Forklift Risk Assessment for Australian Workplaces

A forklift risk assessment is a structured evaluation of the hazards and risks associated with the operation of forklift trucks — including counterbalanced forklifts, reach trucks, order pickers, pallet jacks, and other powered industrial trucks — in warehouses, manufacturing facilities, distribution centres, retail back-of-house areas, construction sites, and other workplaces where forklifts are used to move and stack loads.

Forklifts are involved in approximately 3,000 workers' compensation claims each year in Australia and are responsible for a significant number of workplace fatalities. The principal incident mechanisms are: pedestrians struck or run over by forklifts; loads falling from elevated forks onto workers below; forklifts overturning (particularly on slopes or when carrying elevated loads); workers caught between the forklift and a fixed structure; and workers falling from elevated platforms or the forks of a forklift being used as an improvised work platform.

Many of these incidents are preventable. They occur in workplaces that have not conducted a forklift risk assessment, that allow pedestrians and forklifts to share the same travel paths without physical separation, that operate without a rigorous pre-start check system, or that use forklifts for tasks outside their rated purpose — particularly for elevated personnel access. A well-structured forklift risk assessment, implemented through physical separation, traffic management, and operator training, is one of the most effective investments a logistics, manufacturing, or retail distribution business can make.

The WHS Regulation 2025 requires a risk assessment for forklift operations and a high-risk work licence for operators of forklifts with a rated capacity of 1 tonne or more. The risk assessment must address both the risks associated with operating the forklift and the interaction between the forklift and pedestrians, vehicles, structures, and the facility layout — factors that are unique to each workplace and that require a site-specific assessment rather than a generic document.

Forklift operations in Australian workplaces are regulated through a combination of general WHS obligations, plant-specific requirements, and high-risk work licensing requirements.

**WHS Regulation 2025 — Plant management.** Forklifts are 'plant' under the WHS Regulation, and PCBUs who manage or control plant at a workplace must ensure that the plant is designed, manufactured, supplied, and installed correctly; that it is registered where required; that it is inspected and maintained in accordance with the manufacturer's requirements; and that workers operating the plant are competent. For forklifts with a rated capacity of 1 tonne or more, the Regulation imposes an additional requirement that the operator holds a high-risk work licence.

**High-risk work licence — forklift truck.** The WHS Regulation requires persons operating a forklift truck with a rated capacity of 1 tonne or more to hold a high-risk work licence in the Forklift Truck (LF) class, issued by the relevant state WHS authority. The licence is obtained by completing an accredited training course, demonstrating competency in a written assessment and practical operating assessment, and submitting an application to the regulator. The risk assessment must verify that all forklift operators hold a current LF licence and that the licence class is appropriate for the specific forklift type being operated — for example, an LF licence covers standard counterbalanced forklifts; reach trucks and order pickers may require additional operator training beyond the basic LF licence.

**Plant registration.** Forklifts with a capacity exceeding certain thresholds in some states must be registered as plant on the relevant state WHS authority's plant register. The risk assessment should confirm whether the forklifts used at the workplace are subject to registration and whether registration is current.

**Traffic management and pedestrian separation.** The Managing the Risks of Plant in the Workplace Code of Practice (Safe Work Australia) emphasises that the most effective control for pedestrian safety in forklift operating areas is physical separation — bollards, barriers, and traffic management systems that prevent pedestrians from entering forklift travel paths. The risk assessment must evaluate the adequacy of pedestrian separation at the workplace and specify improvements where the current arrangements are inadequate.

**Pre-start inspections.** The Regulation and the code of practice require that forklifts be inspected before each shift using a documented pre-start check procedure. The pre-start check covers: tyres, forks, mast, overhead guard, seatbelt, brakes, steering, horn, lights, and load capacity indicator. A forklift with defects identified on the pre-start check must be taken out of service until the defects are repaired.

A comprehensive forklift risk assessment must address all relevant hazard categories. Five principal categories account for the majority of forklift incidents in Australian workplaces.

**Pedestrian-forklift interaction.** The most deadly forklift hazard is the collision between an operating forklift and a pedestrian — whether a worker, contractor, or member of the public. Pedestrians are frequently struck in areas where forklift travel paths cross pedestrian walkways, at corners with limited visibility, in loading dock areas with multiple forklift and pedestrian movements, and in situations where forklift operators reverse without adequate warning or visibility. The assessment must map every point of pedestrian-forklift interaction in the facility and specify controls — physical barriers, crossing points with active warning systems, high-visibility flooring markings, convex mirrors at blind corners — for each.

