DRAFT
INDUSTRIAL LIFT TRUCKS
Code of Practice
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
TABLE OF CONTENTS
FOREWORD ................................................................................................................ 3
SCOPE AND APPLICATION ....................................................................................... 3
1.
INTRODUCTION ................................................................................................... 4
1.1
1.2
1.3
1.4
1.5
2.
THE RISK MANAGEMENT PROCESS ................................................................. 8
2.1
2.2
2.3
2.4
3.
Buying or hiring an industrial lift truck ....................................................... 12
Safe work environment ............................................................................. 14
Information, training, instruction and supervision ...................................... 15
Traffic management.................................................................................. 16
USING AN INDUSTRIAL LIFT TRUCK ............................................................... 17
4.1
4.2
4.3
4.4
4.5
5.
Identifying the hazards ............................................................................... 8
Assessing the risks ..................................................................................... 9
Controlling the risks .................................................................................... 9
Maintaining and reviewing control measures ............................................ 11
BEFORE USING AN INDUSTRIAL LIFT TRUCK ............................................... 12
3.1
3.2
3.3
3.4
4.
What is an industrial lift truck? .................................................................... 4
What is a forklift truck? ............................................................................... 4
Who has health and safety duties in relation to an industrial lift truck?........ 4
What is involved in managing risks associated with an industrial lift truck? . 5
High risk work licences ............................................................................... 6
Pre-start safety check ............................................................................... 17
Operating the industrial lift truck ............................................................... 17
Plant not in use......................................................................................... 19
Maintenance, inspection and repair .......................................................... 20
Modifying or altering an industrial lift truck ................................................ 21
SPECIFIC HAZARDS AND CONTROL MEASURES .......................................... 22
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
Loads ....................................................................................................... 22
Instability .................................................................................................. 23
Work platforms and boxes ........................................................................ 24
Attachments ............................................................................................. 25
Tandem lifting ........................................................................................... 26
Ramps and loading docks ........................................................................ 27
Working near electric lines........................................................................ 27
Fuel handling and storage ........................................................................ 28
Battery charging and changing ................................................................. 28
APPENDIX A – EXAMPLES OF INDUSTRIAL LIFT TRUCKS .................................. 30
PAGE 2 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
FOREWORD
This Code of Practice for managing risks associated with industrial lift trucks is an approved
code of practice under section 274 of the Work Health and Safety Act (the WHS Act).
An approved code of practice is a practical guide to achieving the standards of health, safety
and welfare required under the WHS Act and the Work Health and Safety Regulations (the
WHS Regulations).
A code of practice applies to anyone who has a duty of care in the circumstances described in
the code. In most cases, following an approved code of practice would achieve compliance with
the health and safety duties in the WHS Act, in relation to the subject matter of the code. Like
regulations, codes of practice deal with particular issues and do not cover all hazards or risks
which may arise. The health and safety duties require duty holders to consider all risks
associated with work, not only those for which regulations and codes of practice exist.
Codes of practice are admissible in court proceedings under the WHS Act and Regulations.
Courts may regard a code of practice as evidence of what is known about a hazard, risk or
control and may rely on the code in determining what is reasonably practicable in the
circumstances to which the code of practice relates.
Compliance with the WHS Act and Regulations may be achieved by following another method,
such as a technical or an industry standard, if it provides an equivalent or higher standard of
work health and safety than the code of practice.
An inspector may refer to an approved code of practice when issuing an improvement or
prohibition notice.
This Code of Practice has been developed by Safe Work Australia as a model code of practice
under the Council of Australian Governments’ Inter-Governmental Agreement for Regulatory
and Operational Reform in Occupational Health and Safety for adoption by the Commonwealth,
state and territory governments.
A draft of this Code of Practice was released for public consultation on 8 June 2012 and was
endorsed by the Select Council on Workplace Relations on [to be completed].
SCOPE AND APPLICATION
This Code provides practical guidance for persons conducting a business or undertaking who
have management or control of industrial lift trucks in workplaces on how to manage the health
and safety risks when buying, hiring, operating, maintaining and repairing industrial lift trucks. It
includes information about specific control measures required under the WHS Regulations.
This Code should be read in conjunction with the Codes of Practice for Managing Risks of Plant
in the Workplace and Safe Design, Manufacture, Import and Supply of Plant.
How to use this code of practice
In providing guidance, the word ‘should’ is used in this Code to indicate a recommended course
of action, while ‘may’ is used to indicate an optional course of action.
This Code also includes various references to provisions of the WHS Act and Regulations which
set out the legal requirements. These references are not exhaustive. The words ‘must’,
‘requires’ or ‘mandatory’ indicate a legal requirement exists and must be complied with.
PAGE 3 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
1. INTRODUCTION
1.1 What is an industrial lift truck?
An industrial lift truck is a type of powered mobile plant, designed to move goods, materials or
equipment that is equipped with an elevating load carriage and for normal use is equipped with
a load-holding attachment, but does not include a mobile crane or earthmoving machinery.
There are a number of types of industrial lift trucks, for example forklift trucks, straddle carriers
and reach trucks. Further examples can be found at Appendix A.
For the purposes of the WHS Regulations and this Code of Practice, manually-powered lift
trucks for example pallet lifters, reach stackers, multi-purpose tool carriers and telehandlers, are
not industrial lift trucks.
1.2 What is a forklift truck?
A forklift truck is a powered industrial truck equipped with lifting media made up of a mast and
elevating load carriage to which a pair of fork arms or other arms that can be raised 900 mm or
more off the ground.
Ride-on forklift trucks are a greater risk to the health and safety of workers and other people
than pedestrian-operated forklift trucks and therefore require a high risk work licence to operate.
1.3 Who has health and safety duties in relation to an industrial lift truck?
A person conducting a business or undertaking has the primary duty to ensure, so far as is
reasonably practicable, workers and other people are not exposed to health and safety risks
arising from the business or undertaking.
This duty requires the person to manage risks by eliminating health and safety risks so far as is
reasonably practicable, and if it is not reasonably practicable to eliminate the risks, by
minimising those risks so far as is reasonably practicable. It also includes ensuring, so far as is
reasonably practicable the:


provision and maintenance of safe plant, including industrial lift trucks
safe use, handling, storage and transport of plant.
The WHS Regulations include specific duties for a person conducting a business or
undertaking with management or control of plant, as well as requirements for powered
mobile plant and plant that lifts or suspends loads.
If you own an industrial lift truck, you are the person with management or control of that plant. If
you hire or lease an industrial lift truck, you have management or control of that plant for the
period that you have hired it. Both you and the person you have hired or leased it from will have
duties to eliminate or minimise the risks associated with the plant, so far as is reasonably
practicable.
Designers, manufacturers, importers and suppliers of plant must ensure, so far as is
reasonably practicable, the plant they design, manufacture, import or supply is without risks to
health and safety. This duty includes carrying out testing and analysis as well as providing
specific information about the plant or structure. Information must, so far as is reasonably
practicable, be passed on from the designer through to the manufacturer and supplier to the
end user.
Further guidance is available in the Code of Practice: Safe design, Manufacture, Import and
Supply of Plant.
