Comprehensive SWMS for Counterbalance and Reach Forklift Operations

Forklift Safe Work Method Statement

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Forklift operations encompass the use of counterbalance forklifts, reach trucks, and other ride-on material handling equipment for loading, unloading, stacking, and transporting materials in construction and warehousing environments. These versatile machines provide essential logistics support whilst presenting significant hazards including tip-over risks, pedestrian collision potential, falling loads, and struck-by incidents. This SWMS addresses the critical safety requirements for forklift operations including High Risk Work licensing compliance, pre-start inspection procedures, load capacity management, pedestrian separation, and emergency response protocols in accordance with Australian WHS legislation and national competency standards.

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Overview

What this SWMS covers

Forklift operations represent one of the most common and essential material handling activities in construction and warehousing environments, with counterbalance forklifts, reach trucks, and order pickers providing powered lifting and transport capability for palletised goods, construction materials, and equipment components. These versatile machines operate across diverse environments from permanent warehouse facilities with smooth concrete floors to temporary construction site compounds with uneven ground surfaces, requiring operators to continuously assess changing conditions whilst managing complex equipment with significant mass, power, and lifting capacity. The critical safety challenges in forklift operation stem from fundamental design characteristics including high centres of gravity when loaded, limited visibility around loads and through masts, potential for catastrophic tip-over if stability limits are exceeded, and operation in shared spaces with pedestrian workers creating collision risks. Counterbalance forklifts represent the most common forklift configuration, using rear-mounted weights to counterbalance loads positioned forward of front wheels on extending forks. These machines typically have capacity ranging from 1.5 tonnes to 5 tonnes for general industrial use, with larger capacity models up to 45 tonnes for specialised heavy handling operations. Counterbalance designs allow operation without outriggers or stabiliser legs, providing manoeuvrability in congested areas and ability to travel loaded across facilities. However, the counterbalance principle creates inherent instability when loads exceed capacity limits, when operating on slopes, or when loads are raised to substantial heights shifting the combined centre of gravity forward potentially causing forward tip-over. Operators sit perpendicular to travel direction when operating laterally, creating visibility and control challenges requiring operators to constantly adjust body positioning and mirror use to maintain awareness of surroundings. Reach trucks provide high-density storage capability by extending forks horizontally to place loads deep into racking whilst maintaining narrow aisle clearances. Reach mechanisms add operational complexity whilst providing space efficiency advantages in warehouse environments. Stand-on operator platforms rather than seated positions create different operator ergonomics and fatigue profiles. Order pickers elevate operators to working heights allowing retrieval of individual items from racking rather than full pallet handling, creating fall hazards and requiring additional fall protection controls. The variety of forklift configurations means operators must understand specific operational characteristics, stability limitations, and control systems for each equipment type operated. Forklift operation in construction environments presents additional challenges beyond permanent warehouse operations. Construction sites have constantly changing layouts with temporary storage areas, varying ground conditions, uncontrolled pedestrian movements, and interference with other construction activities. Materials handled range from standardised palletised goods to non-standard items including structural steel, timber packs, masonry materials, and equipment components requiring specialised lifting attachments. Outdoor operation exposes equipment to weather including rain affecting traction, dust reducing visibility, and wind loading on large panel materials affecting stability. Coordination with delivery vehicles, tower cranes, and other site logistics creates complex traffic management requirements. Australian WHS regulations classify forklifts as high-risk plant requiring operators to hold High Risk Work Licence class LF (Forklift Truck) issued by state and territory work health and safety regulators. Licensing requires successful completion of training by registered training organisations covering theoretical knowledge and practical skills, followed by competency assessment verified through both written tests and practical demonstration of safe operation. However, licensing represents minimum legal requirement - effective safe operation requires ongoing skills maintenance, site-specific training for different operational environments, and comprehensive understanding of load dynamics, stability principles, and hazard recognition capabilities developed through experience under proper supervision.

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Why this SWMS matters

Forklift operations account for a disproportionate number of serious injuries and fatalities in Australian warehousing and construction sectors relative to the number of workers involved in forklift activities. Safe Work Australia data consistently identifies forklifts among the highest-risk mobile plant equipment categories, with tip-over incidents, pedestrian collisions, and falling loads causing deaths, permanent disabilities, and serious injuries every year. The consequences of forklift incidents are often catastrophic - forklift tip-overs crush operators trapped in falling operator cages, pedestrians struck by moving forklifts suffer critical impact injuries, and loads falling from height cause severe crush injuries to workers positioned beneath or near forklifts during lifting operations. Forklift tip-over represents the highest severity hazard in forklift operations, accounting for significant proportion of forklift-related fatalities. Tip-over can occur in multiple modes including forward tip when load capacity is exceeded or loads are raised too high whilst travelling, lateral tip when operating across slopes or on uneven ground, and rearward tip when descending ramps without loads or when counterweight is inadequate for equipment configuration. The speed of tip-over events, often occurring within 1-2 seconds from initiation to impact, provides no opportunity for operator escape once tipping commences. Operators trapped in tipping forklifts must maintain position within operator restraints and operator cage rather than attempting to jump clear - operators who jump from tipping forklifts are often crushed as they land in tip-over path. The mass of forklifts (typically 3-10 tonnes depending on capacity) means crushing forces are catastrophic, with survival dependent on operator cage integrity maintaining survival space. Pedestrian collision incidents occur when forklifts strike workers conducting manual handling, construction tasks, or simply walking through work areas. Contributing factors include limited visibility from forklift operator positions particularly when loads obstruct forward visibility, inadequate separation between forklift operating areas and pedestrian work zones, pedestrians not monitoring for approaching forklifts due to focus on other tasks, and noise environments preventing pedestrians hearing forklift approach. High-visibility clothing worn by pedestrians provides limited protection if forklift operators are not looking in directions where pedestrians are positioned or if operators are distracted by load management tasks. The momentum of loaded forklifts means stopping distances can be substantial, with operators unable to stop in time even when pedestrians are noticed if speed and load weight are significant. Under the Work Health and Safety Act 2011, persons conducting a business or undertaking have extensive duties regarding powered mobile plant operation. For forklift operations, this includes ensuring operators hold appropriate High Risk Work Licences, equipment is maintained in safe operating condition throughout its service life, adequate supervision is provided particularly for new operators, traffic management systems separate forklifts from pedestrians where possible, and work areas provide adequate space for safe forklift operation without excessive hazard exposure. PCBUs must ensure forklift work is planned to eliminate or minimise risks so far as is reasonably practicable, requiring systematic risk assessment accounting for specific site conditions, load types, and operational requirements rather than assuming generic forklift procedures are adequate for all situations. Failure to meet forklift safety duties results in severe consequences including prohibition notices immediately halting operations until deficiencies are rectified, substantial financial penalties for serious breaches potentially exceeding $500,000 for corporations, and criminal prosecution following serious incidents with potential imprisonment for individuals including company directors and managers found to have breached duties. Beyond legal consequences, forklift incidents cause devastating impacts on injured workers and their families, with permanent disabilities affecting quality of life, psychological trauma affecting ability to work, and in fatal incident cases, life-changing grief for families. The business impacts extend to damaged reputation affecting client relationships and tender opportunities, increased insurance premiums, difficulty recruiting workers concerned about safety culture, and potential civil liability claims from injured parties. Comprehensive SWMS documentation for forklift operations ensures systematic identification and control of diverse hazards encountered across different operational contexts. Documentation covering pre-start inspection procedures prevents operation of defective equipment, load capacity assessment processes prevent overloading and tip-over, traffic management protocols reduce pedestrian collision risks, and emergency response procedures ensure appropriate actions if incidents occur. Training programs supported by detailed SWMS provide operators with knowledge and skills necessary for safe operation whilst giving supervisors reference materials for monitoring compliance and investigating incidents. Given the severity of potential consequences and frequency of forklift incidents across Australian industry, proper SWMS implementation represents essential foundation for protecting workers and ensuring sustainable safe forklift operations in construction logistics and warehousing activities.

