Forklift Safety

Forklift operations are always critical risk. We inspect forklift operations to identify hazards associated with the condition and use of forklifts, operator practices, loads, pedestrian interaction, traffic routes and workplace conditions. The inspection focuses on whether forklifts are being operated and maintained safely within the workplace.

What we look at

Condition and safe operation of forklifts and attachments.
Pre-start checks, defect reporting and maintenance arrangements.
Operator authorisation, training and competency.
Safe operating speeds and control of the forklift.
Pedestrian and forklift separation.
Traffic routes, intersections, blind spots and visibility.
Safe handling, lifting and stacking of loads.
Forklift access to racking and loading areas.
Seatbelts, operator protection and other safety equipment.
Parking, charging, refuelling and battery areas.

1. Forklift Condition

2. Pre-Start Checks & Defect Management

Pre-start inspection: Operators complete a pre-start check before using the forklift.
Check records: Pre-start checks are recorded where required by the business system.
Defect reporting: Operators know how to report forklift defects.
Defective equipment: Forklifts with safety-critical defects are removed from service until appropriately assessed or repaired.
Maintenance: Planned maintenance and servicing are carried out at appropriate intervals.
Repairs: Repairs are undertaken by appropriately competent or authorised persons.

3. Operator Competency

Authorisation: Only authorised workers operate forklifts.
Training: Operators have received appropriate forklift training.
Competency: Operators have demonstrated competency for the type of forklift and tasks they undertake.
Workplace familiarisation: Operators understand the hazards and traffic arrangements within the workplace.
Operating rules: Operators understand and follow the site’s forklift operating rules.
Passengers: Unauthorised passengers are not carried.
Mobile phones: Operators do not use mobile phones or other distracting devices while operating the forklift.

4. Safe Forklift Operation

Speed: Forklifts are operated at a safe speed appropriate to the workplace, load and conditions.
Fork position: Forks are kept in a safe position while travelling.
Load visibility: Operators maintain adequate visibility when travelling and handling loads.
Restricted visibility: Where the load obstructs forward visibility, an appropriate alternative method of travel is used.
Turning: Forklifts are operated carefully around corners, intersections and restricted areas.
Reversing: Reversing is controlled and appropriate for the workplace conditions.
Edges and ramps: Safe precautions are used near loading docks, ramps, edges and changes in level.
Forks raised: Forks are not unnecessarily raised while travelling.
Unauthorised lifting: Workers are not lifted on forks or pallets unless an appropriately designed and authorised system is being used.

5. Load Handling

Load capacity: Loads are within the rated capacity of the forklift and attachment being used.
Load stability: Loads are stable and appropriately secured where necessary.
Fork positioning: Forks are correctly positioned under loads before lifting.
Load centre: Operators consider the load centre and stability when lifting and transporting loads.
Stacking: Loads are stacked safely and do not create a risk of collapse.
Racking: Loads are placed into and removed from racking without striking or damaging the racking.
Attachments: Attachments are suitable for the forklift and the task and are correctly secured.

6. Pedestrian Safety

Separation: Forklift and pedestrian routes are separated where reasonably practicable.
Pedestrian crossings: Designated pedestrian crossing points are provided where appropriate.
Visibility: Pedestrians and forklift operators can see each other at intersections and crossing points.
Blind corners: Appropriate controls are provided at blind corners and restricted-visibility areas.
Warning systems: Appropriate warning signs, markings, mirrors, alarms or other controls are provided where required.
Exclusion areas: Pedestrians are kept clear of areas where forklift operations create a significant risk.
Communication: Workers understand how to communicate safely with forklift operators.

7. Workplace & Traffic Routes

Traffic routes: Forklift routes are clearly defined and kept free from unnecessary obstruction.
Floor condition: Floors and travel surfaces are suitable for forklift operations.
Lighting: Lighting is adequate for safe forklift operation.
Gradients: Ramps and gradients are suitable for the forklifts and loads being used.
Doorways: Doorways and access points provide sufficient clearance.
Loading areas: Loading docks and vehicle loading areas have appropriate controls to prevent falls, collisions or unintended vehicle movement.
Restricted areas: Areas with particularly high forklift risk have appropriate controls and access restrictions.

8. Parking, Charging & Refuelling

Parking: Forklifts are parked only in designated safe areas.
Fork position: Forks are lowered when the forklift is parked.
Parking brake: Parking brake is applied when the forklift is left unattended.
Charging area: Battery charging is carried out in a suitable designated area.
Battery controls: Battery charging areas have appropriate controls for electrical, chemical and other identified hazards.
Refuelling: LPG, diesel or other fuel is handled and stored using appropriate controls.
Ventilation: Adequate ventilation is provided where required for charging or fuel use.

9. Forklift Attachments & Special Operations

Attachment suitability: Attachments are suitable for the forklift and intended task.
Attachment security: Attachments are correctly fitted and secured.
Capacity: The effect of attachments on forklift capacity has been considered.
Special loads: Special or unusual loads have appropriate controls.
Work platforms: Any work platform used with a forklift is suitable, secured and used under appropriate controls.

10. Emergency & Incident Controls

Incident reporting: Forklift collisions, near misses, damage and unsafe events are reported.
Collision response: There is a clear process for dealing with forklift collisions and damage to racking or structures.
Emergency access: Emergency exits, fire equipment and evacuation routes are not obstructed by forklifts or stored materials.
Emergency procedures: Workers understand relevant emergency procedures for forklift incidents.

Critical Findings

The following conditions require immediate attention and may require the forklift or affected work area to be taken out of service until the risk has been controlled:

Forklift has a safety-critical mechanical or structural defect.
Forks, mast, hydraulics, steering or brakes have significant defects.
A forklift is being operated by an unauthorised or inadequately competent person.
Forklift and pedestrian movements create an uncontrolled collision risk.
Loads are unstable, exceed capacity or present a significant falling or overturning risk.
Forklift is being used to lift people without an appropriate and controlled system.
Forklift is operating near an edge, loading dock or other fall hazard without adequate controls.
Significant forklift collision or damage has occurred and the equipment or surrounding structure has not been assessed.

Inspection note: This checklist is intended for routine workplace health and safety inspections. It does not replace the manufacturer’s requirements, scheduled maintenance, operator training or a competent assessment of a forklift where a defect or safety concern has been identified.

For Worksafe guidance on Forklift safety please refer to : Forklifts | WorkSafe

Forklift safety