PAGE 4 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
Officers, such as company directors, have a duty to exercise due diligence to ensure the
business or undertaking complies with the WHS Act and Regulations. This includes taking
reasonable steps to ensure the business or undertaking has and uses appropriate resources
and processes to eliminate or minimise risks from plant.
Workers have a duty to take reasonable care for their own health and safety and to not
adversely affect other people’s health and safety. Workers must co-operate with reasonable
policies or procedures relating to health and safety at the workplace and comply, so far as they
are reasonably able, with reasonable instructions. Workers who operate certain types of forklifts
must have a relevant high risk work licence.
Other persons at the workplace, like visitors, must take reasonable care for their own health
and safety and must take reasonable care not to adversely affect other people’s health and
safety. They must comply, so far as they are reasonably able, with reasonable instructions
given by the person conducting the business or undertaking to allow that person to comply with
the WHS Act.
1.4 What is involved in managing risks associated with an industrial lift truck?
R.203: A person with management or control of plant at a workplace must manage risks to
health and safety associated with the plant.
R.32-38: To manage risk, a person conducting a business or undertaking must:
 identify reasonably foreseeable hazards that could give rise to risks to health and safety
 eliminate risks to health and safety so far as is reasonably practicable
 if it is not reasonably practicable to eliminate risks to health and safety—minimise those
risks so far as is reasonably practicable by implementing risk control measures according to
the hierarchy of control in regulation 36
 ensure the control measure is, and is maintained so that it remains, effective, and
 review and as necessary revise control measures implemented to maintain, so far as is
reasonably practicable, a work environment that is without risks to health or safety.
Chapter 2 of this Code provides guidance on how to manage the risks associated with industrial
lift trucks in the workplace by following a systematic process which involves:




identifying hazards – finding out what could cause harm
assessing risks if necessary – understand the nature of the harm that could be caused
by the hazard, how serious the harm could be and the likelihood of it happening
controlling risks – implementing the most effective control measure that is reasonably
practicable in the circumstances
reviewing control measures to ensure they are working as planned.
Guidance on managing the risks of plant is available in the Code of Practice: Managing Risks of
Plant in the Workplace.
Consulting your workers
S.47: The person conducting a business or undertaking must, so far as is reasonably
practicable, consult with workers who carry out work for the business or undertaking who are, or
are likely to be, directly affected by a matter relating to work health or safety.
S.48: If the workers are represented by a health and safety representative, the consultation
must involve that representative.
PAGE 5 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
It is important to consult your workers as early as possible when planning to introduce new plant
or make any changes that may affect their health and safety.
Consultation involves sharing information, giving workers a reasonable opportunity to express
views and taking those views into account before making decisions on health and safety
matters. Consultation is required at each step of the risk management process and draws on
the experience, knowledge and ideas of workers to identify hazards and develop effective risk
controls.
Consulting, co-operating and co-ordinating activities with other duty holders
S.46: If more than one person has a duty in relation to the same matter under this Act, each
person with the duty must, so far as is reasonably practicable, consult, co-operate and coordinate activities with all other persons who have a duty in relation to the same matter.
There may be other businesses who share the workplace where an industrial lift truck is used or
who are involved in the supply, installation and maintenance of industrial lift trucks. They will
each have health and safety duties to the extent of their ability to influence and control various
aspects of plant safety. Therefore, it is important that these duty holders consult each other on
the risks associated with using the industrial lift truck and work together in a co-operative and
co-ordinated way to control the risks, for example controlling traffic movements in or near the
work area.
Further guidance on consultation requirements is available in the Code of Practice: Work Health
and Safety Consultation, Co-operation and Co-ordination.
1.5 High risk work licences
R.85: A person conducting a business or undertaking at a workplace must not direct or allow a
worker to carry out high risk work for which a high risk work licence is required unless the
person sees written evidence provided by the worker that the worker has the relevant high risk
work licence for that work.
Schedule 3 to the WHS Regulations sets out the types of plant that require a licensed operator.
A person who operates a forklift truck must hold a high risk work forklift license. No other
industrial lift truck requires a high risk work licence to operate.
For high risk work licensing purposes:
 a forklift truck does not include a pedestrian-operated truck or a pallet truck
 an order-picking forklift truck is where the operator’s controls are incorporated with
the lifting media and elevate with the lifting media.
A tractor fitted with ‘lifting media made up of a mast and elevating load carriage to which is
attached a pair of fork arms or other arms’ is classified as a forklift truck for high risk work
licensing purposes (see Figure 1).
PAGE 6 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
Figure 1 Tractor with mast and tynes classified as a forklift truck and the operator requires a
high risk work licensing
Examples of where a high risk work licence is required to operate common types of forklift truck
are listed in Table 1. See also Appendix A for further detail on common types of forklift trucks.
Table 1 High risk work licence requirements for forklift trucks
Type of forklift truck
Counterbalanced forklift truck
Order-picking forklift truck
Powered pedestrian-operated forklift truck
Reach truck
Side-loading forklift truck
Straddle carrier
Ride-on high lift truck
Operator licence required
Yes
Yes
No
Yes
Yes
No
Yes
Training to obtain a high risk work licence must be completed as part of a course from a
Registered Training Organisation (RTO). A person training to operate a forklift may operate a
forklift truck at their workplace if they are:


enrolled with an RTO to train as a forklift truck operator, and
directly supervised while operating the forklift truck by a person who has both the
relevant licence to perform the high risk work and appropriate workplace experience.
PAGE 7 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
2. THE RISK MANAGEMENT PROCESS
There are a range of hazards and risks associated with using an industrial lift truck. A risk
management process that identifies the hazards and controls the risks will help ensure the
industrial lift truck is safe to use.
R.214 The person with management or control of powered mobile plant at a workplace must
manage risks to health and safety associated with the following:
 the plant overturning
 things falling on the operator of the plant
 the operator being ejected from the plant
 the plant colliding with any person or thing
 mechanical failure of pressurised elements of plant that may release fluids that pose
a risk to health and safety.
2.1 Identifying the hazards
The first step to managing the risks is to identify the hazards associated with the industrial lift
truck and its use. Examples of specific hazards associated with an industrial lift truck include:
 industrial lift truck overturning
 loads falling off the industrial lift truck
 unexpected movements of industrial lift trucks
 collision with pedestrians or plant and structures in the workplace
 contact with overhead electric lines
 electrical, hydraulic and mechanical power sources.
When identifying hazards you should think about the activities that may be carried out during
the life of the industrial lift truck at your workplace, for example: operation, inspection,
maintenance, repair, transport and storage.
How to identify hazards
Information gathered from a range of sources can help identify hazards, including from:
 operator manuals and other manufacturer instructions for the industrial lift truck
 consulting with designers, manufacturers, suppliers, importers, maintenance technicians
or engineers and operators
 a visual inspection of the industrial lift truck and associated environmental and operating
conditions in which the truck is to be used
 the ergonomic and safety needs of industrial lift truck operators
 inspection, testing and maintenance information
 analysis of injury and near miss data.
