Product Overview

Summary: This Forklift Operation and Licence Requirements Safe Operating Procedure sets out exactly how forklifts are to be operated, supervised and licensed in your workplace, in line with Australian WHS and high‑risk work licensing requirements. It provides a clear, defensible system for safe operation, from pre-start checks through to traffic management and de-licensing unfit operators, helping you prevent incidents while staying compliant with regulator expectations.

Forklifts are one of the most common causes of serious injuries and fatalities in Australian workplaces, particularly in warehousing, logistics, manufacturing and retail distribution. This Safe Operating Procedure provides a practical, step‑by‑step framework for how forklifts must be operated, who is permitted to operate them, and how licence and competency requirements are managed. It links day‑to‑day tasks such as pre‑start inspections, loading, travel and parking with your obligations under WHS legislation and high‑risk work licensing laws, ensuring that safety is embedded into every forklift movement on site.

Beyond basic safe driving tips, this SOP helps your business control the full lifecycle of forklift operation – from verifying and recording high‑risk work licences, through to traffic management, pedestrian separation, load handling, refuelling/charging and incident response. It addresses common problem areas such as unlicensed operation, inadequate supervision of new or young workers, poor visibility in shared areas, and inconsistent pre‑start checks between shifts. By implementing this procedure, you create a consistent, auditable system that reduces the risk of collisions, tip‑overs and dropped loads, while providing clear guidance for managers and supervisors on how to enforce standards and manage non‑compliance.

Designed specifically for the Australian regulatory environment, this SOP supports businesses of all sizes to demonstrate due diligence, improve operator competency and streamline onboarding and refresher training. It can be integrated into your existing WHS management system, toolbox talks and contractor management processes, giving you confidence that forklift operations are controlled, documented and defensible in the event of an incident or regulator inspection.

Key Benefits

• Ensure only licensed, competent personnel operate forklifts in accordance with Australian high‑risk work requirements.
• Reduce the likelihood of collisions, tip‑overs and load‑handling incidents through consistent, step‑by‑step operating rules.
• Demonstrate compliance with WHS legislation, traffic management obligations and regulator expectations during audits or investigations.
• Standardise pre‑start inspections, refuelling/charging practices and shutdown procedures across all shifts and sites.
• Streamline induction, refresher training and competency assessments for forklift operators and their supervisors.

Who is this for?

• Forklift Operators
• Warehouse and Distribution Centre Managers
• Operations Managers
• Site Supervisors and Leading Hands
• WHS Managers and Advisors
• Logistics and Supply Chain Managers
• Training and Competency Coordinators
• Plant and Equipment Coordinators
• Small Business Owners using forklifts
• Facilities and Yard Managers

Hazards Addressed

• Collision between forklifts and pedestrians in shared work areas
• Forklift tip‑over due to overloading, unstable loads or unsafe driving practices
• Crush injuries from forklifts striking racking, structures, vehicles or other plant
• Falling loads caused by incorrect stacking, lifting or attachment use
• Poor visibility and blind spots in aisles, loading docks and yard areas
• Manual handling injuries from incorrect load handling or securing
• Slips, trips and falls when mounting or dismounting forklifts
• Fire and explosion risks during refuelling or battery charging
• Exposure to hazardous atmospheres in enclosed areas with internal combustion forklifts
• Psychosocial risks associated with time pressure, fatigue and inadequate supervision of operators

Included Sections

• 1.0 Purpose, Scope and Objectives
• 2.0 Definitions and Applicable Forklift Types
• 3.0 Legal and Other Requirements (WHS and High Risk Work Licensing)
• 4.0 Roles, Responsibilities and Competency Requirements
• 5.0 Licence Verification, Records and Monitoring of Currency
• 6.0 Induction, Training, Supervision and Refresher Requirements
• 7.0 Pre‑Start Safety Inspections and Fault Reporting
• 8.0 Safe Operating Procedures – Starting, Travelling and Manoeuvring
• 9.0 Load Handling – Lifting, Stacking, Unstacking and Attachments
• 10.0 Traffic Management and Pedestrian Separation Controls
• 11.0 Operating in High‑Risk Areas (Ramps, Docks, Confined Spaces, Public Interfaces)
• 12.0 Parking, Shutdown and Isolation of Forklifts
• 13.0 Refuelling, Recharging and Battery Handling Procedures
• 14.0 Maintenance, Tag‑Out and Contractor Management for Forklifts
• 15.0 Incident, Near Miss and Non‑Compliance Reporting
• 16.0 Emergency Procedures and Response to Forklift Incidents
• 17.0 Document Control, Review and Continuous Improvement

Legislation & References

• Model Work Health and Safety Act and Regulations (as implemented in each state and territory)
• Safe Work Australia – General Guide for Industrial Lift Trucks (Forklifts)
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Traffic Management in Workplaces guidance material
• State and Territory High Risk Work Licence requirements for LF and LO classes (e.g. SafeWork NSW, WorkSafe Victoria, WorkSafe QLD)
• AS 2359 series: Powered industrial trucks (where applicable)
• AS/NZS ISO 45001: Occupational health and safety management systems – Requirements with guidance for use