In the realm of workplace operations, maneuvering forklifts serve as practical tools for the movement and stacking of goods and materials. However, it is crucial to recognize that they contribute to a significant number of workplace injuries and fatalities each year. Therefore, understanding how to operate forklifts safely is paramount to preventing incidents.

A forklift is essentially a compact industrial vehicle equipped with a power-operated, forked platform at the front. This platform has the capability to be raised and lowered, allowing it to be inserted under a load for lifting or movement. Forklifts can be powered by electric motors or internal-combustion engines, which run on fuels like petrol, diesel, or LPG. They may either be controlled by a licensed onboard operator or function as pedestrian-operated forklifts (POFs) with no onboard operator.

Despite their compact and maneuverable design, forklifts pose inherent risks, leading to serious injuries and even fatalities, particularly when operated at low speeds. These risks extend to both the person using the forklift and pedestrians in the vicinity. Forklifts, designed for ease of movement, can become unstable when carrying loads, especially in uncontrolled traffic areas. Common risks associated with forklift use include instability (tipping over), inappropriate braking leading to forward tipping or load loss, and the potential for sprains, strains, and soft tissue injuries to the neck, back, and arms.

Effectively managing these risks involves adopting safety measures to create a secure work environment. Some simple yet impactful measures include:

• Adhering to speed limits and stop signs
• Wearing properly fitted seat belts
• Slowing down and using the horn at intersections

By implementing these practices, workers can significantly minimize the risk of incidents associated with forklift operations.

Operating forklifts safely

Be well prepared and properly trained

• Only operate a forklift if you hold a high-risk work licence or are an authorised trainee.
• Don’t operate a forklift when you’re tired.
• Do what is reasonably practicable to be safe, such as wearing a seatbelt if one is provided. The only exception is if a risk assessment advises otherwise.
• Use the forklift only for the purpose for which it was designed.
• Read and follow the manufacturer’s specifications for the forklift you’re using.
• Before driving a forklift onto a truck, trailer or rail wagon, check the brakes of the receiving vehicle are set, and the wheels are chocked.
• Take care when loading a forklift
• Make sure loads are within the rated load capacity of the forklift.
• Carry loads as close to the ground as possible.
• Place loads fully against the truck carriage or back rest. The mast should be tilted sufficiently backward to safeguard the load.
• Drive safely
• Don’t use a forklift to raise a person unless there’s an approved work platform attached.
• Keep a clear view ahead and behind, using a correctly adjusted rear-view mirror.
• Clearly indicate your intentions.
• Keep a safe distance from other vehicles.
• Observe speed limits and make sure you can stop safely at any time.
• Don’t speed up or slow down quickly.
• Slow down when turning.
• Drive in reverse if you can’t see past a bulky load.
• If you’re driving up an incline with a load:
  • make sure the load faces forward
  • tilt the mast back sufficiently to safeguard the load
  • raise the forks so they clear the ground.
• If you’re driving up an incline with no load, place the forks on the downhill side of the forklift.
• Remove the starter-switch key when you leave the forklift. Make sure the:
  • controls are in neutral
  • power is shut off
  • park brakes are applied
  • forks are fully lowered.
• Be aware of your work environment
• Drive carefully on wet or slippery surfaces or when pedestrians are nearby.
• Take care that the tip of the fork, or load, or the rear side of the forklift, doesn’t touch a person or object.
• Never park or leave the forklift in any doorway, entrance, or emergency exit, or in front of fire-extinguishing equipment.
• Check for overhead obstructions, such as powerlines, loading docks and other mobile plant.

For more information, see the forklift safety guide.

Maintaining forklifts

Forklifts should be regularly inspected and maintained according to the manufacturer's instructions. If a forklift is flameproofed, maintenance should include the flameproofing features by a competent person in line with Australian standards.

Use qualified inspectors and repairers

• Use only a trained, qualified person to inspect, maintain or repair forklifts. Use only licensed gas fitters to repair and/or replace parts on LP gas-powered forklift.
• Use only qualified tyre fitters to remove and fit tyres.
• Use only a qualified person to inspect and assess damage, and do not use an unsafe or damaged forklift until the qualified person has rendered it safe and removed the tags.
• Develop maintenance procedures and keep records

Keep forklifts clean

• Keep the forklift clean, so it’s easier to detect worn or defective parts.
• Clean with water, not flammable liquids.
• Keep detailed records of every inspection, service, maintenance, repair and modification carried out on a forklift. Record dates, names of authorised people involved, and meter readings.
• Establish a procedure for dealing with unsafe or damaged forklifts. The procedure should include isolating and tagging the vehicle and reporting the problem to the appropriate person.
• Document full details of damage—for example, the cause and type of damage, repairs required and assessment of the vehicle's safety. Include a copy of this should in the inspection and maintenance records.
• Establish and maintain procedures to make sure the spark arrestor tank on the exhaust line of a diesel forklift is maintained according to recommendations of the flameproofing company.
• For more information, see the forklift maintenance factsheet (PDF, 0.35 MB) and forklift safety guide (PDF, 0.27 MB).

Guidelines for pedestrian-operated forklifts (POFs)

POFs differ from forklift trucks because they’re not controlled by an operator riding on the vehicle and don’t require a licence/certificate to operate. While similar safe operating and maintenance procedures apply to all types of forklifts, the following control measures relate specifically to POFs.

Be well-prepared and properly trained

• Only trained operators should operate a POF.
• Do safety checks before and after operating the POF.
• Ensure the POF is suitable for the grades you intend to travel on
• Wear appropriate personal protective equipment, such as a high-visibility vest and steel-capped footwear.
• Don’t operate a POF if your hands or footwear are greasy.
• Check the work area for damaged flooring, overhead obstructions, ramps and docks. Don’t work too close to the edges of ramps or docks.

Drive the POF safely

• If you’re travelling in reverse, take care not to bump into objects, run over loose objects, or trip over objects. Don’t use a POF in an unauthorised area or in explosive atmospheres.
• Keep arms, hands, legs and feet away from the lifting mechanism and wheels.
• Sound the horn when you approach intersecting aisles or blind corners.
• When operating a POF on a ramp or incline, face the load uphill and don’t turn on the incline. If you need to park the POF on an incline, make sure the wheels are securely chocked.
• Don’t ride on the POF or let anyone else ride on it.
• When parking:
  • lower forks to the ground
  • tilt forward if possible
  • don’t leave the key in the ignition if unattended
  • don’t leave the POF in a thoroughfare, doorway, or emergency exit.

Load the POF safely

• Don’t go over the safe lift limit of the POF when handling a load. These limits are specified on the data plate.
• The forklift arm blades (tynes) should be long enough to support at least 75 per cent of the load (see figure below).
• The load should be stable and evenly distributed on both fork arms before lifting and while travelling. Fork arms should far enough apart to ensure the load is stable.
• Tilt the POF forward only when it is over a stack, rack or vehicle. Tilt the POF backwards only enough to stabilise the load.
• Secure attachments according to the manufacturer's instructions and remember that attachments may affect the load centre of gravity.