slightly (if the forklift is equipped with mast tilt function) to nestle the load against the backrest, providing additional stability. Maintain the load at 150mm maximum height above ground level during travel - this low height maintains the forklift's centre of gravity and provides better stability than transporting loads at higher elevations. Never raise the load higher during travel as this dramatically increases tip-over risk, particularly when turning.

Safety considerations

Ensure forks are fully inserted into the pallet - partial insertion can cause loads to slide off during transport. Stop and assess stability after initial lift rather than immediately traveling with an untested load. Watch for pedestrians and other workers during load pickup - your attention is focused on the load making it easy to miss people entering your work area.

Safe Travel and Navigation with Load

After verifying the load is stable and secure on the forks at 150mm height, begin traveling to the destination at a controlled walking pace, approximately 5 km/h maximum speed. Position yourself behind the tiller handle with both hands on the handle, using the control buttons to start motion gradually - avoid sudden acceleration that could cause load shifting. Maintain constant awareness of your surroundings by scanning ahead for pedestrians, other vehicles, obstacles, and traffic. If the load obstructs your forward view, travel in reverse, constantly turning your head to watch the travel path behind you. Use the convex mirrors positioned at intersections to check for approaching traffic before entering blind corners. Sound the horn when approaching intersections, doorways, or areas where pedestrians may be present, providing audible warning of your approach. Maintain safe clearances from racking, walls, columns, and other obstacles - keep at least 500mm distance between the forklift rear (counterweight) and fixed obstacles to prevent crushing hazards. When navigating narrow aisles, reduce speed to slow walking pace (3 km/h) and verify adequate clearance exists on both sides. Be particularly cautious when turning - the forklift's rear counterweight swings wide during turns, reducing clearance between the machine and obstacles behind you. Glance backward before initiating turns to verify no workers are in the swing path. If you must travel up or down ramps or inclines, always travel with the load on the uphill side - when going uphill, travel forward with load ahead of you; when going downhill, travel in reverse with load uphill behind you. This prevents the load from rolling backward off the forks. Never turn on ramps or operate across slopes as this dramatically increases tip-over risk. Reduce speed to minimum (slow walk) when crossing uneven surfaces, expansion joints, or transitions between floor surfaces. Come to a complete stop at designated intersections and give way to pedestrians and larger vehicles. If you need to temporarily leave the forklift to check your destination or consult with workers, first lower the load to the ground, activate the parking brake, and remove the key to prevent unauthorized use.

Safety considerations

Speed is a critical factor in pedestrian forklift safety - excessive speed causes loss of control, inability to stop in time, and increased severity of impacts. Always travel at walking pace and reduce speed further in congested areas or when visibility is limited. Watch for pedestrians stepping backward who may not see you approaching. Be aware of your rear swing during turns to avoid crushing hazards.

Load Stacking and Placement at Height

When operating walkie stackers to place loads into racking or onto elevated storage, approach the target location slowly and position the forklift squarely in front of the intended placement point. Verify the racking or storage structure is rated for the load weight and that you are placing the load in the correct designated location. Check overhead clearance ensuring adequate space exists for the raised load and mast. Position the forklift as close to the racking as safely possible before beginning the lift - this minimises the mast angle and reduces forward tip-over risk. Activate the hydraulic lift control to slowly and smoothly raise the load to the required height. Avoid rapid lifting that can cause load instability or spillage. As the load rises, continuously monitor it for shifting, tilting, or signs of instability. If any instability is observed, immediately stop the lift, lower the load, and reassess. Watch for overhead obstacles including beams, pipes, cable trays, and lighting fixtures - maintain minimum 200mm clearance. When the load reaches the target height, verify it is level with the racking beam or storage surface where it will be placed. If the walkie stacker is equipped with reach function, extend the forks forward to insert the load into the racking. If reach function is not available, carefully drive the forklift forward, inserting the forks and load into the racking structure. Ensure the entire pallet is supported on the racking beam, not just partially resting on it. Lower the forks slowly, transferring the load weight onto the racking beam. Watch carefully during this transfer - if the load tips or shifts during placement, immediately stop lowering and re-assess positioning. Once the load is fully supported on the racking and the forks are free, carefully withdraw the forks by reversing the forklift or retracting the reach mechanism. Tilt the mast backward to return to vertical position. Lower the unloaded forks to 150mm height before traveling to the next load. If at any point during the stacking operation you feel the forklift is unstable, immediately lower the load and reassess the situation - never continue an unsafe lift.