If you have hired or leased an industrial lift truck, you should also consult the person conducting
the business or undertaking who owns the truck about potential hazards because you both have
responsibility for ensuring that the plant is without risk to health and safety.
PAGE 8 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
2.2 Assessing the risks
A risk assessment involves considering what could happen if someone was exposed to a
hazard and the likelihood of this happening. A risk assessment can help you determine:
 how severe a risk is
 whether existing control measures are effective
 what action you should take to control the risk
 how urgently the action needs to be taken.
Many hazards and their associated risks are well known and have well established and
accepted control measures. In these situations, the second step to formally assess the risk is
unnecessary. If, after identifying a hazard, you already know the risk and how to control it
effectively, you may simply implement the controls.
Factors that may impact on the risk associated with the hazards you have identified, include:





the condition of the industrial lift truck, e.g. its age, maintenance history and how
frequently it is used
its suitability and stability for the kinds of loads it is used to lift
the design and layout of the workplace where it is used
slope or evenness of the ground or surface it is operating on
operator competency.
2.3 Controlling the risks
Some control measures are more effective than others. Control measures can be ranked from
the highest level of protection and reliability to the lowest. This ranking is known as the
hierarchy of control.
Eliminating the risk
This means removing the hazard or hazardous work practice from the workplace. This is the
most effective control measure and must always be considered before anything else. For
example, modify the workplace so that materials are delivered directly to the location.
If elimination of the risk is not reasonably practicable, you must consider using substitution,
isolation or engineering controls, or a combination of these control measures, to minimise the
risk.
Minimising the risk
Substitution
Minimise the risk by substituting or replacing the hazardous plant or hazardous work practice
with a safer one. For example use a manually-powered forklift instead of a ride-on forklift truck.
Isolation
Minimise the risk by isolating or separating the hazard or hazardous work practice from people.
For example, isolating a mobile plant work zone from workers and the public with physical
barriers will minimise the risk of contact occurring between a person and the mobile plant.
PAGE 9 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
Engineering Controls
Engineering controls are physical control measures to minimise risk. For example by enclosing
an open cab excavator, using a falling object protective structure (FOPS) or a roll over
protective structure (ROPS), will minimise the risk of an operator being struck by a falling object
or being crushed if the excavator rolls over.
If a risk then remains, the duty holder must minimise the remaining risk, so far as is reasonably
practicable, by using:
Administrative controls
Administrative controls should only be considered when other higher order control measures
are not reasonably practicable, or to increase protection from the hazard. These are work
methods or procedures that are designed to minimise the exposure to a hazard, for example
carrying out pre-start safety checks, installing signs for pedestrians warning that an industrial lift
truck is operating in the area.
Any remaining risk must be minimised, as far as is reasonably practicable, by providing and
ensuring the use of:
Personal protective equipment
Personal protective equipment (PPE) is the lowest order control measure in the hierarchy of
controls. PPE should also only be considered when other higher order control measures are not
reasonably practicable or to increase protection from the hazard. Examples of PPE include hard
hats, high visibility vests, hearing and eye protection.
Combining control measures
In most cases, a combination of the control measures will provide the best solution to minimise
the risk to the lowest level reasonably practicable. For example, a combination of two or more of
the following control measures could be used to minimise the risk to people who work with
industrial lift trucks:
 replacing an operating cabin that has a restricted field of vision with one that has a clear
field of vision (substitution)
 separating workers in a work area from industrial lift truck operation using physical
barriers (isolation)
 installing speed limiters to the industrial lift truck (engineering)
 implementing a traffic management plan to control traffic control (administrative), and
 requiring workers to wear high visibility reflective clothing or vests (PPE).
PAGE 10 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
2.4 Maintaining and reviewing control measures
R.37: A person conducting a business or undertaking must ensure control measures are
maintained so that they remain effective, including by ensuring that the control measures are
and remain:
 fit for purpose
 suitable for the nature and duration of the work, and
 installed, set up and used correctly.
R.38: A duty holder must review and as necessary revise control measures implemented to
maintain, so far as is reasonably practicable, a work environment that is without risks to health
or safety.When deciding how often to carry out a review, you should consider the level of risk,
for example, whether the plant presents high or frequent risks which may need to be reviewed
more often as well as the type of plant involved taking into account that there may be particular
stages in the life of the plant where a more frequent review is needed.
For more general information please also refer to the Code of Practice: How to Manage Work
Health and Safety Risks.
PAGE 11 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
3. BEFORE USING AN INDUSTRIAL LIFT TRUCK
3.1 Buying or hiring an industrial lift truck
Selecting the right equipment for the job is a key factor in eliminating or minimising the risks
associated with industrial lift trucks. Before you select a particular type of industrial lift truck, you
should identify whether the design and construction of the industrial lift truck is suited to the
work and the environment it will be used in. For example, a manually-powered industrial lift
truck may be more suitable to minimise traffic movement risks in a small, busy workplace than a
ride-on industrial lift truck. Consider the various industrial lift truck capabilities, limitations and
type of operator training required.
Discuss your needs with the supplier who must provide you with the following information when
they supply an industrial lift truck:



the purpose for which a industrial lift truck was designed or manufactured
the results of any calculations, analysis, testing or examination
any conditions necessary for the industrial lift truck to be used safely.
R.215(2): A person conducting a business or undertaking with management or control of
powered mobile plant at a workplace must ensure, so far as is reasonably practicable, that a
suitable combination of operator protective devices for the plant is provided, maintained and
used.
Operator protective devices include a roll over protective structure, falling object protective
structure, operator restraining device and seat belt. Wherever possible, these safety features
should be retro fitted by a competent person to older plant where they were not included in the
original design.
Other safety features that should be incorporated into the design or retrofitting of an industrial lift
truck include:








Integrated guarding, for example engine and battery compartments, which should
comply with appropriate technical requirements. If the types of loads to be handled
warrant a design change, for example, a reduction of aperture size of overhead and
other guards, from those nominated in a standard, a risk assessment should be carried
out to determine the suitability of an alternative design.
Safe entry and exit, for example adequate steps and handholds so that the operator
can enter and leave safely.
Low noise and vibration, for example through a sprung and adjustable seat.
A load back-rest extension high enough to prevent the load, or part of the load, falling
back onto the operator.
Adequate visibility, for example adjustable rear vision mirrors of sufficient size.
Emission control systems if there is any likelihood the plant will be working in a poorly
ventilated area.
Flow restrictors or similar fitted to hydraulic lines to prevent free fall in the event of
hydraulic hose failure for example when lifting and suspending people.
Flame and static proofing if it is intended the industrial lift truck will be working in or
near areas containing flammable or combustible atmospheres.
When selecting an industrial lift truck to use in a poorly ventilated area, such as a cool store,
you should consider the exhaust emissions, the time that the industrial lift truck will be operating
and whether people are working in the area. In these situations, battery powered industrial lift
PAGE 12 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
trucks should be used, if it is reasonably practicable to do so. In cases where they are not used,
controls must be put in place to prevent a risk to operators or other people.
