Worker seriously injured after being struck by forklift

Possible control measures to prevent similar incidents

Business owners must ensure the provision and maintenance of safe plant. Higher order risk controls include designing plant to eliminate risks to health and safety. An example would be the introduction of intelligent systems that make it impossible to start the forklift unless the seatbelt is fastened and engineering controls such as proximity sensors.

The risk of forklift-related injuries can also be reduced by making sure workers are well trained, machinery is well maintained, and a traffic management plan (inclusive of implementing and maintaining exclusion zones), is in place.

It’s important to operate a forklift safely and create a safe work environment to minimise the risk of incidents. Simple measures that can make a big difference, are:

• proximity devices to warn and control pedestrian and plant interactions.
• separating pedestrians from forklifts such as overhead walkways and physical barriers
• observing speed limits and stop signs.
• wearing correctly fitted seat belts.
• slowing down and sounding the horn at intersections
• forklift operator having a clear view in the direction of travel.
• use of a spotter directing forklift movement and pedestrian interaction.

Traffic management plan

Whenever mobile plant such as a forklift is used in a workplace, a traffic management plan must be implemented to ensure the safety of drivers and pedestrians. It should be developed by those in charge of the business in consultation with workers and others in the workplace. Everyone affected by the plan must understand it and follow it.

The plan should consider:

• The physical environment, such as lighting, road surfaces, ventilation, and weather.
• Traffic destination, flow, volume, and priorities.
• Forklift stopping distances, turning (tail swing), and operator blind spots.
• Forklift characteristics, such as stability and attachments.
• Load characteristics, such as height, width and type - reorganising the layout of the workplace to minimise areas shared by pedestrians and forklifts.
• Ensuring workers are not placed at risk by walking with a load on the forklift to stabilise the load.
• Blind spots and corners. Blind corners that have been identified as high risk include on entry to warehouse doors and entry to rear factory from both access points. Also most types of mobile plant have blind spots where the operator cannot see certain angles due to obstructions by the plant (mirrors, mast, frames, stacking of dunnage), or difficulty for the driver to twist in position to see in all reversing directions. See Figure 1.

^{Figure 1: Forklift blind spots}

• Installation of convex mirrors in some locations to allow a worker to see around blind corners – everyone should be aware of their location and use them when approaching the corner.
• Using physical barriers such as safety barriers, containment fences, bollards, or railed walkways where possible. See Figure 2.

^{Figure 2: Barriers to separate pedestrians and mobile plant}

• A combination of audio (e.g., reversing alarms and horns) and visual (e.g., flashing lights) warning devices.
• Signs to indicate who must give way.
• Implementing and enforcing procedures that describe how pedestrians and forklifts must interact in different situations.

The traffic management plan should also ensure:

• It is clear to forklift operators and workers who has right of way.
• Any no-go zones for forklifts or pedestrians are clearly isolated and marked.
• If high visibility vests are required, they are readily available to staff and visitors.
• Pedestrian floor markings are highly visible and not faded.
• Speed limits are clearly signed and followed. The speed limit applies to all forklifts, trucks, cars and other mobile plant, without exception.
• Traffic directions, such as 'stop' and 'one way', are clearly signed and followed.
• Proximity devices are operating efficiently to trigger signals, boom gates, and warning signs to give advanced warning to pedestrians and operators.
• That pedestrians and forklift operators are wearing high-visibility or reflective clothing, (although this is no substitute for physically separating pedestrians and forklifts).

Further information and advice on traffic management can be found at:

Traffic management guidance plan and example template (PDF, 1.93 MB).

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.
• 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

• 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.
• 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 driving down an incline with a load:
  • drive in reverse with the load and forks facing up the incline.
  • 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 and when pedestrians are nearby.
• Make sure 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.

Maintaining forklifts

Forklifts should be regularly inspected and maintained according to the manufacturer’s instructions.

For more information, see the forklift safety guide (PDF, 0.27 MB).

The control measures you put in place should be monitored and reviewed regularly to make sure they work as planned.