Safety considerations

Load placement at height is the highest-risk activity in walkie stacker operation. Ensure you are positioned safely beside the machine, not directly beneath or in line with the load's fall path. Watch for racking damage or missing components that could cause collapse. Never exceed the rated capacity at the lift height you are working - consult the load chart for height-dependent capacity limits.

Battery Charging and Electrical Safety Procedures

When the battery charge level drops below 40% remaining capacity, or at the end of shift, the pedestrian forklift must be connected to the battery charging station following safe electrical work practices. Drive the forklift to the designated charging area, which should be a well-ventilated space separated from general work areas. Park the forklift with the battery access panel facing the charging station. Lower forks completely to ground level and activate the parking brake. Switch off the forklift controls and remove the key. Open the battery compartment cover or hood to access the battery terminals. Inspect the battery and terminals for corrosion, damage, or electrolyte leaks before connecting the charger. If battery maintenance is required (checking electrolyte levels or cleaning terminals), wear appropriate PPE including chemical-resistant gloves, face shield, and acid-resistant apron. Locate the charging cable suitable for the forklift's battery voltage (typically 24V or 48V systems). Inspect the charging cable for damage to the insulation, exposed conductors, or damaged plugs - do not use damaged cables. Match the charger connector to the battery charging socket ensuring correct polarity. Connect the charging plug to the battery socket firmly, ensuring it is fully seated. Switch on the charging station power supply - most modern chargers will automatically detect battery condition and commence charging at the appropriate rate. Verify charging has commenced by checking for indicator lights or displays on the charging station. Do not disconnect the charger until the charging cycle is complete - most modern chargers will indicate completion with a green light or display message. During charging, battery electrolyte undergoes chemical reactions producing hydrogen gas which is highly flammable and explosive. Ensure the charging area remains well-ventilated and prohibit smoking, open flames, or spark-producing activities within 5 metres of charging batteries. If the forklift uses removable battery packs requiring changeout, use mechanical lifting equipment such as a battery changing trolley or overhead hoist - never manually lift batteries which can weigh 200-400kg. When the charging cycle is complete, switch off the charging station power, disconnect the charging cable from the battery socket, close the battery compartment cover, and return the charging cable to its storage position.

Safety considerations

Battery charging creates electrical shock hazards and chemical hazards from battery acid. Only authorised and trained personnel should perform battery maintenance. Never create sparks or open flames near charging batteries due to hydrogen gas accumulation. If electrolyte contacts skin or eyes, flush immediately with water for 15 minutes and seek medical attention.

End of Shift Procedures and Parking

At the completion of work or end of shift, park the pedestrian forklift in the designated storage area away from doorways, exits, fire equipment access, and high-traffic zones. Choose a parking location on level ground where the machine will not obstruct pedestrian or vehicle movement. Lower the forks completely to ground level. If the forklift has been operating in wet conditions or has accumulated debris, clean the forks and wheels before parking to prevent buildup of materials. Activate the parking brake by pressing the brake button or switching the brake control to the engaged position. Switch off all forklift controls using the main power switch or key switch. Remove the key from the forklift and store it in the designated secure location to prevent unauthorised use. If the forklift is due for battery charging, connect it to the charging station following the procedures in Step 6. If any defects, malfunctions, or unusual performance was noted during the shift, document these in the daily defect log book with specific details including what the problem is, when it was noticed, and what impact it has on safe operation. Attach a red 'DO NOT USE' tag to the tiller handle if the forklift is unsafe to operate, and immediately notify the supervisor and maintenance department. Check the work area for any spills of hydraulic fluid, battery electrolyte, or other materials that occurred during operations - clean these immediately using appropriate absorbents and dispose of contaminated materials correctly. Complete the daily inspection checklist or log book recording operating hours, any loads handled requiring special attention, battery charging performed, and any incidents or near-misses observed during the shift. If a near-miss or incident occurred, complete an incident report form providing details of what happened, contributing factors, and recommendations to prevent recurrence. Participate in the daily toolbox meeting or end-of-shift debrief to share safety observations, discuss challenges encountered, and contribute to continuous improvement of safe work practices. Return all PPE to designated storage locations ensuring high-visibility vests are hung up to prevent creasing and damage to reflective materials.

Safety considerations

Properly securing the forklift at end of shift prevents unauthorised use and eliminates struck-by hazards from unsecured machines rolling or being accidentally activated. Reporting defects promptly prevents other operators from using faulty equipment. Cleaning spills immediately prevents slip hazards for other workers.

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Frequently asked questions

Do I need a forklift licence to operate a pedestrian pallet jack?