Reinforce licensing, insurance, and regulator expectations for Forklift 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

Forklift Tip-Over from Overloading or Instability

High

Forklift tip-over represents the most severe hazard in forklift operations, occurring when equipment's combined centre of gravity (forklift plus load) moves outside stability triangle formed by front wheels and rear axle centre point. Forward tip-over occurs when load capacity is exceeded, loads are raised to excessive heights whilst stationary or travelling, or sudden braking with elevated loads shifts momentum forward. Lateral tip-over results from operating across slopes (perpendicular to slope direction), turning too sharply at excessive speed particularly when loaded, driving over curbs or edges causing one side to drop, or hitting obstacles causing sudden directional changes. Rearward tip-over occurs when descending ramps without loads or with inadequate counterweight, or when loads fall off forks rearward. Contributing factors include inaccurate assessment of load weights, operating beyond rated capacity, raising loads too high before travelling, excessive speed on slopes or uneven ground, worn or damaged tyres affecting stability, and operator error including sharp steering inputs at speed. Load characteristics significantly affect stability - off-centre loads create asymmetric weight distribution, loads with high centres of gravity reduce stability compared to compact loads, and non-rigid loads can shift during handling changing centre of gravity. Uneven ground surfaces create dynamic loading during travel, whilst slopes fundamentally change stability characteristics requiring capacity derating and modified operational procedures. Once tip-over is initiated, the event progresses rapidly with operators having 1-2 seconds maximum before impact, insufficient time for evasive action beyond bracing within operator cage and maintaining restraint system engagement.

Consequence: Fatal crushing injuries when operator cage impacts ground and operator is crushed within deformed cage, or when operators attempt to jump from tipping forklift and are crushed in tip-over path. Severe injuries including spinal trauma, fractures, internal injuries, and head trauma even when operators survive tip-over. Permanent disability affecting quality of life and employment capacity. Equipment damage requiring extensive repairs or replacement. Investigation, prosecution, and potential imprisonment for responsible parties following fatal incidents.

Collision with Pedestrians in Shared Work Areas

High

Forklifts operating in warehouses and construction sites share space with pedestrian workers conducting manual handling, construction tasks, order picking, and traffic through areas. Pedestrian collisions occur when forklift operators have insufficient visibility due to loads obstructing sightlines, when pedestrians walk into forklift travel paths without awareness of approaching equipment, when forklifts reverse without adequate rear visibility or spotter assistance, or when both forklifts and pedestrians approach blind corners or intersections simultaneously without warning systems. Forklift design creates significant blind spots including directly in front when loads are raised, rearward where mirrors provide only limited coverage, and immediately around forklift sides particularly near front wheels. Pedestrians focused on their own tasks may not monitor for approaching forklifts, whilst high-noise construction environments prevent pedestrians hearing forklift approach particularly electric forklifts operating very quietly. Congested work areas with narrow aisles, multiple simultaneous activities, and temporary storage in traffic routes create numerous potential conflict points. Forklift speed affects both collision likelihood and severity - faster travel reduces reaction time for both operators and pedestrians whilst increasing impact forces and stopping distances. Pedestrians wearing headphones for noise protection or entertainment cannot hear audible warnings from reversing alarms or horns. Some workers become habituated to reversing alarms and warning sounds, no longer responding appropriately to warnings that sound continuously throughout shifts. Seasonal workers or contractors unfamiliar with site traffic management may not understand designated routes or right-of-way protocols.

Consequence: Fatal crushing injuries when pedestrians are struck by forklifts and knocked down then run over, or when pedestrians are crushed between forklifts and structures. Severe impact injuries including fractures, head trauma, spinal injuries, and internal injuries requiring emergency treatment and extended hospitalisation. Permanent disabilities affecting mobility and work capacity. Psychological trauma affecting both injured pedestrians and forklift operators involved in collisions. Prosecution and imprisonment for gross negligence causing death. Business disruption during investigations and implementation of control improvements.

Falling Loads from Forks During Lifting or Transport

High

Loads can fall from forklift forks during lifting, lowering, or transport operations if loads are insecure, loads are not properly centred on forks, or load stability is compromised by forklift movements. Common scenarios include loads sliding off forks during acceleration or braking if loads are not secured or tilted adequately against mast, pallets collapsing under load weight if pallets are damaged or deteriorated, loads tipping sideways if loads are asymmetric or off-centre on forks, and loads caught on overhead structures or racking during lifting dislodging from forks. Sudden stops can cause loads to slide forward off forks even if initially positioned correctly, whilst sudden acceleration can cause loads to tip backward. Inadequate mast tilt failing to nest loads against load backrest allows loads to slide rearward particularly during braking or descending ramps. Damaged or bent forks reduce load support creating potential for loads to slip between forks. Lifting operations near other workers position pedestrians beneath or adjacent to elevated loads where falling load consequences are most severe. Material types affect falling load risks - loose materials including bricks or blocks can spill from pallets striking workers nearby, long materials including timber or steel can pivot during falls creating wide impact zones, and heavy dense materials generate tremendous impact forces even from moderate heights. Workers positioned under forklifts during load placement on elevated racking, or working adjacent to forklifts loading trucks, are in direct fall paths if loads detach from forks.

Consequence: Fatal crushing injuries from heavy loads falling onto workers, particularly loads falling from elevated heights gaining substantial impact energy. Severe fractures, spinal injuries, head trauma, and internal injuries requiring emergency medical treatment. Multiple workers potentially injured simultaneously if loads spill across wide areas. Material damage requiring replacement and project delays. Regulatory investigation and potential prosecution if falling loads cause serious injuries or fatalities.

Struck by Forklift Mast or Load During Reversing Operations

High

Reversing forklifts present struck-by hazards from rear forklift components, raised masts, or loads extending rearward contacting workers positioned behind forklifts. Forklift operators have extremely limited rear visibility particularly when loads are carried, relying on mirrors providing only partial coverage and creating blind zones immediately behind equipment. Workers positioned in blind zones are invisible to operators, with particular risk during reversing when operators focus attention rearward whilst potentially missing workers in direct reversing path. Raised masts and overhead guards extend significantly above operator cab level, creating overhead hazards striking workers' heads or upper bodies when forklifts reverse near workers. Loads extending rearward beyond forklift wheelbase, or loads with irregular shapes, can strike workers even when forklift body has adequate clearance. Construction sites often have workers at various levels including ground level, working from ladders, or on scaffold platforms, creating three-dimensional hazard space around reversing forklifts. Reversing alarms provide audible warnings but are ineffective if workers are wearing hearing protection blocking alarm sounds, in high-ambient-noise environments masking alarm tones, or if workers have become habituated to continuous alarms no longer registering alarm sounds as requiring response. Operators reversing in confined spaces may focus on avoiding structures or other equipment whilst missing pedestrians in complex environments with multiple simultaneous hazards.

Consequence: Fatal head injuries or crushing injuries when workers are struck by reversing forklifts or elevated mast components. Severe impact injuries including skull fractures, spinal trauma, and internal injuries. Workers knocked from elevated positions including ladders or platforms when struck by forklift components, causing fall injuries in addition to initial impact. Investigation and prosecution following serious reversing incidents with potential for imprisonment if gross negligence is identified.

Contact with Overhead Power Lines or Structures

High

Forklift masts, raised loads, or overhead guards can contact overhead power lines creating electrocution risks, or strike overhead structures causing structural damage and load or forklift instability. Outdoor forklift operation near overhead power lines including site boundary lines, service connections to buildings, or temporary site power presents electrocution risk if mast or raised loads approach within minimum safe clearances. Electricity can arc across gaps if approach distances are inadequate, with arcing distance varying based on voltage - high voltage lines require greater clearance than low voltage. Forklift structure provides conductive path for electrical current if contact occurs, with operators at severe risk of electrocution if touching forklift controls or structure during power contact. Wet conditions increase electrical conductivity of forklift components and ground surfaces increasing electrocution risk. Indoor operations present overhead structure hazards including building structural elements, heating/ventilation ducting, sprinkler pipes, lighting, and cable trays. Contact with overhead structures can damage services, dislodge structures onto forklift or surrounding workers, or snag loads causing load instability or forklift tip-over if loads are pulled rearward. Door headers, mezzanine edges, and building entries present recurring overhead hazards that operators may become complacent about if traversed frequently without incident. Loads extending above normal forklift height including tall palletised loads or loads on raised forks require particular awareness of overhead clearances.

Consequence: Fatal electrocution when forklift contacts overhead power lines with current travelling through operator body to ground. Severe electrical burns and cardiac arrest requiring immediate emergency medical intervention. Arc flash burns to operators and nearby workers from electrical arcing. Falling structures if overhead services are dislodged, causing crush injuries to workers beneath. Facility damage from ruptured sprinkler systems, damaged electrical systems, or structural damage requiring expensive repairs and business interruption during repairs.