Second-hand plant
R.198: A supplier of plant must:
 take all reasonable steps to obtain the information required to be provided by the
manufacturer under section 23(4)(a) and (c) of the Act and these Regulations, and
 when the plant is supplied, ensure the person to whom the plant is supplied is given the
information obtained by the supplier.
R.199: A supplier of second-hand plant must ensure, so far as is reasonably practicable, that
any faults in the plant are identified.
Before plant is supplied, the supplier of second-hand plant must ensure that the person to
whom the plant is supplied is given written notice of:
 the condition of the plant
 any faults identified, and
 if appropriate, that the plant should not be used until the faults are rectified.
R.8: A supply of a thing does not include the supply of a thing by a person who does not control
the supply and has no authority to make decisions about the supply, for example an auctioneer
without possession of the thing or a real estate agent acting in their capacity as a real estate
agent.
A person conducting a business or undertaking that imports, supplies or sells second hand plant
has obligations to the person buying or receiving the plant, including for an industrial lift truck.
For further information see section 25 of the WHS Act, regulations 198, 199 and 200 of the
WHS Regulations and the [draft] Code of Practice: Safe Design, Manufacture, Import and
Supply of Plant.
Hiring an industrial lift truck
Before you hire an industrial lift truck you should ensure that the truck is suitable for its intended
use. You should also check that it has been inspected and maintained by the owner according
to the manufacturer’s specifications.
In most cases the supplier will be responsible for inspecting and maintaining the industrial lift
truck. However, if the industrial lift truck is to be hired for an extended period of time, you and
the supplier may develop arrangements to ensure that the industrial lift truck is adequately
inspected and maintained throughout the lease. This may involve the supplier coming to your
workplace to maintain the industrial lift truck, or you maintaining the industrial lift truck while it is
at your workplace.
PAGE 13 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
3.2 Safe work environment
Work areas should be designed and maintained so powered mobile plant can be operated
safely. Factors to consider in providing a safe work environment include:
Measures
Examples of how to use measures
Barricades
Separating pedestrian and traffic areas with physical barriers can prevent
pedestrians entering areas where industrial lift trucks are working.
Bollards or
Should be installed inside and outside on both sides of doorways used by
guard rails
industrial lift trucks to minimise the risk of collision with the doorway,
pedestrians, other vehicles or immovable objects. Bollards and guard rails
should be clearly identified, for example painted with black and yellow diagonal
stripes.
Doors
Doors made of transparent material can assist visibility and reduce the risk of
collision.
Speed limits Apply work area speed limits and install speed limiting devices in ride-on
and road
industrial lift trucks to control speed. Road humps are unsuitable for controlling
humps
the speed of industrial lift trucks. Where they are installed to control other
vehicles, provision should be made for industrial lift trucks to use by-pass the
humps.
Adequate
Must be provided, so far as is reasonably practicable, in work areas where an
lighting
industrial lift truck operates. The area immediately inside a building where
industrial lift trucks enter should be well lit to avoid vision problems when
passing from bright sunlight into a poorly lit area. Travelling in and out of
covered areas creates a risk to operators who wear photo-chromatic glasses.
These are glasses which that darken as light intensity increases.
Adequate
Must be provided, so far as is reasonably practicable, where industrial lift
ventilation
trucks powered by LPG, petrol and diesel fuel are used to minimise the
concentration of exhaust gas contaminants being discharged into the breathing
zone of any person. Battery powered industrial lift trucks should be used in
poorly ventilated or enclosed areas. If it is necessary to use a non-electric
industrial lift truck in a poorly ventilated area such as a shipping container or
cool store it is preferable to use a diesel powered unit because diesel engines
produce less carbon monoxide than petrol or LPG powered units, noting diesel
does produce a visibly dirtier exhaust. Regular engine tuning and air monitoring
should be carried out to minimise carbon monoxide exposure. Where
reasonably practicable, avoid using powered plant within an enclosed area.
Ramps
Should be secure, robust, provided with edge protection, not exceed the
manufacturer’s specific gradient for operating the industrial lift truck and
installed at points where an industrial lift truck needs to be driven from one
level to another. Refer to section 5.6 of this Code for further guidance.
Loading
Adequate edge protection or a system of work to minimise the risk of an
docks
industrial lift truck falling or being driven over the edge of a loading dock should
be provided. The system could include clear delineation of operating areas by
line marking at least two metres from an exposed edge with the area between
the line and the edge declared an industrial lift truck ‘no go’ zone. Refer to
section 5.6 of this Code for further guidance.
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3.3 Information, training, instruction and supervision
S.19: A person conducting a business or undertaking must ensure, so far as is reasonably
practicable, the provision of any information, training, instruction or supervision that is
necessary to protect all persons from risks to their health and safety arising from work carried
out as part of the conduct of the business or undertaking.
R.39: A person conducting a business or undertaking must ensure that information, training and
instruction provided to a worker is suitable and adequate having regard to:
 the nature of the work carried out by the worker
 the nature of the risks associated with the work at the time of the information, training and
instruction, and
 the control measures implemented.
The person must ensure, so far as is reasonably practicable, that the information, training and
instruction provided under this regulation is provided in a way that is readily understandable by
any person to whom it is provided.
A person conducting a business or undertaking must ensure that a person who operates an
industrial lift truck:
 Holds a valid high risk work licence for the type of industrial lift truck they are operating.
Refer to section 1.2 of this Code for further guidance.
 Is trained to operate the type(s) of industrial lift truck(s) and attachments they are
using.
 Is provided with information, training and instruction on the hazards, risks and control
measures relevant to the workplace.
Operators should have easy access to the manufacturer’s instructions to operate the industrial
lift truck safely.
Training specific to operating the industrial lift truck at the workplace should be provided to
workers by a competent person. This training should cover:
 information on the industrial lift truck, such as:
o position, function and operating sequence of controls and instruments, including
seat adjustment controls
o relevant design features and centre of gravity
o attachments and components which can be used
o how to estimate the load centre and mass of the item to be lifted
o capacity, stability and limitations of the industrial lift truck
 safety features, such as guarding, emergency stop controls and warning devices
 safe work practices that apply to the industrial lift truck and the relevant work areas,
including the safety of pedestrians
 operating conditions in work areas, including traffic rules, rights of way, clearances
from overhead electric lines
 procedures for reporting any fault, unsafe practice, damage to the industrial lift truck,
incident or near miss
 inspection, maintenance and repair responsibilities
 emergency procedures.
Management systems should be in place to:
 ensure only those workers who hold an relevant high risk work licence and have
received the required training and instruction carry out the work
 supervise the work so that safe work procedures are being followed
 ensure trainee operators are adequately supervised by a competent person.
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The necessary safety information must also be provided to people who are involved in installing,
commissioning, testing, maintaining or repairing the industrial lift truck, as well as
decommissioning, dismantling or disposing of an industrial lift truck. This information should
include the types of hazards and risks the industrial lift truck may pose to the worker when they
are involved in these activities.
3.4 Traffic management
R.215(4) and (5): A person with management or control of powered mobile plant at a workplace
must ensure that the plant does not collide with pedestrians or other powered mobile plant. If
there is a possibility of the plant colliding with pedestrians or other powered mobile plant, the
person must ensure that the plant has a warning device that will warn persons who may be at
risk from the movement of the plant.