Licensing requirements depend on the type of equipment and its lifting capability. Basic electric pallet jacks (also called walkie pallet trucks) that can only raise loads to a maximum height of 200mm typically do not require a High Risk Work Licence in most Australian jurisdictions, though employers should verify current regulations in their state or territory. However, walkie stackers and pedestrian reach trucks capable of lifting loads above 200mm height do require operators to hold a current Forklift Licence (High Risk Work Licence for forklift operation). This licence must be verified by the employer who must sight the original licence and maintain a photocopy in worker records. Even when licensing is not legally required for low-lift pallet jacks, employers must still ensure operators receive adequate training and demonstrate competency in safe operation specific to the equipment and work environment. Site-specific induction should cover the particular model's controls, capacity limits, traffic management requirements, and emergency procedures regardless of licensing requirements.

What should I do if the load I'm asked to lift looks unstable or damaged?

If you assess a load as unstable, damaged, or potentially unsafe to lift, you have both the right and the responsibility to refuse to lift it. Australian WHS legislation requires workers to take reasonable care for their own safety and the safety of others who may be affected by their actions. This includes refusing work that poses an immediate risk of injury. First, conduct a visual inspection of the pallet and load checking for broken pallet boards, protruding nails, overhang beyond pallet edges, uneven load distribution, or stacking that appears unstable. If you identify any of these issues, do not attempt the lift. Instead, notify your supervisor immediately explaining specifically what safety concern you have identified. Document the load refusal in the daily log book including the reason (damaged pallet, unstable stacking, suspected overweight, etc.). Work with your supervisor to determine the corrective action - this might include re-stacking the load properly, repairing or replacing the damaged pallet, splitting the load into smaller units within capacity, or sourcing appropriate equipment if the load exceeds your forklift's capacity. Never allow yourself to be pressured into lifting unsafe loads - the consequences of a load falling or forklift tipping are far more serious than any delays caused by addressing the hazard properly.

How do I safely work around pedestrians and other workers when operating a pedestrian forklift?

Operating pedestrian forklifts in shared work areas requires constant awareness and proactive communication to prevent struck-by incidents. Always wear high-visibility clothing ensuring you are visible to other workers and operators. Before moving the forklift, conduct a 360-degree scan of your surroundings looking for pedestrians, other vehicles, and obstacles. Sound your horn when approaching intersections, blind corners, or doorways to alert others to your presence. Maintain walking pace (maximum 5 km/h) in general areas and reduce to slow walking pace (3 km/h) near pedestrians or in congested spaces. This slower speed allows more time to react if someone steps into your path. Establish eye contact with pedestrians before proceeding past them - verify they have seen you and are aware of your movement. If transporting loads that obstruct your forward vision, travel in reverse while continuously watching your travel path. Never assume pedestrians can hear you approaching - electric forklifts are quiet and workers wearing hearing protection may not hear warning devices. Comply with site traffic management including designated forklift lanes, one-way routes, and pedestrian exclusion zones marked on floors. If you need to work in areas where pedestrians are present, consider using physical barriers or safety tape to create an exclusion zone around your work area. When parking temporarily, position the forklift where it will not obstruct walkways or create trip hazards. If you observe unsafe practices such as workers walking while looking at phones or wearing headphones preventing situational awareness, report this to supervision as it creates hazards for everyone in the area.

What pre-start checks are legally required before operating a pedestrian forklift each day?

The WHS Regulations require operators to inspect powered mobile plant before use each day or shift to verify it is in safe operating condition. While specific checklist items may vary based on equipment type, a comprehensive pre-start inspection for pedestrian forklifts should include: battery charge level verification (minimum 40% for full shift operation), brake function testing (machine must hold stationary when brakes activated), steering response check (tiller handle turns smoothly without binding), hydraulic lift operation (forks raise and lower smoothly without leaks), fork condition inspection (no cracks, bends, or wear below minimum thickness), emergency stop function test (must immediately cease all operation when activated), tyre condition check (no cuts, excessive wear, or damage), horn/warning device operation (must produce adequate audible signal), and visual inspection for hydraulic leaks, damaged mast components, or loose fittings. The inspection must be documented on a checklist or log book showing the date, operator name, equipment identification, inspection results, and any defects identified. If defects are found that affect safe operation, the equipment must be tagged 'DO NOT USE' and withdrawn from service until qualified technicians complete repairs and verify the equipment is safe. The employer must provide the inspection checklist, ensure operators are trained in how to conduct inspections, and maintain inspection records as evidence of compliance. Operators who skip pre-start inspections or use equipment with known defects may face disciplinary action and could be personally liable if an incident results from operating defective equipment.

