Forklift Safe Work Method Statement

Forklift operation requires an LF (Lift Truck - Forklift) class high-risk work licence issued under Work Health and Safety Regulations 2011. This licence covers operation of powered industrial trucks including counterbalance forklifts, reach trucks, order pickers, and similar equipment. The LF licence has two levels: LF (Forklift) covering standard counterbalance forklifts and sit-down reach trucks, and LO (Order Picking) covering order-picking forklifts where operator platforms elevate with forks. Most construction and warehouse forklift operations require the basic LF licence. Obtaining an LF licence requires completing registered training comprising theoretical knowledge covering load capacity principles, stability triangle, safe operating procedures, hazard recognition, and pre-operational inspections, plus practical skills training demonstrating competent operation of representative forklift equipment. Assessment involves written theory examination and practical demonstration of all forklift operations including load pickup, transport, stacking, and equipment control assessed by registered training organisation. Successfully assessed candidates receive provisional licence certificate from training organization, then apply to state/territory WHS regulator for licence card issuance. Licences are valid nationally and require renewal every 5 years including refresher training. Employers have obligations under WHS law to verify operators hold current appropriate licences before allowing forklift operation, maintain copies of licence cards in site records, and provide site-specific training covering hazards unique to the workplace even when operators hold appropriate licences. Operating forklifts without licences where required constitutes serious WHS breach attracting penalties exceeding $10,000 for individuals and $50,000 for corporations for first offences, with penalties increasing for repeat violations. Additionally, operators without licences have no legal indemnity for incidents, with personal liability for injuries or damage caused during unlicensed operation.

Forklift capacity calculation involves understanding the relationship between load weight, load center position, and lift height, with capacity decreasing as loads move further from fork face or lift higher. Every forklift has a capacity plate (also called data plate or load chart) mounted in operator compartment showing rated capacity at standard load center—typically 500mm or 600mm measured from fork face to load center of gravity for Australian and European forklifts. The capacity shown applies only when load center is at this rated distance and load is lifted to low heights (typically under 2 metres). For loads with center of gravity further from fork face, capacity reduces proportionally: if load center is 800mm but forklift is rated for 500mm center, capacity reduces to approximately (500/800) × rated capacity = 62% of rated capacity. For example, a 2,500kg rated forklift with 500mm load center can safely lift only about 1,550kg when load center is 800mm from fork face. Calculating actual load center requires knowing load dimensions and weight distribution. For uniformly distributed loads (common for palletised goods), load center is at geometric center of load—measure from fork face to center of pallet. For example, standard 1165mm Australian pallet has center at 582mm from front edge, exceeding most forklifts' rated load center and requiring capacity reduction. For irregularly shaped loads or loads with concentrated weight at one end, estimate center of gravity position by finding balance point—if load would balance on a fulcrum positioned at estimated center point, that's the center of gravity. Load height also affects capacity with most forklifts losing 5-10% capacity for every metre of lift height above 3 metres, with specific derating factors shown on capacity plate or in operator manual. Practical approach to capacity management: First, determine load weight from pallet labels, shipping documentation, or by calculation from dimensions and material density. Second, estimate load center by measuring or calculating center of gravity position. Third, compare to capacity plate—if load weight and center exceed any values on capacity plate, load is overweight requiring splitting, larger forklift, or alternative handling method. Fourth, apply 80% safety factor to provide margin for estimation errors and dynamic forces during operation—limit lifts to 80% of calculated available capacity. For critical lifts near capacity limits or with uncertain load characteristics, use load scales, load moment indicators, or weighbridge data to verify weights before proceeding. Never guess or estimate for loads approaching forklift capacity—obtain verified weight data or refuse lift. Remember that attachments such as side-shifters, clamps, or specialized forks reduce effective capacity by their weight plus additional moment created by moving load further from fulcrum—capacity plates show capacity with attachments fitted if equipped, or derating factors to apply when attachments added.