Forklift Brake Failure or Loss of Control on Slopes

Medium

Brake system failures or inadequate brake capacity when operating on slopes can cause uncontrolled forklift movement resulting in collisions, tip-overs, or run-away equipment incidents. Hydraulic brake systems can fail due to low hydraulic fluid, deteriorated brake lines or seals, worn brake pads or discs, or hydraulic pump failures. Warning signs of brake deterioration include increased pedal travel, spongy brake feel, brake fade during sustained use, or unusual sounds during braking. Operators descending slopes with inadequate braking capacity may attempt to use steering to control speed, increasing lateral forces and tip-over risk. Loaded forklifts descending ramps gain significant momentum with gravity assistance, requiring greater braking force than level ground operation. Engine braking provides supplementary braking on combustion forklifts but electric forklifts may have limited engine braking capability depending on motor configuration. Operators may under-estimate slope gradients particularly when slopes are gradual but extended, not recognising braking demands until already committed to slope descent. Wet or contaminated surfaces reduce tyre traction compounding brake inadequacy. Brake failures on slopes can result in forklifts running away at accelerating speeds beyond safe operation, striking structures, other equipment, or workers unable to clear forklift path. Operators attempting to jump from run-away forklifts can be crushed if they land in travel path or are struck by forklift during dismounting.

Consequence: Uncontrolled forklift collision causing injuries to operator from impact forces, pedestrians or workers struck by run-away forklift suffering crush injuries, structural damage from high-speed forklift impact with buildings or equipment. Forklift tip-over if high-speed collision causes directional change exceeding stability limits. Operators crushed attempting to jump from run-away forklifts. Major equipment damage requiring extensive repairs or replacement. Investigation and potential prosecution if brake maintenance inadequacy contributed to failure.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Pre-Start Inspection Programme and Equipment Maintenance

Engineering

Preventing forklift incidents from equipment failures requires comprehensive pre-start inspection programmes identifying defects before operation, combined with systematic preventive maintenance ensuring equipment remains in safe condition throughout service life. Daily pre-start inspections conducted by operators before first use verify critical safety systems including brakes, steering, hydraulics, mast operation, tyre condition, lights and alarms, overhead guard integrity, and seatbelt functionality. Inspection checklists tailored to specific equipment models ensure all critical components are checked with inspection results documented providing evidence of systematic approach. Defect reporting procedures must ensure equipment with identified defects is immediately quarantined preventing use until repairs are completed and verified. Scheduled preventive maintenance based on manufacturer recommendations and operating hours addresses component wear before failures occur, including brake system servicing, hydraulic system inspection and fluid changes, tyre replacement, chain and mast inspection on reach trucks, electrical system testing, and load testing verifying capacity ratings remain valid. Maintenance work should be conducted by qualified technicians with specialist forklift knowledge, with critical safety work including brake repairs documented and verified through testing before return to service. Equipment maintenance logs tracking inspection history, defects found, repairs completed, and parts replaced provide comprehensive equipment condition records supporting compliance verification and incident investigation if required.

Implementation

1. Develop equipment-specific pre-start inspection checklists covering all critical safety systems and components appropriate for each forklift type operated. 2. Train all forklift operators to conduct daily pre-start inspections before first use each shift, recognising defects requiring immediate attention versus items schedulable for next service. 3. Require documented pre-start inspections with operator signature and supervisor review, with checklists retained minimum 90 days for regulatory compliance verification. 4. Implement defect reporting procedures including tagging systems, equipment quarantine processes, and priority repair scheduling ensuring defective equipment cannot be used until repairs are completed. 5. Establish scheduled preventive maintenance intervals based on manufacturer recommendations and actual operating hours, typically including monthly detailed inspections and annual comprehensive servicing. 6. Engage qualified service technicians to conduct maintenance including brake testing and adjustment, hydraulic system inspection, mast and chain examination, and load capacity testing. 7. Maintain comprehensive maintenance logs documenting inspection findings, maintenance work performed, parts replaced, load test results, and verification of repairs before return to service. 8. Implement equipment replacement programmes ensuring aged equipment exceeding economic repair viability or with deteriorating safety system reliability is replaced rather than continuing repairs on unreliable equipment.

High Risk Work Licensing and Competency-Based Training

Administrative

Ensuring operators possess adequate competency for safe forklift operation requires verification of High Risk Work Licence compliance, delivery of comprehensive training addressing equipment operation and hazard recognition, and ongoing skills assessment ensuring competency maintenance. All forklift operators must hold current High Risk Work Licence class LF (Forklift Truck) issued by state or territory work health and safety regulators, with licence verification conducted before operators commence work. However, licensing alone does not ensure safe operation - site-specific training covering traffic management systems, load types and handling requirements, work area layouts, emergency procedures, and communication protocols supplements formal licensing. Familiarisation training for different forklift models ensures operators understand control systems, stability characteristics, capacity ratings, and specific operational requirements for each equipment type operated. Competency assessment through supervised operation verifies operators can demonstrate safe practices before authorisation for independent work, with particular emphasis on load assessment, travel with loads, slope operation, and pedestrian awareness. Refresher training addresses skill degradation over time and reinforces critical safety messages, with annual retraining recommended for all operators regardless of experience. Supervision requirements should be heightened for newly licensed operators transitioning from training to independent operation, with graduated reduction in supervision as experience develops. Training documentation including licence verification, site-specific training records, familiarisation for specific equipment, and competency assessment results provides comprehensive operator competency evidence.

Implementation

1. Verify all forklift operators hold current High Risk Work Licence class LF before commencing forklift operations, maintaining licence photocopies in operator files. 2. Provide comprehensive site-specific induction covering traffic management, designated forklift routes, exclusion zones, load types, capacity limits, emergency procedures, and site-specific hazards. 3. Deliver equipment familiarisation training when operators will use different forklift models than previous experience, covering control systems, stability characteristics, and operational requirements. 4. Conduct supervised operation competency assessment requiring operators to demonstrate safe operation including pre-start inspection, load pickup and placement, travel loaded and unladen, and emergency procedures. 5. Implement refresher training programmes providing annual retraining reinforcing critical safety messages, updating operators on procedural changes, and addressing incident learnings from previous period. 6. Provide enhanced supervision for newly-licensed operators during initial independent operation period, with designated mentors providing guidance and feedback until competency is well-established. 7. Maintain comprehensive training records documenting licence verification, site induction completion, equipment familiarisation, competency assessments, refresher training, and supervisor observations of operator performance. 8. Establish disciplinary procedures for unsafe operation including retraining requirements, temporary licence suspension for serious breaches, and dismissal for gross negligence or repeat violations.

Traffic Management and Pedestrian Separation Systems

Engineering

Preventing pedestrian-forklift collisions requires systematic traffic management separating forklift operating areas from pedestrian work zones where possible, and controlling interactions where separation cannot be achieved. Engineering controls include physical barriers delineating forklift-only zones from pedestrian areas, floor markings showing designated forklift routes and pedestrian walkways using highly-visible colours and line marking, one-way traffic systems in aisles reducing conflict points where forklifts may meet, and pedestrian crossings equipped with appropriate controls including mirrors, signage, or signals. Exclusion zones preventing pedestrians entering areas during active forklift operations, enforced through barriers or assigned personnel, eliminate exposure during high-risk activities including truck loading or work at height. Visibility enhancement features including convex mirrors at blind intersections, elevated crossing points allowing pedestrian traffic over forklift routes, and proximity detection systems alerting operators and pedestrians to each other's presence provide defence-in-depth. For loading dock operations, designated safe zones where pedestrians can stand clear during forklift movements, clear demarcation between forklift operating areas and manual handling areas, and sequential operations preventing simultaneous forklift and pedestrian activity in same spaces reduce conflict potential. Administrative controls supplement physical separation including restricting forklift operation to specific times when pedestrian traffic is minimised, requiring spotters for operations in congested areas, and establishing communication protocols between forklift operators and other workers.

