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Forklift (Electric) Risk Assessment

Forklift (Electric) Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
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  • • Includes 2 Years of Free Compliance Updates

Forklift (Electric) Risk Assessment

Product Overview

Identify and control organisational risks associated with electric forklift operations using this management-level Forklift (Electric) Risk Assessment, focused on planning, governance, systems and WHS oversight rather than task-by-task work instructions. This document supports executive Due Diligence under the WHS Act, helping to demonstrate proactive WHS Risk Management and reduce organisational and operational liability exposure.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance & WHS Duties: Assessment of officer due diligence, PCBU responsibilities, consultation arrangements and integration of forklift risks into the broader Safety Management System.
  • Procurement & Plant Selection: Management of purchasing criteria for electric forklifts and attachments, supplier verification, design suitability, and engineering controls prior to site introduction.
  • Site Layout & Traffic Management: Evaluation of warehouse and yard layout, segregation of pedestrians, speed control, signage, line-marking, loading zones and interaction with other mobile plant.
  • Registration, Documentation & Record Control: Protocols for plant registration (where required), manuals, risk assessments, maintenance records, licences, and document version control.
  • Competency, Licensing & Training Systems: Oversight of high-risk work licensing, verification of competency, induction programs, refresher training and assessment of operator fitness for duty.
  • Operating Rules, Procedures & Supervision: Development and enforcement of site-specific operating procedures, load handling rules, exclusion zones, and supervisory monitoring of operator behaviour.
  • Inspection, Pre-Use Checks & Maintenance: Systems for scheduled servicing, pre-start inspections, fault reporting, isolation of unsafe plant and contractor management for maintenance providers.
  • Battery Charging, Electrical & Fire Safety: Management of charging station design, ventilation, spill control, electrical safety, fire detection and suppression, and emergency shut-down arrangements.
  • Ergonomics, Fatigue & Workload: Assessment of seating and control layout, visibility, shift patterns, break scheduling, repetitive movements and workload planning to minimise human error and strain.
  • Contractor, Labour-Hire & Visitor Interaction: Controls for onboarding external operators, verifying competencies, communicating site rules, and managing visitor exposure to forklift operating areas.
  • Incident Reporting & Corrective Action: Systems for reporting near misses and incidents, root-cause investigation, trend analysis and implementation of corrective and preventive actions.
  • Emergency Preparedness & Response: Planning for collisions, rollovers, battery fires, medical emergencies and evacuations, including communication protocols and emergency equipment readiness.
  • Change Management & Continuous Improvement: Formal processes for assessing WHS impacts of new forklifts, layout changes, new attachments or processes, and ongoing review of risk controls and KPIs.

Who is this for?

