By Gaby Grammeno Contributor

WorkSafe Victoria’s new Guidebook: Forklift safety, released in May 2024, sets out what to look for at all stages of forklift use. It’s based on industry expectations, and current best practice. 

Forklifts – so common in so many industries – present a unique set of risks. Operators and pedestrians can be hit or crushed by a forklift, by a load that the forklift is moving or when a forklift tips over. Using petrol, diesel or gas forklifts indoors – for example, in a shipping container or cold store – can cause a build-up of fumes such as carbon monoxide. 

The Guidebook covers the full range of forklift safety considerations, from the duties of people at the workplace, forklift selection and planning, training and competency, hazards and risk controls, work practices, attachments such as jibs, inspection and maintenance.

Selection and planning

As with so many other WHS risks, more attention to planning saves a lot of potential trouble later.

It is critical that the forklift must be appropriate for the task. Before buying, hiring or leasing a forklift, consider whether it’s suitable for:

  • the loads to be lifted and moved
  • the site conditions
  • the operator’s knowledge, skills and abilities
  • controlling the identified hazards and risks.

It warns against a decision to use a specific forklift solely on the basis of its availability.

Pedestrian safety is a key consideration in the light of the many injuries resulting from collisions with people on foot.

Traffic management plans

Where forklifts and pedestrians share the same areas – or where other mobile plant is operating and space is restricted – a traffic management plan should include a diagram showing forklift and pedestrian travel paths, exclusion zones, electrical and overhead structure no-go zones and illustrations of the layout of barriers, walkways, signs and other arrangements to protect people.

Devices such as audible and visible alarms should also be fitted and appropriately licensed operators should be instructed to make use of them as needed.

Tipping over

The Guide warns of factors that can increase instability and make a forklift tip over, especially if travelling:

  • at speed
  • around corners
  • with tilted, raised or unstable loads
  • on uneven surfaces or gradients outside the manufacturer’s recommendations, or
  • if using an inappropriate attachment to lift or suspend a load.

It notes that injuries and fatalities from tipping forklifts have resulted in prosecutions, including conviction under Victoria’s workplace manslaughter laws.

Seats and seatbelts

As an employer or self-employed person, you must ensure anyone who rides on a forklift with a seat is sitting in the seat. The seat must be specifically designed for carrying a passenger, fitted with appropriate seat restraints and located within the zone of protection provided by the required operator protective device (roll-over protective structures and falling object protective structures).

Sequential interlocking seatbelts have been required in new forklifts by Australian Standards since 2013. Sequential interlocking seatbelts prevent forklifts from starting or moving unless the operator is first seated and then buckled in. Sequential interlocking seatbelts are readily available and can be retrofitted to an existing forklift.

Safety-enhancing features

Other safety-enhancing features listed in the Guide include:

  • pedestrian detection systems and automatic braking
  • visibility assistance, for example, mirrors and cameras that can monitor around the forklift and monitor the operator
  • perimeter zone warning lights
  • automatic speed reduction zones
  • slowing electric forklifts when the mast is elevated
  • dynamic stability control to improve the forklift’s stability during braking and manoeuvring
  • impact monitoring sensors
  • labels and markings on the mast that indicate the point where capacity changes at a given lift height, as shown on the information plate
  • mechanical or electronic limit switches or proximity sensors that stop the fork carriage at defined shelf heights
  • weighing equipment to reduce overloading.

Retrofitting

If they are not fitted, the Guide advises users to consider retrofitting safety-enhancing features where reasonably practicable. It warns that retrofitting safety features could introduce new hazards and risks. Those hazards and risks must be controlled, so far as is reasonably practicable. Where possible, consult with the manufacturer or supplier when retrofitting safety features.

Maintenance and inspection

To control risks, forklifts and any attachments must be regularly inspected and maintained. The Guidebook includes a checklist that can be used to make sure all aspects are satisfactory before operating the forklift.

What it means for employers

Though the Guidebook’s focus is mainly on forklifts, the safety principles it sets out can be applied to other powered mobile plant to help eliminate or reduce risks to operators and pedestrians.

Read the Guidebook

Guidebook: Forklift safety