Workplace fatality - crush injuries while loading a forklift for transport

Ways to manage health and safety

Before loading or unloading a forklift, the person conducting a business or undertaking should identify the hazards, assess the risks and implement appropriate control measures.

Further information about the hierarchy of controls and managing risks is available.

Possible control measures

Where reasonably practicable, consider using a purpose-designed loading system or a vehicle fitted with a winch to avoid driving the forklift onto or off the trailer.

Where ramps are used, always ensure:

• the forklift, trailer and ramps are suitable for the task
• the forklift’s weight, dimensions, ground clearance and operating limitations are considered
• the ramps are designed and rated for the forklift
• the ramps are wide enough and securely attached to the trailer or vehicle
• the ramp incline and any change in gradient are within the forklift manufacturer’s limits
• the transition between the ground, ramps and trailer does not cause the forklift to ground or become unstable
• the ramp and trailer surfaces provide adequate traction, taking account of rain, dew, mud, oil or other contaminants
• the trailer is positioned on firm, stable and level ground and secured against movement
• suitable edge protection, wheel guides or other engineering controls are considered to reduce the risk of the forklift travelling beyond the edge
• the forklift tyres, steering and brakes are maintained and functioning correctly
• workers and other people are kept clear of the loading area and any potential fall or crush zone
• the activity is stopped if the forklift slips, grounds, becomes unstable or cannot safely negotiate the ramps
• a competent spotter is used where required and remains outside the forklift’s path and potential fall zone
• an agreed communication method is used between the operator and spotter.

Operators should:

• operate in accordance with the manufacturer's instructions
• be trained and assessed as competent before being allowed to operate a forklift
• hold a current high risk work licence to operate the forklift*
• wear the seatbelt
• keep all body parts inside the forklift and don’t reach through the mast while it is operating
• maintain a clear view in the direction of travel
• avoid sudden acceleration, braking or steering movements
• not turn the forklift while it is on a ramp
• do not dive a forklift on ramps when loaded.

*Note: a person who carries out high-risk work involving plant is not required to be licensed if the work is moving the plant within the workplace, this includes operating plant in order to load it on to, or unload it from, a vehicle or equipment used to move it.

Section 82(2)(a) and (3) of the WHS Regulation provides an exception to the licensing requirement.

• vehicles and methods used for loading and unloading forklifts are appropriate including:

Seatbelt use

Where a seatbelt is fitted, it must be worn throughout the loading or unloading activity. The seatbelt helps keep the operator within the protective structure of the forklift if it falls or overturns.

If the forklift begins to overturn, the operator should:

• remain seated with the seatbelt fastened
• brace themselves and firmly grip the steering wheel
• lean away from the direction of the overturn.

Attempting to jump from an overturning forklift can expose the operator to a risk of serious injury or death.