Product Overview

Summary: This SOP sets out clear, step-by-step requirements for operating forklifts safely within Australian timber mills, where heavy loads, uneven surfaces and high traffic create elevated risk. It helps businesses control critical hazards, protect workers and visitors, and demonstrate due diligence under WHS legislation while maintaining efficient product flow through the mill.

Forklift operation in a timber mill is very different from working in a standard warehouse. Operators are constantly navigating rough yard surfaces, variable weather, stacked packs of timber, log decks, loading bays and shared zones with trucks, pedestrians and mobile plant. This Safe Operating Procedure provides a structured, practical framework for managing those risks, from pre-start inspections and traffic management to stacking timber packs and working around log yards, kilns and processing lines.

Developed for the Australian timber industry, this SOP helps businesses align day‑to‑day forklift use with WHS laws, Australian Standards and industry best practice. It addresses common pain points such as near misses between forklifts and pedestrians, unstable or shifting timber loads, damage to stock and infrastructure, and inconsistent operator practices between shifts and sites. By implementing this procedure, you create a consistent, defendable system of work that supports safe productivity, improves operator competency and provides clear evidence of risk management in the event of an incident or regulator visit.

Key Benefits

• Ensure consistent, safe forklift operation across log yards, production areas and dispatch zones in timber mills.
• Reduce the likelihood of collisions, tip-overs and falling timber loads that can result in serious injury or fatality.
• Demonstrate compliance with WHS legislation, Australian Standards and industry expectations for mobile plant safety.
• Improve traffic flow, loading efficiency and stock handling while maintaining strong safety controls.
• Support effective training, induction and competency assessment for new and existing forklift operators.

Who is this for?

• Timber Mill Managers
• Production Supervisors
• Forklift Operators
• Yard Hands and Storepersons
• WHS Managers and Advisors
• Health and Safety Representatives (HSRs)
• Maintenance Supervisors
• Log Yard Coordinators
• Training and Induction Coordinators

Hazards Addressed

• Forklift collisions with pedestrians, trucks, loaders and other mobile plant
• Forklift tip-overs on uneven, sloping or soft timber yard surfaces
• Falling or shifting timber packs, logs and bundled products during lifting, transport and stacking
• Crush injuries between forklifts, timber stacks, racks and fixed structures
• Poor visibility due to large loads, stacked timber and weather conditions (dust, rain, glare)
• Struck-by incidents during truck loading and unloading operations
• