Worker falls from forklift

Possible control measures to prevent similar incidents

If work at height is essential, a Persons Conducting a Business or Undertaking (PCBU), where reasonably practicable, should consider the use of working platforms. These could include Elevating Work Platforms (EWP) or scaffolds which should be used as an alternative to a workbox or work platform. If this is not possible, the below controls must be implemented.

You must ensure forklifts are operated in a safe manner including when using a work cage as a control measure for workers performing work at heights. Controls may include but are not limited to:

Workboxes

Workboxes and work platforms consist of a platform surrounded by edge protection, designed to provide an elevated work area for people working from the box. Workboxes are designed to be supported from above by a crane, hoist, or other mechanical device whereas work platforms are designed to be supported from underneath or the side by forklifts or other mechanical devices. Suitable control measures are outlined below:

• Workboxes must only be used to raise people if performing short-term tasks (see Australian Standard AS 2359 Powered industrial trucks (series) Part 2—2013 clause 3.10.1(b)).
• A workbox fitted to a forklift must be securely attached to the forklift carriage and engineer-designed and constructed in accordance with AS 2359 Powered Industrial Trucks – Part 1: See also Managing the risk of falls at workplaces Code of Practice 2021 (PDF, 3.9 MB)
• Workboxes must be securely attached to the forklift with a minimum of two independent securing devices. The devices must be visible to the person in the workbox.
• People using a workbox must be protected from the mast of the forklift and associated moving parts by a barrier at the back of the workbox.
• Tines lifting a workbox must be spaced widely apart to avoid the cage overbalancing.
• The tines must be in tunnels or clamps under the work cage. They may not be in an open arrangement like in a pallet as they may be accidently placed too far from the edge and tip over. Fork tunnels or clamps must be located within 150mm to 250mm of the outside edge of a workbox, with further tolerances as specified in AS 2359 Powered Industrial Trucks series.
• Refer to AS 2359 Powered Industrial Trucks series for other requirements, such as handrails, gates, and anchorage points for safety harnesses.
• Also, PCBUs using a work platform to provide an elevated work area should ensure
  • workers are only raised by a forklift when in a compliant work platform
  • workers remain within the work platform when it is elevated or being raised or lowered
  • no other device such as a ladder or pallet is used to gain additional height
  • the safety gate is self-closing and kept shut when in the elevated position.

Source: Figure 13 An engineer-designed work platform correctly positioned on tynes Managing the risk of falls at workplaces Code of Practice 2021 (PDF, 3.9 MB)

Forklifts

• Workboxes should only be attached to a compliant forklift, with a load capacity data plate stating the attachments that may be used.
• Ensure your traffic management plan deals with tasks involving workboxes.
• Before starting work, ensure the parking brake is set, the controls are in neutral, the mast is vertical, and all controls are immobilised except lift and lower.
• Employees should be trained in the safe use of workboxes including emergency procedures to ensure occupants can be rescued if an incident or breakdown occurs.
• Employees must stand on the floor of the workbox not on a ladder or other object.
• Never use workboxes to transport people.
• The employee operating the forklift must always remain at the controls.
• The forklift operator should perform an initial trial lift without a person inside to make sure the cage has a clear path.
• Only operate a forklift if you hold a high-risk work licence or are an authorised trainee.
• Use the forklift only for the purpose for which it was designed.

Read and follow the manufacturer’s specifications.

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 put in place should be reviewed regularly to make sure they work as planned.