Implementation

1. Designate specific forklift operating routes using floor marking, signage, and barriers creating clear separation between forklift zones and pedestrian work areas where space permits. 2. Install physical barriers including guardrails, bollards, or safety gates separating pedestrian walkways from forklift operating areas, particularly in permanent facilities where layouts are stable. 3. Mark pedestrian crossing points across forklift routes using high-visibility floor markings, warning signage for both forklifts and pedestrians, and convex mirrors showing approaching traffic. 4. Implement one-way traffic systems in narrow aisles preventing forklifts meeting head-on requiring complex manoeuvring in confined spaces, with clear directional signage and entry/exit controls. 5. Establish exclusion zones around active forklift operations using barriers, tape, or assigned personnel preventing pedestrians entering during truck loading, load placement at height, or work in confined areas. 6. Install convex mirrors at blind corners and intersections allowing forklift operators and pedestrians to see approaching traffic before entering intersection areas. 7. Provide elevated pedestrian crossings (overhead walkways) where high-volume forklift and pedestrian traffic cannot be effectively managed through surface-level separation. 8. Implement proximity detection systems on forklifts providing audible or visual warnings to operators and pedestrians when in close proximity, supplementing visual observation and physical separation controls.

Load Capacity Assessment and Management Procedures

Administrative

Preventing tip-over and load instability incidents requires systematic load capacity assessment ensuring loads do not exceed equipment ratings accounting for load weights, lift heights, load centres, and operational conditions. Administrative procedures establish requirements for operators to assess loads before lifting including visual inspection of load condition, pallet integrity, load balance, and weight estimation or verification. Load capacity data plates on forklifts show maximum safe working load at standard load centre (typically 500-600mm), with capacity reducing as lift height increases or load centre distance increases. Operators must verify load characteristics fall within equipment capacity envelope accounting for actual lift height required and load centre distance measured from fork face to load centre of gravity. For unusual loads without standard pallets, non-standard load centres, or loads approaching capacity limits, procedures should require supervisor consultation and documented capacity verification. Restrictions on travel speed with elevated loads, prohibition on travelling with loads raised higher than minimum clearance required, and limits on operating with loads on slopes prevent dynamic loading and stability compromise. Load securing requirements for non-palletised loads using straps, chains, or other restraints prevent loads shifting during transport. Documentation requirements including load weight logs for high-value or unusual loads provide evidence of systematic capacity management.

Implementation

1. Display load capacity data plates on all forklifts showing maximum capacity at various lift heights and load centres, ensuring plates are clearly visible to operators and in good condition. 2. Establish load assessment procedures requiring operators to inspect loads before lifting, checking pallet condition, load symmetry, apparent weight, and securing of items on pallets. 3. Provide load weight verification systems including weighing equipment, load documentation from suppliers, or reference tables showing typical weights for common construction materials. 4. Require operators to verify load weights and load centres do not exceed forklift capacity for intended lift height before commencing lifting operations, with consultation if uncertainty exists. 5. Prohibit travelling with loads raised above minimum clearance height required for ground obstacles, reducing centre of gravity and tip-over risk during transport. 6. Establish maximum travel speeds for loaded forklifts, typically 10-15 km/h depending on site conditions, with reduced speeds in congested areas, on slopes, or with elevated loads. 7. Require load securing using straps, chains, or banding for non-palletised loads, loose materials, or items susceptible to shifting during transport. 8. Maintain load handling logs for unusual loads documenting load weights, lift heights, equipment used, operator verification of capacity compliance, and supervisor authorisation for loads approaching limits.

Slope Operation Procedures and Gradient Restrictions

Administrative

Managing forklift operation on slopes requires specific procedures addressing stability and control challenges presented by inclined surfaces. Procedures should specify maximum slope gradients where forklifts may operate safely, typically limiting to slopes less than 10% (approximately 6 degrees) for standard forklifts unless equipment specifications permit steeper operation. Slope operation techniques include requirements to travel straight up or down slopes rather than across slopes (perpendicular to fall line) which creates lateral tip-over risk, maintaining loads on uphill side of forklift during slope travel, keeping loads low during slope operation, and using reduced speeds. Specific procedures for ascending slopes loaded require travelling forward with load raised only minimum height for ground clearance, whilst descending slopes loaded requires reversing down slope with load on uphill side allowing operator to walk forward and maintain visibility. Prohibition on turning whilst on slopes eliminates combination of lateral forces from turning and gravitational forces from slope. For sites with recurring slope operation, gradient measurement and marking alerts operators to actual slope steepness enabling appropriate procedure selection. Enhanced brake inspections for forklifts regularly operating on slopes verify brake systems maintain adequate capacity for controlling loaded descents. Alternative handling methods including using equipment with better slope capability, establishing level loading areas, or using conveyor or crane systems to traverse slopes may be preferable to forklift slope operation for frequent slope requirements.

Implementation

1. Measure and document slope gradients throughout site, marking slopes exceeding 5% gradient with warning signage alerting operators to slope presence and required procedures. 2. Establish maximum slope gradient limits for forklift operation based on equipment specifications and operational risk assessment, typically maximum 10% unless equipment rated for steeper slopes. 3. Require loads to be maintained at minimum height above ground during all slope travel, prohibiting travelling with loads raised which severely compromises stability on slopes. 4. Specify that operators must travel straight up or down slopes rather than across slopes, with turning only conducted on level areas to prevent lateral tip-over. 5. Require ascending slopes loaded to be conducted travelling forward with load on uphill side, whilst descending slopes loaded requires reversing with load on uphill side and operator walking forward. 6. Implement reduced speed limits for slope operation, typically 5 km/h maximum on slopes regardless of gradient, with slower speeds for steeper slopes or loaded operation. 7. Prohibit any turning whilst on slopes including slight directional adjustments - operators must return to level ground before making directional changes. 8. Consider alternative material handling methods for frequent slope operation including using earthmoving equipment with better slope capability, establishing level work areas, or mechanical aids avoiding slope operation.

Overhead Clearance Identification and Awareness Systems

Engineering

Preventing contact with overhead power lines and structures requires systematic identification of overhead hazards, maintaining adequate clearances, and awareness systems alerting operators to overhead risks. Engineering controls begin with identifying all overhead hazards including mapping power line locations with voltage information, surveying building structural elements, service lines, and temporary structures. Minimum safe clearances must be established based on voltage for power lines (typically minimum 3 metres for low voltage, greater for high voltage), and structural clearances accounting for forklift and load heights. Physical barriers including height restriction bars, overhead protection screens, or exclusion zones prevent forklifts approaching overhead hazards too closely. For power lines that cannot be relocated or elevated, consider requesting utility de-energisation during forklift operations or implementing alternative material handling avoiding power line proximity. Visual warnings including overhead hazard markers, height awareness devices fitted to forklifts showing clearance available, and brightly-marked overhead structures increase operator awareness. Administrative controls including site inductions highlighting overhead hazard locations, operating procedures prohibiting loads being raised near overhead hazards except when essential, and spotter requirements for operations near overhead hazards supplement physical controls. For recurring overhead hazard areas, consider whether material handling can be redesigned to eliminate need for forklift operation in hazardous locations.

Implementation

1. Conduct overhead hazard survey identifying all power lines, structural elements, services, and other overhead hazards within forklift operating areas, documenting locations and clearances. 2. Establish minimum safe clearances from overhead hazards based on voltage for power lines (3m minimum for low voltage) and structural clearances accounting for maximum forklift and load height. 3. Install physical barriers including height restriction bars, overhead screens, or exclusion zone fencing preventing forklifts approaching overhead hazards closer than safe clearance distances. 4. Mark overhead hazards using high-visibility warning markers, bunting, or suspended warning signs positioned to be visible to forklift operators approaching hazard areas. 5. Fit forklifts with height awareness devices or proximity alarms providing audible or visual warnings when approaching overhead clearance limits, calibrated for specific forklift maximum heights. 6. Coordinate with utility providers to arrange power line relocation, elevation, or temporary de-energisation if forklift operations must occur near power lines unable to be adequately isolated. 7. Provide site induction highlighting overhead hazard locations, safe clearances, and procedures for operations near hazards including reduced speeds and heightened awareness requirements. 8. Consider alternative material handling methods avoiding overhead hazard areas including relocating storage areas, using cranes or other lifting equipment, or manual handling for items requiring placement near hazards.

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Personal protective equipment

Hard Hat

Requirement: Type 1 helmet compliant with AS/NZS 1801

When: Mandatory when operating forklifts in areas with overhead work, when working near other equipment with elevated loads, or when required by site-specific safety management plans. Essential for protecting head from falling objects or head strike on overhead guards during rough terrain operation.