**Load instability.** Unsecured, unstable, or overloaded loads can fall from the forks or from elevated storage positions, causing serious or fatal injuries to workers below. The assessment must evaluate the load types handled, the maximum load heights, the stability of the stacking arrangements, and the adequacy of racking and shelving systems. Overloaded forklifts — loads exceeding the rated capacity at the relevant load centre — are inherently unstable and can overturn or cause mast and fork failure.

**Forklift instability and overturning.** Forklifts have a narrow stability triangle — the area within which the combined centre of gravity of the machine and load must remain for the machine to remain stable. The stability triangle is easily compromised by: turning with an elevated load; operating on a slope; striking a bump or pothole with a load elevated; or operating with uneven load distribution. Forklift overturns can trap and fatally injure the operator if they leave the cab during the overturn. The risk assessment must identify the slopes, surface conditions, and load handling practices that could compromise stability.

**Crush and entrapment.** Workers can be caught between a forklift and a wall, rack, or other fixed structure, particularly when the forklift is reversing in a congested area. The assessment must evaluate the aisle widths, the turning clearances, and the visibility conditions in the areas where forklifts operate to identify locations where crush and entrapment risk is elevated.

**Improvised elevated work.** Workers or supervisors who use forklift forks or the forklift's lifting mechanism as an improvised elevated access platform — without an approved safety cage that is rated for personnel and mechanically secured to the forks — are exposed to a serious fall risk. The assessment must establish and document a clear prohibition on using forklifts for elevated access without an approved and securely fitted personnel cage.

A forklift traffic management plan (TMP) is a documented system that regulates the movement of forklifts, vehicles, and pedestrians in the workplace. For workplaces with regular forklift operations, a TMP is the primary mechanism for managing pedestrian-forklift interaction and is required by the code of practice and by many principal contractor and client safety management systems.

**Traffic flow mapping.** The TMP begins with a site plan showing the facility layout — storage areas, aisles, loading docks, charging areas, pedestrian entry points, and exits — annotated with forklift travel routes, pedestrian walkways, and the locations of each pedestrian-forklift interaction point. The map identifies the highest-risk interaction points and forms the basis for specifying controls.

**Physical separation.** The most effective pedestrian protection in a forklift operating area is physical separation — a physical barrier that prevents pedestrians from entering the forklift travel path. Options include: dedicated pedestrian walkways protected by bollards, barriers, and guardrails; elevated pedestrian catwalks over forklift aisles; automatic pedestrian gates that require the forklift to stop before the gate opens; and designated forklift-free pedestrian areas.

**Speed limits.** The TMP must specify maximum forklift travel speeds for each area of the facility. Recommended speed limits are: 10 km/h in areas with pedestrian access; 5 km/h in areas with active pedestrian movement and at pedestrian crossings; and walking pace in reversing and congested areas. Speed limit signs must be visible to forklift operators from their operating position.

**Lighting and visibility.** Forklift operating areas must be adequately lit for the operator to see pedestrians and obstructions. The TMP must specify the minimum illumination level (typically 150–200 lux in operating areas) and the maintenance of lighting systems. Convex mirrors must be installed at blind corners and at intersections between forklift aisles and pedestrian walkways.

**Reversing alarm and visual warning systems.** Forklifts must be equipped with an audible reversing alarm. Where the operating environment has high ambient noise levels that may render the audible alarm ineffective, a visual warning (flashing strobe light) is required. Proximity warning systems — radar or ultrasonic systems that detect pedestrians within a defined distance of the machine and provide both operator and pedestrian warnings — are increasingly used in high-pedestrian-density environments as a supplement to physical separation.

A forklift risk assessment must address operator training and competency as a key control. Even with physical separation and traffic management systems in place, the quality of operator training has a direct impact on forklift safety outcomes — particularly in the management of load stability, the safe approach to pedestrians and structures, and the response to developing hazard situations.

**High-risk work licence (LF class).** Operators of forklifts with a rated capacity of 1 tonne or more must hold an LF high-risk work licence. The licence is obtained through an accredited training provider who delivers both theoretical and practical training. The training covers: types of forklifts and their components; load handling calculations; stability principles; pre-start inspection; safe operating procedures; and emergency procedures. Licence renewal is required every five years.