This Risk Assessment is designed for Business Owners, Warehouse and Operations Managers, and Safety Professionals responsible for planning, approving and overseeing electric forklift operations across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Safety Management System
  • • Lack of clear allocation of WHS duties for Persons Conducting a Business or Undertaking (PCBUs), officers, managers and supervisors in relation to pedestrian operated electric forklifts
  • • Inadequate WHS policies or procedures specifically addressing powered mobile plant and forklift operations in accordance with WHS Act 2011 and WHS Regulations
  • • Poor integration of forklift risks into the overall Safety Management System (SMS), risk register and consultation processes
  • • Failure to provide adequate resources (time, budget, competent personnel) to manage forklift risks at a systemic level
  • • Absence of formal WHS objectives, KPIs and performance monitoring for forklift-related incidents, near misses and compliance activities
2. Procurement, Design and Selection of Forklifts and Attachments
  • • Procurement of pedestrian operated electric forklifts that are not fit for purpose or not compliant with relevant Australian Standards and WHS Regulations
  • • Inadequate consideration of operating environment (e.g. gradients, floor surfaces, aisle widths, racking, doorways, loading docks) when selecting equipment
  • • Lack of formal assessment of load types, dimensions and weights leading to inappropriate capacity selection or use of unsuitable attachments
  • • Failure to obtain and retain manufacturer’s information, instructions, load charts and safe operating limits
  • • Purchase of forklifts with controls, visibility or safety features that are not compatible with the site’s pedestrian traffic patterns and controls
3. Site Layout, Traffic Management and Pedestrian Interaction
  • • Inadequate traffic management planning for interaction between pedestrian operated electric forklifts and pedestrians or other vehicles
  • • Poorly designed or congested aisles, crossings, doorways and loading areas increasing the likelihood of collision, crushing or trapping incidents
  • • Lack of clear separation between forklift travel paths and pedestrian walkways in high foot-traffic areas
  • • Insufficient signage, floor markings and visual cues to indicate forklift operating zones, exclusion zones and speed-restricted areas
  • • Inadequate control of access to forklift operating areas by unauthorised personnel, visitors or contractors
4. Plant Registration, Documentation and Record Management
  • • Failure to maintain required documentation for electric forklifts, including manuals, inspection records and maintenance history
  • • Lack of a central system to track plant status, availability, defects and out-of-service notifications
  • • Inability to demonstrate compliance with WHS Act and WHS Regulation requirements in the event of an incident or regulator enquiry
  • • Use of forklifts without current inspection or maintenance records, increasing the likelihood of unrecognised mechanical faults
5. Competency, Licensing, Induction and Training
  • • Insufficient training and assessment of workers operating or working around pedestrian operated electric forklifts
  • • Reliance on informal or on-the-job instruction without structured competency assessment or refresher training
  • • Lack of site-specific induction covering local traffic rules, pedestrian interactions, emergency procedures and equipment-specific controls
  • • Failure to verify competency of labour-hire workers, contractors or temporary staff who may operate or work near forklifts
  • • Inadequate training for supervisors and managers responsible for enforcing forklift safety procedures
6. Operating Rules, Procedures and Supervision
  • • Absence of clear, documented operating rules for pedestrian operated electric forklifts, leading to inconsistent and unsafe practices
  • • Inadequate supervision or enforcement of safe operating procedures, particularly in high-demand or time-pressured periods
  • • Informal shortcuts becoming normalised, such as operating outside designated areas or handling loads beyond rated capacity
  • • Lack of clear rules for interaction with pedestrians, including communication, right-of-way and exclusion zones
7. Inspection, Pre-Use Checks and Maintenance Systems
  • • Failure to detect mechanical or electrical faults due to lack of systematic inspections and servicing
  • • Inadequate process for reporting, recording and rectifying defects identified during pre-use checks
  • • Use of forklifts beyond their service intervals or contrary to manufacturer’s maintenance requirements
  • • Reliance on unqualified personnel for critical maintenance tasks, increasing likelihood of latent failures
8. Battery Charging, Electrical Safety and Fire Risk Management
  • • Inadequate controls around battery charging areas leading to exposure to electrical hazards, fire risk or hazardous atmospheres (e.g. gassing from certain battery types)
  • • Poor housekeeping or storage practices around charging stations increasing the risk of fire spread or trip hazards
  • • Insufficient procedures for managing damaged batteries, power cords, charging equipment or emergency response for electrical incidents
  • • Use of unsuitable power outlets, extension leads or adaptors creating overload or shock risks
9. Ergonomics, Fatigue and Workload Management
  • • Poor ergonomic design of controls, handles or operating postures leading to musculoskeletal disorders for pedestrian operators
  • • High work pace, extended shifts or repetitive movements associated with frequent forklift use contributing to fatigue and reduced attention
  • • Insufficient planning of staffing levels and task rotation resulting in over-reliance on a small number of operators
  • • Lack of consideration for environmental factors such as noise, temperature or lighting that may affect operator alertness and posture
10. Contractor, Labour-Hire and Visitor Management
  • • Contractors or labour-hire staff operating or working near forklifts without adequate induction, supervision or competency verification
  • • Inconsistent safety standards and procedures between the host PCBU and contracting organisations
  • • Visitors entering forklift operating areas without awareness of local hazards, traffic rules and emergency procedures
11. Incident Reporting, Investigation and Corrective Actions
  • • Under-reporting of forklift near misses, property damage or minor injuries, resulting in missed opportunities to identify systemic issues
  • • Inadequate incident investigation processes leading to focus on operator error rather than root causes such as system, design or management failures
  • • Failure to track completion and effectiveness of corrective actions, allowing repeat incidents to occur
12. Emergency Preparedness and Response
  • • Lack of planning for emergencies involving pedestrian operated electric forklifts, such as collisions, overturns, electrical faults or battery fires
  • • Workers and supervisors unsure of their roles and actions in the event of an emergency involving a forklift
  • • Inadequate emergency equipment or inaccessible emergency stops and isolation points in forklift operating and charging areas
13. Change Management and Continuous Improvement
  • • Introduction of new forklifts, attachments, layouts, products or work methods without reassessing risks or updating controls
  • • Modifications to forklifts, racking, traffic routes or operating hours leading to unintended consequences for safety
  • • Failure to incorporate worker feedback, incident learnings or technological advances into ongoing forklift risk management

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Model Code of Practice – Managing Risks of Plant in the Workplace: Guidance on plant lifecycle risk management, including powered industrial trucks.
  • Model Code of Practice – Managing Risks of Hazardous Chemicals in the Workplace: Relevant to battery electrolytes, charging areas and chemical spill control.
  • Model Code of Practice – Work Health and Safety Consultation, Cooperation and Coordination: Requirements for engaging workers and other duty holders in managing forklift risks.
  • AS 2359 (series) – Powered Industrial Trucks: Requirements for the safe design, operation and maintenance of forklifts.
  • AS/NZS 3000:2018 – Electrical Installations (Wiring Rules): Requirements relevant to electrical safety of charging stations and associated installations.
  • AS 4084 – Steel Storage Racking: Guidance for safe design and use of racking systems interacting with forklifts.
  • AS 3745:2010 – Planning for Emergencies in Facilities: Framework for emergency planning, response and evacuation procedures.
  • AS/NZS ISO 45001:2018 – Occupational Health and Safety Management Systems: Principles for integrating forklift risk management into the overall WHS management system.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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