Effective traffic management for forklift operations requires combination of physical segregation, procedural controls, and training to prevent struck-by incidents between forklifts and pedestrians. Physical segregation represents most effective control—designate separate routes for forklifts and pedestrians using physical barriers such as bollards, safety fencing, or concrete barriers creating pedestrian walkways protected from forklift incursion. Mark forklift traffic routes using high-visibility line marking including yellow lines for route boundaries, speed limit signs at regular intervals (typically 10 km/h in warehouses, 5 km/h in congested construction areas), zebra crossings at approved pedestrian crossing points, and stop lines at intersections requiring forklifts to pause and check for conflicting traffic. Install mirrors at blind corners and intersections allowing operators to see approaching traffic before entering crossing areas. Implement one-way traffic systems where practicable eliminating head-on collision risks in narrow aisles or roadways. For construction sites where complete segregation is impracticable due to changing work areas and temporary nature of facilities, implement time-based segregation scheduling forklift material deliveries and handling activities during periods when pedestrian workers are not present in operating areas, or spatial segregation maintaining minimum 5-metre exclusion zones around operating forklifts marked using witches hats or barrier tape. Deploy trained spotters with high-visibility clothing and two-way radios for operations in congested areas, with spotters positioned to see both forklift operators and approaching pedestrians, empowered with stop-work authority to direct forklifts to cease movement when hazards develop. Implement maximum speed limits enforced through operator training, supervision, and telematics monitoring—typical limits are 10 km/h in warehouses, 5 km/h in congested areas, 3 km/h when approaching pedestrian crossing points or intersections. Procedural controls include requirements for operators to sound horn when approaching intersections, blind corners, or doorways alerting pedestrians to forklift presence; requirement for 360-degree visual check before commencing movement from stopped position; prohibition on reversing without visible clearance verification requiring operators to use spotter assistance when reversing with vision obstructed; and mandatory stop procedure when pedestrians approach within 3 metres requiring forklifts to stop immediately until pedestrians clear operating area. Install warning devices including blue LED spot lights projecting blue spot onto ground 3-5 metres ahead of forklift providing visual warning to pedestrians even before audible alarms heard, plus rotating amber beacons on forklift roof providing 360-degree visibility of forklift to surrounding workers. Conduct regular traffic management reviews observing actual forklift and pedestrian movements, identifying locations where segregation is being breached requiring additional barriers, where near-misses are occurring indicating inadequate controls, and where procedural requirements are not being followed requiring retraining or disciplinary action.

Forklift tip-overs occur when combined center of gravity of forklift plus load moves outside the stability triangle or stability rectangle defined by contact points between forklift wheels and ground. For three-wheeled forklifts (most common type), stability triangle is formed by two front wheels and single rear wheel pivot point—combined center of gravity must remain within this triangle to prevent tip-over. Understanding the causes enables implementing preventive controls. Forward tip-overs occur most commonly from: overloading beyond rated capacity causing front-heavy weight distribution, lifting loads with center of gravity beyond rated load center distance, traveling on slopes or ramps with heavy end (loaded forks) pointing downhill, sudden stops or braking while traveling with elevated loads, and operating with loads extended forward beyond normal carry position. Lateral (sideways) tip-overs result from: turning too quickly with elevated loads creating centrifugal forces shifting center of gravity outside stability triangle, traveling across slopes with loaded or elevated forks, operating on uneven ground causing one wheel to lift, and wheel drop-off when forklift travels off edge of loading dock or roadway creating sudden lateral instability. Preventing tip-overs requires disciplined adherence to operational procedures and awareness of conditions affecting stability. Load management controls include: never exceed 80% of rated capacity to provide safety margin, obtain verified load weights for loads without documented weights rather than estimating, understand load center concept and calculate capacity reduction for loads with centers beyond rated distance, distribute loads evenly on forks to prevent lateral imbalance, and reject loads on damaged pallets that could collapse during lifting. Operating technique controls: maintain loads in low carry position (150-200mm above ground) during all travel operations except final positioning for stacking, tilt mast fully backward before lifting and maintain throughout transport moving load center toward forklift centerline, travel at safe speeds appropriate to conditions typically 5-8 km/h in warehouses reducing to 3-5 km/h when loaded or operating on rough ground, reduce speed to walking pace before turns allowing smooth radius turns rather than sharp turns creating lateral forces, and avoid sudden acceleration or braking that shifts weight distribution creating instability. Slope and ground condition controls critical for stability: measure slope angles before operations using inclinometer or slope gauge, restrict forklift operations to slopes under 5 degrees when loaded or 10 degrees unloaded, always travel with heavy end uphill—when loaded this means forks and load face uphill, when unloaded rear counterweight uphill, travel straight up or down slopes never diagonally across slope which creates lateral tip-over risk, avoid turning on slopes instead turning on level ground before ascending or descending, and prohibit forklift operations on soft ground including mud, wet grass, or inadequately compacted fill until ground improved to adequate bearing capacity. Maintain forklifts in good condition ensuring tyres have adequate pressure (underinflation reduces stability), steering components have no excessive play allowing precise control, and hydraulic systems function without leaks preventing unexpected load or mast movement. Finally, ensure operators wear seatbelts always—seatbelts cannot prevent tip-overs but maintain operators within ROPS protection during tip-over preventing ejection and fatal crushing that causes most tip-over fatalities.