Workers struck by forklifts in separate incidents

Possible control measures to prevent similar incidents

A person conducting a business or undertaking (PCBU) has a duty to ensure workers and others are not exposed to health and safety risks, including the risks associated with powered mobile plant such as forklifts and traffic hazards in the workplace.

The most effective control measure is to eliminate the hazard or hazardous work practice associated with forklift and pedestrian interactions. Where elimination cannot be achieved, other controls can be implemented to minimise the risk.

The risk of forklift-related injuries can be reduced by ensuring 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 also important to operate a forklift safely and to create a safe work environment to minimise the risk of incidents. This can include but not limited to:

• proximity devices to warn and control pedestrian and plant interactions
• separating pedestrians from forklifts
• observing speed limits and stop signs
• forklift operators wearing a correctly fitted seat belt
• slowing down and sounding the horn at intersections
• forklift operators having a clear view in the direction of travel.

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 pedestrians, forklift operators and others. It should be developed by those in charge of the business in consultation with workers and others at the workplace.

Everyone affected by the plan, including contractors and visitors, must know the plan and follow it. Communicate the plan through induction and training sessions in addition to posting information at workplace entrances and notice boards as well as other areas.

The plan should consider:

• creating and implementing exclusion zones to prevent pedestrians from entering the forklift operating areas along with pedestrian only zones
• the size of the exclusion zone should be based on a written risk assessment and clearly marked
• 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
• blind spots and corners
• 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
• physical barriers such as safety barriers, containment fences, bollards, or railed walkways, where possible
• a combination of audio and visual warning devices such as reversing alarms and horns, and flashing lights for forklifts
• signs to indicate who must give way
• each loading and unloading zone having a marked exclusion zone.
• a driver safety zone located a short distance away, with a direct line of sight to the loading area. implementation and enforcement procedures that describe how pedestrians and forklifts must interact in different situations
• a safe location to park forklifts that is well lit, under cover and on an even surface.

Forklifts should be regularly inspected and maintained according to the manufacturer’s instructions. Inspection, maintenance and repair are to be carried out by a competent person.

Any remaining risk must be minimised with suitable personal protective equipment (PPE), for example, the use of hard hats, steel cap boots, eye protection and high visibility vests where necessary.

Administrative control measures and PPE rely on human behaviour and supervision. If used on their own, they are least effective in minimising risks. The control measures you put in place should be reviewed regularly to make sure they work as planned.