High-Visibility Clothing

Requirement: Class D Day/Night compliant with AS/NZS 4602.1

When: Required for all forklift operations to ensure operator visibility to other equipment operators, delivery drivers, pedestrians, and other site workers particularly when exiting forklift cab for inspections, load adjustments, or communication with other workers.

Safety Boots with Steel Toe Caps

Requirement: Certified to AS/NZS 2210.3 with steel toe protection and penetration-resistant soles

When: Mandatory footwear for all forklift operators to protect feet when dismounting equipment and working around loads, providing protection from items dropped during manual load securing or if loads fall from forks during handling operations.

Seatbelt/Operator Restraint

Requirement: Forklift manufacturer-specified restraint system maintained in good condition

When: Must be worn at all times when operating forklift with operator restraint system fitted. Essential for tip-over protection preventing operator ejection and ensuring operator remains in protected zone of operator cage during tip-over events. Never operate without wearing restraint if fitted.

Safety Glasses

Requirement: Impact-rated to AS/NZS 1337 with side shields

When: Required when operating in dusty environments, when working outdoors in windy conditions with airborne dust or debris, or when site-specific risk assessments identify eye hazards from construction activities occurring in vicinity of forklift operations.

Hearing Protection

Requirement: Class 4 or 5 earplugs or earmuffs per AS/NZS 1270

When: Required when operating diesel or LPG forklifts for extended periods in enclosed warehouse environments, or when operating in high-noise construction site areas with multiple plant and equipment generating significant noise exposure. Electric forklifts in open areas may not require hearing protection.

Sun Protection

Requirement: Broad-brim hat or cap, long-sleeve shirt, sunglasses with UV protection, SPF 50+ sunscreen

When: Required for outdoor forklift operation during sunny conditions to prevent skin cancer from UV exposure. Particularly important for operators working extended outdoor shifts in construction site material yards or loading areas without shade.

Inspections & checks

Before work starts

  • ✓Conduct visual walk-around inspection checking for obvious damage, fluid leaks, tyre condition, and obstructions around forklift before entering cab
  • ✓Test seatbelt or operator restraint system for secure attachment, proper adjustment, and buckle functionality before starting engine
  • ✓Start engine and verify all gauges show normal readings including oil pressure, engine temperature, battery charge, and fuel or battery level adequate for planned operations
  • ✓Test brake systems including service brakes, park brake engagement and holding capacity, and verify brake pedal feel is firm without excessive travel or sponginess
  • ✓Operate hydraulic controls checking mast raises and lowers smoothly through full range, forks tilt forward and backward correctly, and side-shift functions operate if equipped
  • ✓Test steering system for appropriate response, checking for excessive free play, unusual sounds, or difficulty turning steering wheel
  • ✓Verify all lights operate correctly including headlights, taillights, brake lights, reversing lights, and warning beacons or strobes if fitted
  • ✓Test horn and reversing alarm for adequate volume, and check mirrors are clean, properly adjusted, and provide clear rear visibility
  • ✓Inspect forks for cracks, bends, or excessive wear particularly at heel and mounting points, verifying forks are securely locked in carriage and properly spaced for loads
  • ✓Check overhead guard and load backrest for damage or deterioration that could affect protective capability during tip-over or load contact events
  • ✓Document pre-start inspection completion on checklist, noting any deficiencies requiring attention and quarantining equipment if defects prevent safe operation

During work

  • ✓Monitor forklift performance throughout operation noting any unusual sounds, vibrations, changed handling characteristics, or warning lights requiring investigation
  • ✓Check load stability before and during transport observing for shifting, asymmetric loading, pallet damage, or signs loads may tip or fall from forks
  • ✓Verify brake performance remains adequate during loaded and unladen operation, particularly on slopes where brake demands are highest
  • ✓Observe hydraulic system operation for smooth consistent performance without jerking, unusual sounds, or visible leaks from hoses or cylinders
  • ✓Monitor battery charge or fuel levels planning refuelling or recharging before levels drop to points affecting safe operation or risking equipment stopping mid-operation
  • ✓Maintain awareness of surrounding environment including other workers, equipment, obstacles, overhead clearances, and changing site conditions requiring operational adaptations
  • ✓Check tyre condition periodically for damage, excessive wear, or foreign objects embedded in tyres affecting traction or stability
  • ✓Verify loads remain properly positioned on forks during transport, with periodic stops to check load security if travelling extended distances or over rough terrain

After work

  • ✓Lower forks completely to ground level removing trip hazards and preventing hydraulic system strain from maintaining elevated forks while parked
  • ✓Park forklift in designated storage area on level ground clear of traffic routes, doorways, fire exits, or locations where equipment creates obstacles
  • ✓Engage park brake firmly, place transmission in park or neutral, and switch off engine or power systems following manufacturer shutdown procedures
  • ✓Remove key and secure in designated location preventing unauthorised use, particularly important on construction sites with public access or multiple contractors
  • ✓Connect forklift to battery charger if electric forklift requires charging, following proper charging procedures including ventilation verification and appropriate charger selection
  • ✓Report any equipment defects, operational issues, or near-miss incidents in forklift logbook or electronic reporting system for supervisor review and maintenance scheduling
  • ✓Clean operator cab windows, mirrors, and lights removing dust, debris, or contaminants accumulated during operation maintaining visibility and safety system functionality
  • ✓Document hours operated if forklift has hour meter, supporting scheduled maintenance intervals based on actual operating hours rather than calendar time periods

Step-by-step work procedure

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

Field ready
1

Conduct Pre-Start Inspection and Equipment Verification

Before commencing forklift operations each shift, conduct comprehensive pre-start inspection following documented checklist specific to forklift model being operated. Begin with external walk-around inspection looking for obvious damage to forklift body, overhead guard, or mast structures, checking for hydraulic fluid or oil leaks under forklift indicating system problems, inspecting tyres for adequate inflation, damage, excessive wear, or foreign objects embedded in treads, and verifying forks show no visible cracks, severe bending, or dangerous wear patterns. Enter operator cab and adjust seat positioning for comfortable reach to all controls, fasten seatbelt or operator restraint ensuring proper fit across lap and shoulder if three-point restraint, and adjust mirrors for clear rear visibility. Start engine or activate power systems following manufacturer procedures, allowing diesel engines to warm up if required and observing all warning lights extinguish indicating systems initialisation. Verify all instrument gauges show normal readings including oil pressure in acceptable range, engine or motor temperature normal, battery charge or fuel level adequate for planned shift duration, and no warning lights indicating system faults. Test brake systems by depressing service brake pedal verifying firm pedal feel without sponginess or excessive travel indicating air in system, attempt to move forklift with brakes applied confirming brakes hold equipment stationary, and engage park brake verifying positive engagement and mechanical lock rather than hydraulic brake relying on system pressure. Operate hydraulic controls raising and lowering mast through full range of travel listening for unusual sounds and observing smooth operation without jerking or hesitation, tilt forks forward and backward verifying tilt function operates correctly throughout range, and activate side-shift if equipped verifying carriage moves laterally smoothly. Test steering through full left and right rotation checking for excessive free play, binding, or unusual resistance requiring mechanical attention. Verify all lights operate including headlights, taillights, brake lights, reversing lights, and warning beacons, test horn produces adequate audible warning, and check reversing alarm sounds when transmission is placed in reverse. Document inspection completion on checklist signing and dating record, and resolve any deficiencies before commencing operations or quarantine equipment preventing use until repairs are completed if defects affect safe operation.

Safety considerations

Never operate forklifts with defective brakes as brake failure creates uncontrolled equipment potentially causing collisions, tip-overs, or run-away incidents on slopes with catastrophic consequences. Damaged forks can fracture under load causing sudden load drop potentially crushing workers beneath. Hydraulic system problems including leaks or jerky operation can cause loss of load control or equipment failures during critical load handling. Defective lights severely compromise visibility and ability of other workers to see approaching forklift particularly in dim warehouse areas or during evening construction work. Seatbelt or operator restraint is critical safety equipment for tip-over protection - never operate without wearing restraint as being thrown from cab during tip-over typically results in fatal crushing injuries.

