Truck-mounted Forklift Safe Work Method Statement

Operators require both appropriate truck driver licensing and forklift high-risk work licensing. For truck driving, licence class must match the vehicle's Gross Vehicle Mass: Light Rigid (LR) for trucks 4.5-8 tonnes, Medium Rigid (MR) for 8-15 tonnes, or Heavy Rigid (HR) for larger vehicles. For forklift operation, operators must hold current High Risk Work Licence Class LF (Forklift Truck) issued by state or territory work health and safety regulators. This licence requires successful completion of both theoretical and practical assessment by registered training organisations. The forklift licensing requirement applies regardless of the forklift being truck-mounted rather than conventional warehouse configuration. Standard forklift training does not cover truck-mounted deployment and mounting procedures, so additional operator training specific to piggyback equipment is essential. Operators should also complete general construction induction (White Card) if deliveries are to construction sites requiring site access. Employers must verify and maintain records of all operator qualifications, as chain of responsibility legislation extends liability to businesses directing transport operations if operators lack appropriate licensing. Some states require operators to carry physical licence cards that must be produced on request by work health and safety inspectors or police.

Ground assessment should evaluate three critical factors: slope angle, bearing capacity, and surface condition. Slope angle can be measured using a simple inclinometer, smartphone level app, or estimated by observing water drainage patterns. Piggyback forklifts should ideally operate on level ground, can operate cautiously on slopes up to 5 degrees, require supervisor approval and reduced load heights for 5-10 degree slopes, and should not operate on slopes exceeding 10 degrees due to severe tip-over risk. Bearing capacity assessment involves observing whether the ground surface is recently disturbed, saturated, or shows evidence of softness. Push a probe or steel stake into the ground - if it penetrates easily, bearing capacity may be inadequate for forklift weight. Watch whether forklift wheels sink when first deployed - if significant sinking occurs, relocate to firmer ground. Surface condition including loose gravel, mud, or debris affects traction and stability. The best approach is to identify the most level, stable, well-compacted area available on site and position truck to allow forklift operation in this area. If no suitable area exists, alternative unloading methods should be considered including manual handling with mechanical aids, crane offloading arranged through site, or requesting site operators use their forklifts to unload from the truck. Never proceed with forklift operations on marginal ground due to time pressure or reluctance to discuss alternatives with site supervisors - the consequences of tip-over incidents far outweigh any perceived inconvenience of arranging alternative unloading methods.

Immediately halt deployment of the forklift until overhead clearances are assessed and verified adequate. Identify power line locations and estimate or measure the height of lines above ground. Determine the maximum height your forklift mast will reach when handling the loads to be delivered - this is typically 4-5 metres for piggyback forklifts at full mast extension. Australian electrical safety regulations require minimum clearances of 3 metres from high-voltage power lines (typically distribution lines on power poles) and varying distances from low-voltage lines depending on voltage and risk assessment, often 1 metre minimum for residential low-voltage services. However, electricity can arc from conductors to plant before actual contact occurs, particularly with high-voltage lines. If available clearance is less than 3 metres from any overhead lines, relocate unloading area away from power lines, limit mast height during load handling to maintain required clearances, or use alternative unloading methods not involving elevated loads. Do not proceed with elevated load handling near power lines based on visual estimation of clearances or assumptions that clearances are adequate. If power line contact occurs, do not exit the forklift unless fire makes remaining in the machine impossible. Instruct all personnel to remain clear of the forklift and truck. Call electricity provider emergency number immediately to isolate power. Only after positive confirmation from electricity provider that power is isolated should personnel approach the vehicle. These conservative procedures reflect the catastrophic consequences of power line contact including electrocution fatalities.