The work environment should be set up, so far as reasonably practicable, so that industrial lift
trucks and pedestrians are separated and their paths do not cross, for example by using
overhead walkways or high impact physical safety barriers.
If this is not reasonably practicable, consider:
 using boom gates and proximity devices that trigger signals, boom gates and warning
signs
 using speed-limiting devices and implementing speed limits
 using a combination of audio and visual warning devices—like alarms, horns and
flashing lights—and ensuring these are working when the industrial lift truck is operating
 creating pedestrian exclusion zones, e.g. forklift-only areas in loading bays
 creating ‘no go’ zones for powered industrial lift trucks, e.g. pedestrian-only areas
around tearooms, amenities and entrances
 scheduling work to prevent industrial lift trucks and pedestrians being in the same area
at the same time
 removing or identifying blind corners and ensuring intersections are well lit
 locating signs and implementing procedures that cover how pedestrians and industrial lift
trucks give way to each other
 providing high-visibility or reflective clothing for workers and plant operators and highvisibility markings for industrial lift trucks, in addition to other measures.
A person with control of a business or undertaking (managers) that uses industrial lift trucks or
other load shifting equipment and vehicles should develop and implement a Traffic
Management Plan.
A traffic management plan documents and helps you communicate how risks will be managed
at the workplace.
Further guidance is provided in the Code of Practice: Traffic Management in Workplaces.
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4. USING AN INDUSTRIAL LIFT TRUCK
Some issues to consider when controlling risks associated with using industrial lift trucks in the
workplace include:
 work areas are designed, established and maintained for safe operation
 pre-start safety checks
 safe work procedures for shut down, maintenance, modification or alteration.
4.1 Pre-start safety check
Before operating an industrial lift truck, the industrial lift truck including attachment(s) should be
checked and the operator should be familiar with the controls.
A pre-start safety check should be conducted every time an operator uses a different industrial
lift truck and at the beginning of each shift, as the industrial lift truck may not have been left in a
safe condition by a previous operator.
Pre-start safety checks or procedures should include the following:
 reading the data and load rating plates to ensure the industrial lift truck and attachment
is suitable for the task
 lift and tilt systems including whether attachments like clamps, hydraulics lines for oil
leaks, chains, cables and limits are operating properly and safely
 steering, brakes including park brakes, controls and lights
 each tyre for wear, damage, and inflation for pneumatic types
 guarding is in place and functional, e.g. around the battery compartment or fuel lines
 warning devices are operational
 fork arms and attachments for deformation, damage or wear
 liquid levels, e.g. hydraulic oil, brake fluid and water
 gas cylinder, where relevant, and its securing system
 seat belts to ensure they work reliably.
4.2 Operating the industrial lift truck
R.218: The person with management or control of an industrial lift truck at a workplace must
ensure that the lift truck is:


equipped with lifting attachments that are suitable for the load to be lifted or moved by the
truck, and
operated in a manner that ensures that the risks to the operator of the truck and other
persons at or near the workplace that arise from systems of work and the environment in
which the truck is used, are eliminated so far as is reasonably practicable, or if not
reasonably practicable, minimised so far as is reasonably practicable.
The person with management or control of an industrial lift truck at a workplace must ensure
that the truck is not used to carry a passenger unless:
 the truck is designed to carry a seated passenger
 the passenger seat is fitted with suitable seat restraints, and
 the passenger seat is located within the zone of protection that is provided by the operator
protective device required to be fitted to the industrial lift truck.
The person with management or control of an industrial lift truck at a workplace must take all
reasonable steps to ensure that a passenger in an industrial lift truck is seated in a seat that
complies with the above design requirements.
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A person with management or control of an industrial lift truck at a workplace must ensure that,
where seat restraint attachment points are incorporated into the original design, a seat restraint
is provided. The person should instruct a person using an industrial lift truck to wear any seat
restraint provided. Pedestrian-operated industrial lift trucks do not require seat restraints.
If it is considered that it is not safe to wear seat restraints, a risk assessment should be carried
out and alternative risk controls implemented to ensure the health and safety of the operator
and people nearby are not put at risk.
Industrial lift trucks should be operated according to the manufacturer’s instructions and within
the manufacturer’s design parameters. For instance, it is not safe to use an industrial lift truck in
an area with a potentially explosive atmosphere unless it has been specifically designed or
modified for such use
Operators should:
 look in the direction of travel and keep a clear view of the way ahead
 if vision is obscured, e.g. by the load they should seek help from others to direct them,
or drive in reverse
 keep all body parts within the industrial lift truck while in operation
 avoid distracting behaviour while operating an industrial lift truck, e.g. using a mobile
phone or smoking
 where no traffic signs or signals exist to control industrial lift truck operation; give clear
indications of their intentions to others, e.g. sound the horn to alert other vehicles and
pedestrians
 when approaching crossings in aisles or gangways, slow down, take appropriate site
specific actions, e.g. sound the horn, and if vision is obstructed, keep well over to the
correct side of the aisle
 avoid crossing railway lines at a right angle
 be aware of other vehicles and people when approaching and crossing intersections
 drive at a safe speed consistent with site speed restrictions, the load and the existing
weather and road conditions
 drive slowly and without changing direction suddenly on wet or slippery or loose
surfaces because in these conditions industrial lift trucks can slide and overturn even at
low speeds
 whether with or without a load, drive with the fork arms as close to the ground as
practicable, with the tips of the fork arms tilted slightly upwards and away from the
ground
 take into account the operating surface, weather conditions, physical layout of the
operating area and any other hazards that may exist, like water
 stop before doorways and take appropriate site specific actions, e.g. sound the horn
and proceed slowly, but only if clear to do so
 avoid accelerating, decelerating and turning quickly
 ensure you can bring the industrial lift truck to a safe stop at any time, particularly on
wet, slippery or loose surfaces
 drive slowly if there is a need to reverse.
Driving in reverse should be kept to the practicable minimum unless the industrial lift truck has
controls that can be turned through 180 degrees, or dual controls, as long periods of driving in
reverse can cause neck problems for operators.
Rapid tail swing can cause an industrial lift truck to tip over which creates a risk of serious injury
or harm to the operator and pedestrians. The speed of rear end swing will be approximately
three times that of the industrial lift truck’s forward speed. To avoid rapid tail swing, operators
should reduce speed when turning. They should be aware that the tail swing causes
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exaggerated movement of the tail and fork tips. The tip of the fork, load or rear side of the
machine should be prevented from bumping against a person or object, such as shelving
supports.
A loss of lateral stability means the industrial lift truck will tip sideways, often with serious
consequences for the operator and pedestrians. To avoid overturning, operators should:
 centre loads—this means having their centre of gravity on the industrial lift truck’s
longitudinal centre line
o for loads with one end heavier than the other, e.g. connecting rods for large
engines, the heavy end should be nearer the centre line than the light end
 if multiple units are to be carried, the units should be located on a pallet so that every
second unit is reversed—this means the first unit should have the heavy end to the
right, the second unit should have the heavy end to the left and so on, so that the full
load is balanced
 correctly secure the load on the pallet
 carry loads as close to the ground, or other supporting surfaces, as possible
practicable
 ensure tyres, where applicable, are correctly inflated, as under inflated tyres can further
reduce stability
 slow down when driving across a sloping or wet surface.