2

Assess Work Area and Identify Hazards Before Operations

Before commencing forklift movement and load handling, conduct systematic assessment of work area identifying hazards requiring specific controls during operations. Survey traffic routes noting locations where other workers are conducting activities potentially creating conflict with forklift movements, identifying blind corners or intersections requiring increased vigilance or spotter assistance, and observing positions of other forklifts or mobile equipment requiring coordination. Identify overhead hazards including power lines with voltages and minimum clearance requirements, building structural elements, services including sprinkler pipes or electrical conduits, and temporary structures or materials stored overhead. Assess ground surface conditions noting uneven areas requiring reduced speeds or altered routes, wet or contaminated surfaces affecting traction, slopes requiring specific operating procedures, and soft ground areas that may not support loaded forklift weight. Identify pedestrian traffic patterns and high-traffic areas requiring enhanced awareness, locations where visibility is restricted requiring reduced speeds or mirrors, and positions where pedestrians may be working beneath or near loads during placement operations. Note locations of emergency equipment including fire extinguishers, first aid kits, and emergency communication systems for reference if incidents occur. Verify traffic management systems including designated forklift routes, one-way traffic directions, pedestrian crossing points, and exclusion zones are understood and will be followed. Coordinate with site supervision regarding day's activities including scheduled deliveries requiring loading dock access, materials placement requirements including racking locations and load specifications, and any site works affecting normal traffic routes or requiring temporary route modifications. Communicate with other forklift operators establishing right-of-way protocols for shared aisles, coordination signals for passing in narrow spaces, and emergency stop communications if hazards develop affecting multiple operators.

Safety considerations

Failure to identify overhead power lines before commencing operations creates severe electrocution risk if mast or loads contact energised lines. Unidentified overhead structural hazards can be struck during load elevation causing structural damage, load instability, or dislodged materials falling onto operators or workers below. Operating on slopes without appropriate procedures creates tip-over risk particularly if operators do not recognise slope gradient exceeds safe limits. Soft ground can cause forklift sinking or tip-over particularly when loaded, with risk highest when ground conditions have changed due to weather or construction activities since previous forklift operation in areas. Lack of coordination with other workers creates collision risk with pedestrians, manual handling operations, or other equipment operating simultaneously in shared spaces.

3

Approach Load and Conduct Pre-Lift Assessment

When approaching load requiring handling, reduce speed and conduct systematic assessment verifying load is suitable for safe handling using available forklift. Visually inspect pallet or load support structure checking for damaged pallet boards, cracks, broken stringers, or deterioration that could cause pallet collapse during lifting or transport. Observe load configuration on pallet verifying items are stacked symmetrically centred on pallet, items are secured through banding, shrink-wrap, or strapping preventing shifting during handling, and load height does not create instability or excessive centre of gravity height. Look for load identification markings, shipping documentation, or visible characteristics allowing estimation of load weight, comparing estimated or documented weight against forklift capacity for intended lift height. Assess load centre distance measuring or estimating distance from front face of pallet to load centre of gravity, noting whether load is standard configuration with centre approximately 600mm from pallet edge or whether load extends rearward significantly creating non-standard load centre requiring capacity derating. Identify any unusual load characteristics including asymmetric weight distribution visible from load leaning, protruding items extending beyond pallet footprint creating snagging hazards, or multiple pallets banded together requiring treatment as single load. Verify adequate clearance exists for forklift approach to load including overhead clearance for mast, lateral clearance for forklift body width, and clear path allowing straight-on approach rather than angled approach requiring complex manoeuvring. Confirm planned destination for load is prepared including racking location is clear, ground placement area is available, and loading dock is accessible, preventing situations where loads are lifted but cannot be placed requiring holding loads elevated whilst solutions are developed. For unusual loads including those approaching capacity limits, loads with non-standard configurations, or loads with uncertain weights, consult supervisor obtaining verification of appropriateness before attempting lift.

Safety considerations

Damaged pallets can collapse during lifting dropping loads suddenly potentially crushing operators' feet or lower legs, or causing loads to fall striking nearby workers. Exceeding forklift capacity creates tip-over risk potentially fatal to operators crushed in operator cages. Asymmetric or off-centre loads create lateral instability causing loads to tip sideways from forks or causing forklift lateral tip-over during travel or cornering. Loads with items not secured can shift during handling changing centre of gravity and stability, or individual items can fall from loads striking operators or other workers. Attempting to lift loads when destination is not prepared can result in operators holding loads elevated for extended periods creating fatigue and increasing likelihood of load drops, or operators placing loads in inappropriate temporary locations creating subsequent handling challenges and hazards.

4

Position Forklift and Pick Up Load Using Correct Procedures

Approach load at controlled speed, aligning forklift perpendicular to pallet ensuring straight approach allowing forks to slide fully under pallet without requiring adjustments. Adjust fork spacing if using adjustable fork carriage, positioning forks to support pallet evenly with forks distributed across pallet width whilst maintaining clearance between forks for pallet boards. Lower forks to ground level before commencing approach preventing fork tips striking pallet or load items during insertion. Slowly advance forklift inserting forks fully under pallet until fork tips approach rear pallet edge, ensuring forks extend through pallet supporting full depth rather than partial insertion creating cantilever loading. Verify forks are inserted straight without angling, and that load appears balanced across both forks without more weight on one fork indicating asymmetric loading. Tilt mast rearward approximately 5-10 degrees nestling load firmly against load backrest preventing loads sliding rearward during travel. Raise load only sufficient height to clear ground during travel, typically 100-200mm clearance adequate for smooth surfaces whilst maintaining low centre of gravity optimising stability. Before travelling, pause and observe load confirming load is stable on forks, pallet is not damaged allowing load tilt, items on pallet have not shifted during lifting, and overall load appearance indicates proper weight distribution and stability. Sound horn alerting other workers that loaded travel is commencing, check mirrors and surrounding area verifying no workers are in immediate travel path, and commence travel at reduced speed appropriate for loaded operation.

Safety considerations

Partial fork insertion under pallets concentrates load weight near fork tips creating severe instability risk with loads likely to tip forward off forks particularly during braking or descending ramps. Forks inserted at angles rather than straight create uneven load distribution causing loads to slide sideways off forks or creating lateral instability during cornering. Raising loads too high before travel elevates centre of gravity significantly increasing tip-over risk particularly during travel over uneven surfaces, on slopes, or during emergency stops. Failure to tilt mast rearward allows loads to slide rearward during braking potentially striking mast structures or operators, whilst excessive rearward tilt can cause rearward tip-over when descending ramps. Commencing travel without verifying load stability can result in discovering load instability only after load is elevated and equipment is moving, creating difficult recovery situations and increased incident risk.

5

Transport Load Safely Maintaining Visibility and Control

Transport load to destination maintaining safe speed appropriate for conditions, typically maximum 15 km/h when loaded on smooth level surfaces with reduced speeds in congested areas, near pedestrians, on slopes, or over rough terrain. Maintain loads at minimum height above ground throughout travel reducing tip-over risk, only raising loads when reaching destination for placement operations. Travel with mast tilted rearward keeping loads secure against load backrest, adjusting tilt angle if required during travel to maintain load security. Navigate corners and turns at reduced speed using gradual steering inputs preventing sudden lateral forces that could cause load shift or lateral tip-over. Maintain visibility in travel direction continuously, using mirrors when reversing or when forward visibility is limited by loads, and requesting spotter assistance when visibility is severely restricted. Monitor load stability throughout transport watching for signs of load shifting, pallet damage becoming apparent, or items on loads moving requiring immediate stop to re-secure or abort load handling. Sound horn when approaching intersections, blind corners, pedestrian crossings, or areas where other workers may be present providing audible warning of forklift approach. Maintain safe separation from other forklifts allowing adequate stopping distance, avoiding travelling close behind other forklifts where sudden stops create collision risk. Observe overhead clearances continuously when transporting loads verifying adequate clearance to structural elements, services, doorways, and power lines particularly when loads extend above normal forklift height. If travelling across slopes cannot be avoided, cross at right angles to fall line (straight up or down slope rather than across), maintain very slow speed, monitor load stability intensely for signs of shifting, and complete slope crossing quickly returning to level ground minimising time in unstable condition.

Safety considerations

Excessive speed reduces reaction time for obstacles or pedestrians, increases stopping distance potentially inadequate if sudden stops are required, and generates dynamic forces during cornering that can cause load tip-over or lateral forklift tip-over. Travelling with loads raised high creates top-heavy configuration with centre of gravity elevated severely increasing tip-over risk particularly over uneven ground or during sudden manoeuvres. Load instability not detected during transport can progress to load falling from forks striking operators, other workers, or causing property damage. Travelling across slopes (perpendicular to fall line) creates maximum lateral tip-over risk as gravitational forces act perpendicular to travel direction destabilising forklift. Inadequate visibility when loads obstruct forward vision creates collision risk with pedestrians, other equipment, or structures that cannot be seen until impact occurs or is imminent with insufficient stopping distance.