**Site-specific induction.** In addition to the high-risk work licence, every forklift operator who is new to a specific facility must receive a site-specific induction that covers: the site TMP and speed limits; specific hazards at the facility (blind spots, uneven surfaces, pedestrian crossing points); the loading dock procedures; the charging area procedures; and the emergency procedures. The site induction must be documented and the operator's understanding verified before they commence independent operation.

**Refresher training.** The risk assessment should specify a refresher training schedule for forklift operators — typically every three to five years, or sooner if an operator is involved in an incident or near-miss or if their operating performance is identified as inadequate through supervisory observation.

**Documented competency assessment.** The PCBU should maintain a record of each operator's licence, induction, and refresher training, and should conduct periodic on-machine competency assessments. A documented competency record is evidence that the PCBU exercised due diligence in verifying operator competence before authorising operation.

Our consultant-drafted forklift risk assessment is designed for use in warehouses, manufacturing facilities, distribution centres, retail environments, and construction sites where forklifts are operated regularly. It is priced at $49 AUD and delivered as a fully editable Microsoft Word document.

**Site layout and traffic flow section:** A prompt for drawing or attaching the site plan with forklift routes, pedestrian walkways, and interaction point annotations. Includes a pedestrian separation assessment for each interaction point.

**Hazard identification table:** The five principal hazard categories (pedestrian interaction, load instability, machine instability, crush/entrapment, improvised elevated work) with sub-hazards specific to the workplace type.

**Risk matrix:** Likelihood and consequence ratings before and after controls, for each hazard.

**Control register:** Controls in hierarchy order for each hazard, with responsible person, implementation date, and verification method. Includes specific controls for the most common forklift hazards — pedestrian separation, load stability, speed limits, lighting, and operator training.

**Traffic management plan:** A companion TMP including site plan annotation instructions, speed limit specifications, lighting standard references, and reversing alarm requirements.

**Daily pre-start check form:** A checklist for operators covering all standard pre-start inspection items, with sign-off by the operator and a record of any defects found and action taken.

**Operator register:** A table for recording operator names, high-risk work licence numbers, licence expiry dates, site induction dates, and refresher training dates.

All documents are reviewed annually and include Australian-specific regulatory references, including WHS Regulation 2025, the Managing the Risks of Plant in the Workplace Code of Practice, and AS 2359 (industrial trucks — safety requirements).

**Do I need a licence to operate a forklift in Australia?** Yes, for forklifts with a rated capacity of 1 tonne or more, you must hold a high-risk work licence (Forklift Truck — LF class) issued by the relevant state WHS authority. Operators of forklifts under 1 tonne do not require an LF licence but must be trained and assessed as competent by the PCBU. The LF licence is valid for five years and must be renewed through re-assessment.

**Is a risk assessment required if I already have a traffic management plan?** Yes. A traffic management plan addresses the movement of forklifts and pedestrians within the facility but does not address all the hazards associated with forklift operations — load instability, machine stability, pre-start inspection, operator competency, and emergency procedures. A risk assessment is required to identify and document controls for all forklift hazards; the TMP is one of those controls.

**Can I use a forklift to raise a person to work at height?** Only using an approved personnel cage that is designed and rated for personnel lifting, mechanically secured to the forklift's carriage, and fitted with a safety harness anchor. A worker standing on the forks or on a pallet placed on the forks without a rated personnel cage is exposed to an extreme fall risk and the practice is prohibited under the WHS Act. The risk assessment must explicitly prohibit the use of forklifts for elevated access without a rated and securely fitted personnel cage.

**How often should the pre-start check be completed?** Before each shift or before each change of operator during a shift. The pre-start check must be completed and any defects recorded before the forklift is operated. A forklift with defects that affect safety — tyre damage, brake failure, fork cracks, mast damage, seatbelt failure — must be taken out of service and repaired before returning to operation. The pre-start check records must be retained as evidence of the PCBU's maintenance and inspection obligations.

**What is the maximum speed for a forklift in a warehouse?** There is no single national speed limit for forklifts in warehouses. The maximum safe speed depends on the facility layout, the pedestrian density, the forklift type, and the load being carried. Best practice guidance specifies a maximum of 10 km/h in areas with pedestrian access, 5 km/h near pedestrian crossings and in congested areas, and walking pace (about 4–5 km/h) when reversing. These limits should be specified in the site's traffic management plan and marked with speed limit signs visible to operators.