Truck-mounted forklifts require enhanced maintenance schedules due to harsh road transport environments. Road transport at highway speeds generates severe vibration causing accelerated wear of hydraulic connections, electrical terminals, battery connections, and structural fasteners that warehouse forklifts do not experience. Maintenance schedules should account for both forklift operating hours and road transport hours, with components susceptible to vibration inspected more frequently. Hydraulic hoses should be inspected weekly rather than monthly, with replacement at any sign of abrasion, cracking, or deterioration. Electrical connections including battery terminals require monthly inspection and cleaning to prevent corrosion from road spray exposure. All structural bolts should be torque-checked quarterly as vibration causes progressive loosening. Tyres experience additional wear from deployment and mounting processes with potential damage from impacts against deployment ramps, requiring more frequent inspection and replacement than warehouse equivalents. Battery water levels should be checked weekly as charging may be less systematic than warehouse environments with scheduled charging. The overall effect is that truck-mounted forklifts typically require service intervals 30-50% more frequent than manufacturer recommendations for warehouse forklifts with equivalent operating hours. Comprehensive service records should track both transport and operational usage, supporting predictive maintenance and identifying components requiring enhanced attention. Pre-operation inspections become particularly important as they are the primary opportunity to identify transport-related deterioration before operations commence at delivery locations where repair support is unavailable.

Load securing during piggyback forklift operations follows standard forklift principles but requires additional attention due to uneven ground conditions. Ensure forks are inserted fully under pallets or load bases with load weight evenly distributed across both forks. Tilt mast backward slightly (approximately 5-10 degrees) before lifting to angle load against the mast backrest, creating positive retention. Raise loads only to minimum height required for ground clearance during travel - typically 150-200mm above highest ground point in the travel path. Higher loads elevate the centre of gravity and increase tip-over risk, particularly on uneven construction site surfaces. For loads that are unstable, top-heavy, or inadequately packaged, additional securing may be required using load restraint straps attached to the forklift if such attachment points are provided, though this is not common on piggyback forklifts. For particularly unstable loads, consider manual repositioning or re-stacking to create more stable configurations before forklift handling. Travel at reduced speed appropriate to ground conditions, typically walking pace (5 km/h maximum) on rough or uneven surfaces. Avoid sudden braking or sharp steering that could cause load shift. Lower loads gently when positioning, using tilt function to ease loads onto the ground rather than dropping from height. If operating on slopes (which should be avoided where possible), travel with forks uphill when loaded to maintain load against the mast. After load placement, verify loads are stable and positioned safely before departing, ensuring loads are not positioned where they could fall onto workers or traffic routes. For banded or strapped pallet loads, verify packaging integrity before lifting - damaged packaging may not contain load adequately during handling.

During deployment from the truck, if the forklift begins to veer off deployment ramps or shows signs of instability, immediately stop all movement by releasing the accelerator and applying brakes gently. Do not attempt sudden steering corrections that could worsen instability. If safe to do so, reverse slowly back up ramps to truck platform and reassess deployment approach. If the forklift has already begun to fall or tip from ramps, operators should remain in the operator position with seatbelt fastened if equipped (though many piggyback units lack seatbelts), holding firmly to steering wheel or operator handles, and bracing for impact. Do not attempt to jump clear as operators are frequently crushed when trying to escape tipping forklifts. After incident stabilises, assess injuries before attempting to exit the forklift, waiting for assistance if injured. During ground operations, if the forklift begins to tip due to ground collapse, slope, or overloading, operators should remain in the operator position, brace firmly against the steering wheel, and ride out the tip-over. Modern forklifts have rollover protective structures (ROPS) providing protection when operators remain in position, but operators jumping clear are frequently crushed by the machine. After tip-over incidents, isolate the area preventing others from approaching, assess operator for injuries requiring emergency services, and notify supervisors and work health and safety personnel. Do not attempt to right the tipped forklift without qualified rigging personnel and appropriate lifting equipment. For power line contact scenarios, remain in the forklift and instruct all other personnel to stay clear. Only exit if fire makes remaining in machine impossible, and if exiting is necessary, jump clear landing with both feet together, then shuffle away with small steps keeping feet together to avoid becoming a path for electrical current. These procedures must be included in operator training and reinforced through regular safety discussions to ensure operators respond correctly under stress.