6

Place Load at Destination and Lower Safely

When approaching destination, reduce speed further and position forklift precisely at load placement location accounting for adequate clearance to obstacles and accurate alignment with placement position. For ground-level placement, position forklift with load directly over intended placement area verifying ground surface will adequately support load weight and surrounding clearances allow safe fork extraction. Lower load slowly using hydraulic controls maintaining smooth controlled descent, observing load makes contact with ground evenly across pallet without tipping or rocking. Once load weight is fully supported on ground, tilt mast forward slightly releasing load from backrest allowing fork extraction. Slowly reverse forklift withdrawing forks straight backward from under pallet without side angle preventing fork contact with pallet sides that could drag pallet from position. For placement on racking, approach rack position slowly verifying adequate clearance to rack uprights, adjacent loads, and overhead structures. Raise load to appropriate height for rack level being loaded using smooth hydraulic control, observing load remains stable throughout raising operation and pausing if instability is noticed. Position forklift accurately aligning load with rack beam positions where load will rest, accounting for load overhang requirements for rack type being used. Extend forks into rack if using reach truck, or advance forklift forward for counterbalance placement until load is positioned over rack beams. Lower load carefully onto rack beams verifying load is properly seated on supports before withdrawing forks, watching that load does not shift or tip as forks are extracted. Extract forks slowly whilst maintaining observation of load ensuring load remains stable on supports and does not follow forks backward potentially falling from rack. After placement, step back and verify load is correctly positioned, stable, and not creating hazards to other workers or subsequent rack loading operations before departing area.

Safety considerations

Placing loads on damaged or inadequate racking can cause rack collapse potentially releasing multiple loads onto workers or equipment beneath creating catastrophic outcomes. Improper load placement on rack beams including loads not seated correctly or loads overhanging unsafely can result in loads tipping from racks during subsequent handling or loads shifting during facility vibrations from other equipment. Contact with rack uprights during load placement can damage racking compromising structural integrity potentially leading to progressive rack collapse involving multiple rack bays. Operators working beneath elevated loads during rack placement are in direct fall path if loads tip or fall - maintain safe positioning and never stand directly beneath loads during placement or extraction operations. Withdrawing forks at angles after placement can drag loads from intended positions potentially causing loads to fall, loads to contact adjacent racked items causing domino effects, or loads to become unstable on supports.

7

Respond to Emergency Situations and Equipment Malfunctions

If equipment malfunction occurs during operation including brake failure, hydraulic problems preventing load lowering, or steering failure, immediate actions required depend on specific failure mode. For brake failures whilst travelling, attempt to slow equipment using reduced throttle, lower gear selection if using manual transmission, or hydraulic retarder if equipped, whilst steering towards safe stopping area away from workers or valuable equipment. Do not attempt to steer equipment to controllable stop on slopes as steering control on slopes without adequate braking creates severe tip-over risk. If equipment is run-away on slopes beyond control, sound horn continuously alerting workers to clear area, and prepare for impact by bracing in operator position with restraint secured - never attempt to jump from run-away equipment as landing in travel path creates crushing risk. For hydraulic failures preventing load lowering when loads are elevated, do not drive loaded forklift attempting to reach maintenance area - establish exclusion zone beneath and around elevated load preventing workers entering fall zone, and request mechanical assistance or specialised equipment capable of supporting load whilst hydraulic repairs are made. If forklift begins tipping, do not attempt to jump from operator cage - remain in seat with restraint secured, brace for impact, and protect head and neck as equipment impacts. After tip-over, assess for injuries before attempting to exit equipment, switch off engine or power if accessible preventing fire risk, and call for assistance if trapped or injured. For incidents involving injuries, provide first aid appropriate for injuries observed, call emergency services if injuries appear serious, and secure incident scene preventing further workers being exposed to hazards. Establish exclusion zones around tipped equipment, elevated loads unable to be lowered, or equipment with significant mechanical failures preventing safe operation. Do not attempt to right tipped equipment using other forklifts or construction equipment - engage specialist equipment recovery services. Document all incidents including equipment involved, failure sequence, conditions present, and any injuries or property damage supporting investigation and prevention of recurrence.

Safety considerations

Attempting to jump from tipping forklifts results in operators landing in tip-over path and being crushed as equipment continues tipping - remaining in operator cage with restraint secured provides best survival chance. Brake failures on slopes create rapidly deteriorating situations with equipment gaining speed beyond control ability - early recognition and response whilst speed is still manageable provides best outcome prospects. Elevated loads that cannot be lowered due to hydraulic failures create ongoing fall hazards to any workers beneath - exclusion zones must remain in place until loads are safely secured even if this requires extended time and specialist equipment. Equipment tip-over incidents require careful operator extraction particularly if operators are trapped or injured - attempting hasty equipment movement for operator rescue can cause additional injuries from equipment shifting on operators.

8

Complete Operations and Secure Equipment at Shift End

At completion of forklift operations or end of shift, return forklift to designated parking area on level ground clear of traffic routes, doorways, fire exits, or locations where parked equipment would obstruct other work. Lower forks completely to ground level preventing trip hazards to pedestrians walking through areas and removing hydraulic system loading from maintaining elevated fork positions. Ensure forks are positioned straight ahead aligned with normal travel direction rather than angled creating snagging hazards. Apply park brake firmly engaging mechanical lock ensuring equipment cannot roll if hydraulic systems lose pressure or if ground surface is not perfectly level. Place transmission in park position for automatic transmissions or neutral position for manual transmissions. Switch off engine or power systems following manufacturer shutdown procedures allowing diesel engines to idle for cool-down period if required before shutdown. Remove key from ignition and secure in designated location preventing unauthorised equipment use particularly important on construction sites with public access or multiple contractors working. For electric forklifts requiring charging, connect to appropriate battery charger following manufacturer specifications, verifying charging area has adequate ventilation preventing hydrogen gas accumulation, and confirming charger display shows charging is progressing correctly. Clean operator cab windows, mirrors, and light lenses removing accumulated dust, dirt, or debris maintaining visibility and safety equipment functionality for next use. Document any equipment defects, unusual performance characteristics, or operational concerns in forklift logbook or electronic reporting system providing information for maintenance scheduling and supervisor review. Record hours operated if forklift has hour meter supporting scheduled maintenance intervals based on actual operating hours. Complete operator shift documentation if required including loads handled, incidents or near-misses, and confirmation of pre-start inspection completion. Debrief with supervisor if significant incidents occurred, equipment problems were identified, or operational challenges were encountered requiring management attention.

Safety considerations

Forklifts left in traffic routes create collision hazards with other equipment or vehicles and obstruct emergency evacuation routes potentially delaying emergency response. Elevated forks create trip hazards causing injuries to pedestrians walking through areas, whilst also consuming hydraulic system pressure if pressure cannot be fully released when engine is stopped. Equipment parked on slopes can roll unexpectedly if park brakes fail or are not engaged, potentially crushing workers or causing equipment damage and additional hazards. Failure to secure keys allows unauthorised and potentially untrained personnel to operate forklifts creating severe safety risks from incompetent operation. Battery charging without adequate ventilation creates explosion risk from hydrogen gas generated during lead-acid battery charging. Defects not reported prevent maintenance scheduling allowing problems to worsen potentially causing equipment failures during subsequent operations and creating safety risks for operators using equipment in following shifts.

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Frequently asked questions

What licensing is required to operate forklifts in Australia?

Operating forklifts in Australian workplaces requires holding a current High Risk Work Licence class LF (Forklift Truck) issued by state or territory work health and safety regulators. This national licence is obtained through registered training organisations (RTOs) that deliver structured training covering theoretical knowledge including load capacity principles, stability factors, hazard recognition, and legislative requirements, combined with practical skills training in actual forklift operation. Competency assessment includes both written tests verifying theoretical knowledge and practical assessment requiring demonstration of safe operation including pre-start inspection, load pickup and placement, travel loaded and unladen, and emergency procedures. Once competency is verified, applications are submitted to state/territory regulators who issue licences valid across all Australian jurisdictions. Licences must be renewed every five years with requirements varying by jurisdiction but typically including continuing education or competency reassessment. Different forklift licence classes exist including LF for standard forklifts, LO for order-picking forklifts where operators are elevated with loads, and combinations where operators hold multiple classes. Employers must verify operator licences before allowing forklift operation, maintain licence verification records, and ensure operators receive site-specific induction even when holding appropriate licences as licensing alone does not address site-specific traffic management, load types, or emergency procedures specific to each workplace.