Operator controls
Badly designed or maintained operator controls can make the plant operate unpredictably and
unsafe to operate.
R.210: The person with management or control of plant at a workplace must ensure that any
operator’s controls are:
 identified on the plant so as to indicate their nature, function and direction of operation
 located so as to be readily and conveniently operated by each person using the plant
 located or guarded to prevent unintentional activation, and
 able to be locked into the “off” position to enable the disconnection of all motive power.
4.3 Plant not in use
R.207: The person with management or control of plant at a workplace must ensure, so far as is
reasonably practicable, that plant that is not in use is left in a state that does not create a risk to
the health or safety of any person.
Parking and shut down
When parking an industrial lift truck the operator should:
 park the lift truck on level ground and with the load removed
 park the lift truck is parked in a way which does not obstruct the flow of other traffic
 apply the park brake
 fully lower the fork arms and tilt them slightly forward so the tips of the fork arms touch
the ground
 leave the drive controls in neutral
 shut off the power and the start control locked in the ‘off’ position.
When an industrial lift truck is left unattended, the ignition key should be removed or the start
control locked off to stop unauthorised people from using the industrial lift truck.
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Out-of-service procedures
If an industrial lift truck is found to be unsafe for normal use, out-of-service procedures should
include:
 a requirement for the operator to report the matter to an appropriate person
immediately after an unserviceable condition is identified
 a method used to identify and isolate the industrial lift truck as being
out-of-service
 that an out-of-service industrial lift trucks is not operated until it is made safe by a
competent person and the out-of-service identification removed.
Where an industrial lift truck is damaged, a competent person should inspect and assess:
 the nature and cause of the damage
 whether the industrial lift truck can be safely used in its damaged condition
 whether or not the industrial lift truck can be repaired and, if so, what repairs must be
done to make it safe to operate.
A copy of this assessment should be included in the inspection and maintenance records.
4.4 Maintenance, inspection and repair
R.213: The person with management or control of plant at a workplace must ensure that the
maintenance, inspection and, if necessary, testing of the plant is carried out by a competent
person.
A preventative maintenance, inspection and testing program for industrial lift trucks helps to
ensure the plant is safe to use. Where maintenance, inspection and testing is required it must
be carried out by a competent person. For example, only licensed gas fitters are permitted to
repair or replace gas piping on LPG powered industrial lift trucks.
Industrial lift trucks should be serviced and maintained regularly. A maintenance, inspection and
testing program should be based on the manufacturer’s instructions or, if it is not reasonably
practicable to comply with the manufacturer’s instructions, then in accordance with the
instructions of a competent person.
The maintenance, inspection and testing program should include the:
 manufacturer’s instructions and technical standards against which the industrial lift
truck is to be inspected, maintained and tested
 instructions developed by a competent person, if any
 frequency of inspections and maintenance
 procedures to be followed when carrying out inspections and maintenance
 procedures for reporting and investigating dangerous occurrences or any variations
from normal operation that have occurred since the last inspection and maintenance.
When carrying out maintenance, inspection and repair all energy sources likely to cause a risk
of injury should be removed or isolated to eliminate or minimise risks like electrocution or
crushing. This includes stored energy, for example from hydraulic components under pressure
or potential energy from an elevated forklift carriage that can move under gravity.
Inspections of industrial lift trucks should be performed as instructed by the manufacturer, a
competent person or at least annually.
Industrial lift trucks should be regularly cleaned to enable the detection of loose, worn or
defective parts and to prevent defects that might lead to, for example oil or fuel leaks and fires.
Maintenance and inspection records
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Records of maintenance, inspections, alterations or tests carried out on each industrial lift truck
should be kept at or near the workplace for as long as it is in the workplace.
Records should include:
 information that identifies the industrial lift truck
 date when inspected, serviced and repaired
 where an hour meter is fitted, operating hours readings
 detailed report of all repair work carried out
 name, qualifications and competency of the person who carried out the work
 details of any alterations made to the industrial lift truck.
4.5 Modifying or altering an industrial lift truck
A person intending to modify an industrial lift truck or its attachments in any way which affects
how it operates or performs should seek advice from the original designer, manufacturer and
supplier before making the change.
If you intend to use an industrial lift truck in a different way or for a purpose for which it was not
designed, you must ensure that the risks created by the new use are assessed by a competent
person.
Modifications that involve drilling holes or welding may destroy the integrity of the structure.
Modifications must not be carried out unless they have been specified by a competent person,
for example, mechanical engineer.
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5. SPECIFIC HAZARDS AND CONTROL MEASURES
5.1 Loads
R.219: The person with management or control of plant at a workplace must ensure, so far as is
reasonably practicable, that the plant used is specifically designed to lift or suspend the load.
The person must ensure that the lifting and suspending is carried out:
 with lifting attachments that are suitable for the load being lifted or suspended, and
 within the safe working limits of the plant.
The person with management or control of plant at a workplace must ensure, so far as
reasonably practicable, that:
 no loads are suspended or travel over a person unless the plant is specifically designed for
that purpose
 loads are lifted or suspended in a way that ensures that the load remains under control
during the activity, and
no load is lifted simultaneously by more than 1 item of plant unless the method of lifting ensures
that the load placed on each item of plant does not exceed the design capacity of the plant.The
weight, shape, size and composition of a load effects the way it can be lifted safely. Every
industrial lift truck should have attached, in clear view, a manufacturer’s data plate and load
chart. These two items may be combined on one plate.
The data plate should clearly state the:
 make, model number and serial number
 mast tilt (degrees), forward and rear
 maximum lift height (metres)
 tyre pressures (Kpa), if pneumatic
 gross vehicle mass (kgs) and steer axle load (kgs) (unloaded, mast vertical), or drive
axle loads (kgs).
The load chart should clearly state the rated load capacity (kgs) at nominated load centre
distance (mm) and at maximum lift height (metres) (mast vertical). It is important to limit the load
to the rated load capacity of the industrial lift truck or attachment as shown on the load chart.
If the rated load capacity is changed as a result of modifications to the industrial lift truck or its
attachments, the load chart should be revised before use. Each attachment should have its own
load chart to assist the operator.
Operators should be able to calculate whether loads of varying shapes and masses can be
lifted by their industrial lift trucks to ensure the capacity of the machine allocated to a given task
is not exceeded.
Loads should be firmly placed against the carriage or back-rest with the mast tilted back
sufficiently to safeguard against the load slipping, falling or rolling off the fork arms. Loads that
have the potential to slip, fall or roll off the fork arms or pallet should be appropriately restrained
with straps or similar.
Loads should always be carried as near to the ground as practicable. Operators should not
drive an industrial lift truck with a raised load.