How should I handle battery charging to avoid electrical hazards?

Battery charging for electric pedestrian forklifts must follow safe electrical work practices and chemical handling procedures to prevent electrical shock, acid burns, and hydrogen gas explosions. Only charge batteries in designated charging areas that have adequate ventilation (minimum 4 air changes per hour) to disperse hydrogen gas produced during charging. The charging area should be separated from general work areas with appropriate signage and restricted to authorised personnel only. Before connecting charger cables, inspect them for damage to insulation, exposed conductors, or damaged plugs - never use damaged cables as they create electrical shock hazards. Match the charger specifications to the battery voltage (typically 24V or 48V) and follow manufacturer procedures for connection. Most modern chargers have automatic charging cycles that detect battery condition and adjust charging rate accordingly - do not override these automated systems. Ensure the charging plug is firmly connected to the battery socket with correct polarity. During charging, prohibit smoking, open flames, welding, grinding, or any spark-producing activities within 5 metres of charging batteries as hydrogen gas is highly flammable. Position emergency eye wash stations within 10 metres of charging areas for acid exposure incidents. If you need to check battery electrolyte levels or clean terminals (typically during scheduled maintenance rather than routine charging), wear chemical-resistant gloves, face shield, and acid-resistant apron. Battery electrolyte is concentrated sulphuric acid that causes severe burns to skin and eyes. If electrolyte contacts skin or eyes, flush with water for 15 minutes and seek medical attention immediately. Never disconnect a charger before the charging cycle completes unless an emergency requires it. When changing battery packs in forklifts with removable batteries, always use mechanical lifting equipment - batteries weigh 200-400kg and cannot be safely manually handled.

What is the maximum safe speed when operating a pedestrian forklift?

Pedestrian forklifts should never be operated faster than a comfortable walking pace, which translates to approximately 5 km/h maximum in general, clear areas with good visibility. However, this is an upper limit that must be reduced based on conditions. In congested areas with other workers or vehicles present, reduce speed to slow walking pace approximately 3 km/h. When approaching intersections, blind corners, doorways, or areas where pedestrians may step into your path, slow to speeds that allow you to stop within your visible path length. When operating in narrow aisles, near racking systems, or in confined spaces, reduce speed to minimum to allow precise control and prevent collisions. If transporting loads that obstruct your forward vision requiring reverse travel, reduce speed to allow adequate time to scan your travel path. When traveling over uneven surfaces, ramps, or floor joints, slow to prevent load shifting or loss of control. The key principle is that speed must always allow the operator to maintain full control of the forklift, stop within the visible path ahead, and react to pedestrians or obstacles that may suddenly appear. Site speed limits should be posted at entry points to forklift operating areas, and supervisors should monitor compliance during site observations. Remember that unlike road vehicles with graduated accelerators, many pedestrian forklifts have simple thumb controls that apply maximum motor power when fully pressed - operators must learn to modulate these controls to maintain appropriate speed rather than operating at full throttle continuously. Excessive speed is a contributing factor in many pedestrian forklift incidents including collisions with racking, struck-by incidents involving pedestrians, and tip-over events when turning too sharply at speed. Always prioritise safety over productivity - a few seconds saved through faster travel is never worth the risk of a serious incident.

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Key Controls

• Pre-start briefing covering hazards
• PPE: hard hats, eye protection, gloves
• Emergency plan communicated to crew

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Forklift - Pedestrian Operated Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Operator Crushing Between Forklift and Fixed Objects

Loads Falling from Forks During Stacking Operations

Struck-By Incidents Involving Other Workers

Tip-Over of Pedestrian Forklift During Operations

Collision with Racking, Doorways, and Structures

Battery Charging and Electrical Hazards

Repetitive Strain from Prolonged Tiller Handle Operation

Control measures

Operator Clearance Zones and Traffic Management

Pre-Operational Inspection and Maintenance Protocols

Load Assessment and Capacity Compliance

Operator Licensing, Training, and Competency Verification

Speed Limits and Safe Operating Procedures

Battery Charging Safety Protocols

Personal Protective Equipment for Pedestrian Forklift Operations

Personal protective equipment

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Pre-Operational Inspection and Equipment Verification

Load Assessment and Capacity Verification

Load Pickup and Initial Lift Procedure

Safe Travel and Navigation with Load

Load Stacking and Placement at Height

Battery Charging and Electrical Safety Procedures

End of Shift Procedures and Parking

Frequently asked questions

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