How do I calculate if a load is within my forklift's capacity?

Forklift load capacity depends on multiple factors that must all be considered to prevent overloading and tip-over. Start by locating the forklift data plate showing rated capacity at standard load centre (typically 500-600mm for forklifts, 600mm common for industrial applications). This rated capacity applies only when load centre of gravity is at or closer than standard load centre distance, and when loads are at minimum lift height. As lift height increases, capacity reduces - refer to load capacity chart on forklift showing reduced capacities at elevated heights. If load centre exceeds standard distance (load centre of gravity is further from fork face than standard), capacity must be derated using formula: Adjusted Capacity = (Rated Capacity × Standard Load Centre) ÷ Actual Load Centre. For example, forklift rated 2500kg at 600mm load centre handling load with 900mm load centre has adjusted capacity of (2500 × 600) ÷ 900 = 1667kg maximum. Calculate actual load weight through weighing if possible, reference to shipping documentation, or estimation based on known material densities and load dimensions. Always apply safety factor maintaining operations below maximum capacity rather than at limits - operating at 80% of calculated capacity provides margin for uncertainties and dynamic loading. Account for attachments - any non-standard attachments including side-shifters, rotators, or clamps reduce forklift capacity and require capacity recalculation using attachment weight and changed load centre. When in doubt about load weight or capacity calculations, weigh loads using certified scales, consult supervisor for verification, or use larger capacity forklift providing greater safety margin. Never gamble on capacity - consequences of tip-over are too severe to risk operating near limits without verification.

What should I do if my forklift starts tipping over?

If forklift begins tipping, your actions in the immediate 1-2 seconds before impact can mean difference between survival and fatal outcome. DO NOT attempt to jump from operator cage - operators who jump from tipping forklifts typically land in tip-over path and are crushed as multi-tonne equipment continues tipping onto them. REMAIN in operator seat with seatbelt or restraint system secured - operator cage and restraint system provide best protection by maintaining you in protected zone with structural protection around you. Brace for impact by gripping steering wheel firmly, tucking elbows in protecting arms, and pulling head back against seat headrest protecting neck and spine from whiplash during impact. Lean away from direction of tip - if tipping forward lean back, if tipping sideways lean away from direction of fall maintaining body within operator cage protective structure. Keep feet on floor or operator platform - do not extend legs attempting to brace against structures as this can cause leg fractures. After impact, assess yourself for injuries before attempting to exit equipment. If trapped or injured, call for help using mobile phone or by shouting if people are nearby rather than attempting to free yourself potentially worsening injuries. If you can exit safely, do so carefully watching for secondary hazards including hydraulic fluid leaks creating fire risk, battery acid spills, and unstable equipment that may shift further. Switch off engine or power if accessible preventing fire risk from fuel or electrical systems. Move clear of equipment to safe distance before assessing injuries and calling for medical assistance if required. The fundamental principle is operator restraint systems and operator cages are designed to provide survival space during tip-over - attempting to escape this protection by jumping results in being crushed.

How fast should I travel when operating a forklift?

Forklift travel speeds must be appropriate for operating conditions, load status, and work environment rather than using maximum equipment capability in all situations. On smooth level warehouse floors in designated forklift routes with good visibility and no pedestrians, maximum travel speed for unladen forklifts is typically 15-20 km/h depending on equipment type and manufacturer specifications. When carrying loads, reduce speed to maximum 10-15 km/h accounting for increased stopping distance due to load weight and reduced stability from elevated centre of gravity. In congested areas with other workers, equipment, or obstacles, reduce speed further to 5-10 km/h providing adequate reaction time if sudden stops are required. When approaching intersections, blind corners, pedestrian crossings, or doorways reduce to walking pace (approximately 5 km/h) allowing time to observe cross traffic and respond to unexpected pedestrians or obstacles. On slopes and ramps, maximum 5 km/h regardless of load status due to reduced stability and braking challenges on inclines. Over rough or uneven surfaces, reduce speed sufficiently to prevent excessive jolting that could cause load instability or forklift loss of control, typically 5 km/h or less depending on surface severity. When reversing, maximum 5 km/h due to limited rear visibility even with mirrors. When visibility is restricted by loads or environmental conditions including dust or poor lighting, reduce speed to distance within which you can see clearly. The governing principle is travel at speed allowing you to stop safely within distance you can see to be clear, accounting for your loaded or unladen status, ground conditions, and stopping distance limitations. Speed restrictions should be reinforced through signage, site inductions, and supervision ensuring operators understand speed limits are not merely suggestions but critical safety requirements.

Can I give other workers rides on my forklift?

Absolutely not - carrying passengers on forklifts not designed for passenger transport is prohibited and extremely dangerous creating multiple serious risks. Standard forklifts have single operator positions designed for one person with one seatbelt or restraint system. Adding passengers creates risks including passengers falling from forklifts during travel or when forklifts stop suddenly, passengers being struck by loads if loads shift or fall, passengers interfering with operator controls or visibility creating collision or tip-over risks, and additional weight changing forklift weight distribution potentially affecting stability. Passengers positioned on forks, operator cage, or other forklift components are at severe risk of crushing if they fall into forklift path or are caught between forklift and structures during manoeuvring. Some forklifts are designed with work platforms allowing elevation of personnel for specific tasks including maintenance, stock picking, or inspection work at height. These specialised platforms meet design standards for personnel elevation including guardrails, fall protection attachment points, and controls preventing platform lowering or travel whilst personnel are elevated. Using work platforms requires specific additional training beyond standard forklift operation, documented procedures addressing safe elevation and lowering, and verification platform is manufacturer-specified for the forklift model being used rather than improvised attachment. Even with approved work platforms, personnel elevation should be limited to situations where alternative methods including scissor lifts or elevating work platforms are not available. Never improvise personnel platforms using pallets, cages, or containers positioned on forks - these are not designed for personnel elevation and provide no fall protection. Passengers requesting rides may not understand risks but operators must refuse regardless of pressure or perceived inconvenience - consequences of passenger falls or tip-over with passengers can be catastrophic. If personnel must access heights, use purpose-designed access equipment rather than forklifts.

What maintenance is required for forklifts and how often?

Forklift maintenance comprises multiple levels from daily operator checks to comprehensive annual servicing, each addressing different aspects of equipment condition and safety system reliability. Daily pre-start inspections conducted by operators before first use check critical safety systems including brakes, steering, hydraulics, tyres, lights, alarms, seatbelt, and overhead guard, with any defects reported immediately and equipment quarantined until repairs are completed. Operators cannot comprehensively assess all mechanical systems but can identify obvious problems requiring technical assessment. Weekly detailed inspections by supervisors or maintenance personnel examine equipment more thoroughly including checking hydraulic fluid levels and condition, inspecting mast and chains for wear or damage, testing brake adjustment and effectiveness, checking battery condition and electrolyte levels for electric forklifts, and examining structural components for cracks or damage. Monthly preventive maintenance by qualified technicians includes oil and filter changes, brake system service including pad/lining inspection and replacement if required, hydraulic system detailed inspection, tyre condition assessment and replacement scheduling, mast and chain lubrication and adjustment, and electrical system testing. Annual comprehensive servicing provides detailed examination of all systems including load testing to verify capacity ratings remain valid, brake system overhaul, hydraulic cylinder rebuild if required, structural inspections for cracks or fatigue, comprehensive safety system testing, and compliance verification with Australian Standards. Maintain detailed logbooks documenting all inspections, maintenance work, parts replaced, load testing results, and defects found and rectified providing comprehensive equipment history supporting compliance demonstration and incident investigation if required. Budget adequately for maintenance recognising that preventive maintenance costs are insignificant compared to costs of equipment failures, incidents, or regulatory prosecution for operating defective equipment. Equipment operating in harsh environments including dusty construction sites, corrosive atmospheres, or intensive multi-shift operations may require more frequent maintenance than standard schedules.

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