Suspended loads
When handling a suspended load the operator should:
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




secure the load across both fork arms for balance, using an attachment designed
specifically to be used on the industrial lift truck
not exceed the de-rated capacity of the industrial lift truck or the rated capacity of the
attachment
only lift the load vertically with no dragging or off-vertical lifts
manoeuvre slowly and cautiously when the load is elevated
travel with the load as low as practicable.
If bulk bags, for example, flexible intermediate bulk containers, or similar loads are suspended
from the forks of an industrial lift truck, the lifting capacity should be reduced by a safety factor
of at least 20 percent to allow for the dynamic forces introduced as a result of sudden stops,
starts or turns causing the load to swing.
5.2 Instability
A common risk with operating an industrial lift truck is it tipping over with most tip-over incidents
involving unloaded industrial lift trucks. Industrial lift trucks can tip over by rolling or overturning
sideways, or by pitching forward when the back wheels lift off the ground. Serious injury can
occur when an operator jumps from a tipping industrial lift truck. Seatbelt restraints should be
worn so far as they are reasonably able to be worn.
Industrial lift trucks can tip over if the operator:
 drives with an elevated load with the fork arms raised too high
 accelerates quickly in reverse
 brakes too quickly, especially on a loaded industrial lift truck
 brakes or accelerates while cornering or driving down a slope
 carries a load facing down a slope, or an unevenly balanced load
 collides with another vehicle
 drives across inclines or uneven ground, such as potholes, particularly with a height
difference greater than 20 mm across the front wheels
 strikes low doors or overhead structures
 turns too fast
 uses an industrial lift truck that is not designed to tow, this may also be referred to as
pushing or pulling.
A counter balanced forklift truck is fitted with a counterweight at the opposite end to the forks.
This counteracts the weight of the load to be transported and reduces the risk of the forklift
tipping over.
Counter balanced forklifts are usually supported at three points called the ‘Triangle of
Stability’ (see points A, B and C in Figure 2). The front left wheel, the front right wheel and the
middle of the rear axle at the pivot pin connected to the steer axle make an imaginary triangle.
This is important because the centre of gravity (C.G) must remain within this triangle of stability.
If the centre of gravity falls outside the triangle, the forklift will tip over. This principle explains
why an un-laden forklift can easily tip over with a simple sharp turn, even on a level surface.
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Figure 2 Triangle of stability
5.3 Work platforms and boxes
R.219: The person with management or control of plant at a workplace must ensure, so far as is
reasonably practicable, that the plant used is specifically designed to lift or suspend the load.
If it is not reasonably practicable to use plant that is specifically designed to lift or suspend the
load, the person must ensure that:
 the plant does not cause a greater risk to health and safety than if specifically designed
plant were used, and
 the lifting or suspending must also comply with regulation 220.
Some industrial lift trucks are specifically designed to lift people. For example, an ‘order-picking
industrial lift truck’ has an elevating platform from which the operator can load shelves as well
as control platform elevation and steer the industrial lift truck.
R.220: The person with management or control of the plant at a workplace must ensure:
 the persons are lifted or suspended in a work box that is securely attached to the plant
 the persons in the work box remain substantially within the workbox while they are being
lifted or suspended
 a safety harness is worn if there is a risk of a worker falling from a height, and
 means are provided by which the persons being lifted or suspended can safely exit from the
plant in the event of a failure in its normal operation.
Forklift trucks may be used to provide a safe work platform, see Figures 3 and 4. Work
platforms and boxes should only be used to raise people performing infrequent tasks and must
be securely attached to the industrial lift truck. The following risk control measures should be
implemented when using work platforms or boxes:
 Industrial lift trucks are equipped with flow restrictors or similar, meaning the valves in
the hydraulic lines to prevent free fall in the event of a hose failure.
 Work boxes should only be attached to a compliant industrial lift truck with a load
capacity data plate stating the attachments that may be used.
 The industrial lift truck is to be suitably stabilised at all times while lifting a person or
people, and preferably only used on a hard, even and nominally level surface.
 Prior to the work commencing, ensure the parking brake is set, the controls are in
neutral, the mast is vertical, and controls are immobilised except lift and lower.
 Workers are trained to use work boxes safely including emergency procedures to
ensure occupants can be rescued if an incident or breakdown occurs.
 Workers stand on the floor of the work box, not on a ladder or other object.
 Work boxes should not be used to transport people.
 The worker operating the industrial lift truck remains at the controls at all times.
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

The industrial lift truck operator should perform an initial trial lift without a person inside,
to ensure the work box has a clear path and will not make contact with overhead power
lines or other overhead obstructions.
The work box safety gate is self-locking and kept shut when in the elevated position.
Figure 3 An example of an engineer-designed
work box with safety harness and lanyard
correctly positioned on the forklift tynes.
Figure 4 It is not safe to use a forklift as a
work platform or to gain extra height by
standing on the tynes or a pallet.
Anchorage points
Each anchorage point should comply with the work box manufacturer’s instructions or those of a
competent person.
All anchorage points should be tested and approved by a competent person before use as a
visual inspection may not reveal the structural integrity of the anchor point.
Each anchorage point should be located so that a lanyard of the system can be attached to it
before the person using the system moves into a position where the person could fall.
5.4 Attachments
R.218: The person with management or control of an industrial lift truck at a workplace must
ensure that the truck is equipped with lifting attachments that are suitable for the load to be lifted
or moved by the truck.
Many specialised attachments are available for industrial lift trucks such as slippers, bin lifters,
carpet spikes, jibs, spreaders and drum handlers. When an attachment is fitted to an industrial
lift truck, the centre of gravity may change, making it necessary to de-rate the lift truck capacity
and restrict some operating controls.
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This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
When selecting an attachment for an industrial lift truck, confirm with the manufacturer whether
it can be used safely on your industrial lift truck. Attachments must be designed and
manufactured by a competent person, such as an engineer, and designed for the industrial lift
truck they are used on.
The load rating for the combination of the industrial lift truck and the attachment depends on the
rating of the attachment and capacity of the lift truck. Therefore the load chart should identify the
attachment and show the corresponding capacity of the lift truck when using the attachment.
The load chart can show ratings for using more than one attachment. Attachments such as jibs
have more than one lifting point and the load chart should show the lifting capacity for each
point.
If an attachment is fitted to an industrial lift truck, make sure you have access to information on
the de-rated capacity of the industrial lift truck. By using the industrial lift truck load chart and the
information provided with the attachment, often found on the attachment’s load rating plate, the
de-rated capacity of the industrial lift truck can be calculated.
The attachment should be secured correctly on the industrial lift truck. The mast should not be
tilted forward. Using an attachment is likely to require additional training and supervision.
Holes should not be drilled or cut through attachments, for example the fork arms, as this can
weaken and destroy the integrity of the attachment. Modifications should not be carried out
unless they have been specified by a competent person, for example a mechanical engineer.
Figure 5 Drum handler
Figure 6 Jib attachment
5.5 Tandem lifting
R.219: The person with management or control of plant at a workplace must ensure, so far as is
reasonably practicable, that no load is lifted simultaneously by more than 1 item of plant unless
the method of lifting ensures that the load placed on each item of plant does not exceed the
design capacity of the plant.
Using two industrial lift trucks simultaneously to handle a common load is a dangerous and
requires extra controls in place. It is only permitted when it is not reasonably practicable to lift
the load with a single item of plant and there is no other reasonably practicable alternative.
PAGE 26 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
Where two industrial lift trucks are used in tandem to handle a common load, each industrial lift
truck should be operated by an experienced operator. The whole operation should be coordinated by a third person who is experienced and everyone has agreed is supervising the lift.
The tandem lift should be planned and discussed with the both operators before lifting starts.
The methods of signalling and other communications between those involved should also be
agreed and used. Radio communication is not sufficient unless it is kept free from interference
from other radio systems and enables clear communication at all times.
The recommended practice is that industrial lift trucks used in a tandem lift are identical. The
load applied to each industrial lift truck in a tandem lift should not exceed 75 per cent of the load
capacity of the industrial lift truck. The distance a load is carried in a tandem lift should be the
minimum necessary to load, unload or place the load.
5.6 Ramps and loading docks
Before using an industrial lift truck on an incline, for example driving the industrial lift truck onto
another vehicle, the operator should:
 ensure the brakes on the trailer or rail wagon being unloaded are set and the wheels
chocked
 check that a disconnected trailer is able to carry the combined weight of the industrial
lift truck and the load along its whole length
 inspect the trailer or rail wagon floor for defects and to assess whether the floor will
support the mass of the industrial lift truck and its load
 always place the load on the uphill side when travelling up or down an incline
 when travelling with a load, ensure the mast is tilted back sufficiently so that the load
does not slide or roll off and in the process overturn the industrial lift truck
 ensure the ramps are wide enough and maintained in good condition
 when travelling up or down an incline without a load, ensure the forks are always on
the downhill side, i.e. reverse up and drive down.
Raised edges or buffers should be fitted on loading docks and ramps where there is a risk a
wheel may be driven over an edge.
5.7 Working near electric lines
R.166: A person conducting a business or undertaking at a workplace must ensure, so far as is
reasonably practicable, that no person, plant or thing at the workplace comes within an unsafe
distance of an overhead or underground electric line.
If this is not reasonably practicable to ensure the safe distance, the person must ensure that a
risk assessment is conducted for the proposed work and control measures implemented are
consistent with the risk assessment and the requirements of an electricity supply authority
where it is responsible for the electric line.
Overhead electric lines create significant risks, including electrocution, for people operating
industrial lift trucks nearby. The following should be considered:
 Will the work mean the truck or its load could go near electric lines? If so, how high are
the lines and the truck, including any attachments?
 Contact the relevant electrical supply authority to eliminate the energised electricity risk
by isolating the electricity supply for the duration of the work
 Contact and the electrical regulatorfor information on specific requirements when
working near electric lines, including safe approach distances and qualifications
required for people working near electric lines.
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This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
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Does the industrial lift truck operator have the appropriate training and competency to
operate or direct the truck near power lines?
Overhead lines may be hard to see in the sky or hidden by trees
Is a safety observer in place to watch the industrial lift truck when it is operating close
to electric lines?
Emergency rescue procedures, including calling the electrical supply authority to
isolate the electricity supply before trying to rescue a person receiving an electric
shock.
Most risks can be addressed by observing safe working distances for people and plant working
near electric lines. Safe working distances will depend on the type of work being carried out and
the voltage of the electric lines.
Further information about electrical safety is available in the Code of Practice: Working in the
Vicinity of Overhead and Underground Electric Lines and the regulator.
Contact with energised overhead electric lines may have an impact on mechanical aspects of
the plant, for example tires, hydraulic, electrical systems. The plant should be immediately
made out-of-service until the plant has been inspected by a competent person and proven to be
safe to resume normal operation.
5.8 Fuel handling and storage
If an industrial lift truck is to operate in a flammable gas atmosphere or combustible dust
atmosphere, it should comply with the relevant standard, including the requirements for use in
hazardous areas. Liquid fuel should be handled and stored in accordance with the relevant
standard for the handling and storage of flammable and combustible liquids. Liquefied
Petroleum Gas (LPG) should be handled and stored in accordance with the relevant standards.
 Industrial lift trucks powered by an LPG engine should be refuelled, parked and stored
in well-ventilated areas a safe distance from combustible material, heat sources,
ignition sources or open pits, unless the pits are adequately ventilated.
Only people who have received relevant training should remove empty LPG cylinders from
industrial lift trucks and install full LPG cylinders. Cylinders should be positioned so that the
safety relief valve is in direct communication with the vapour space of the cylinder at all times,
so that if the relief valve operates it will release vapour and not liquid.
The cylinder valve should be turned off when the industrial lift truck is not in use.
5.9 Battery charging and changing
Only people who have received relevant training should be permitted to charge and change
batteries on industrial lift trucks. Personal protective equipment to prevent eye or skin injury
from battery acid can include face shields, aprons and rubber gloves. Where personal protective
equipment is provided for use the worker must, so far as the worker is reasonably able, use or
wear the equipment in accordance with information, training or reasonable instruction provided
by the person conducting the business or undertaking.
The industrial lift truck should be parked in a safe position and the parking brake applied before
battery-charging operations begin. Operators should ensure the vent caps in the batteries are
functioning correctly and remain in place during charging to prevent electrolyte spraying.
The cover over the battery should be held open while the battery is on charge to allow
generated gases to escape into the atmosphere. Potentially explosive hydrogen gas is freely
generated during the charging process.
People involved in a battery charging operation should observe the following safety precautions:
PAGE 28 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
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no smoking
no open flames
not using mobile phones or any other such electronic device
not using metal objects that might strike a spark near battery cells
proper tools provided and used
eyes protected
rings and bracelets removed.
In areas where batteries are charged or changed, it is important that washing, including eye
washing, and cleaning-up facilities for removing acid spills or splashes are provided. If acid is
spilled a ‘spill kit’ should be available to be used to remove the hazard. If workers are splashed
with battery acid they should quickly remove contaminated clothing and flush skin with large
quantities of water.
Fire extinguishers with capacity consistent with the potential risk should be provided in the
charging area.
The area should have adequate ventilation is so that any gases generated during battery
charging are dispersed to prevent an explosive mixture developing. In areas where the
hydrogen concentration could exceed one per cent, the ventilation system should be spark free.
The charging and changing of batteries at battery charging installations should be done
according to the manufacturer’s instructions.
PAGE 29 OF 33
This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
APPENDIX A – EXAMPLES OF INDUSTRIAL LIFT TRUCKS
Figure a Counterbalanced Forklift Trucks
Figure b High-lift forklift truck
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This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
Figure c Rider seated pallet truck
Figure d Order-picking forklift trucks
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This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
Figure e Powered pedestrian-operated forklift
Figure f Side-loading forklift trucks
Figure g Container forklift truck
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This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.
DRAFT
Figure h Straddle carrier
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This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by the
Select Council on Workplace Relations (Ministerial Council). This Code will become a model WHS Code of
Practice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it is
approved by the Ministerial Council.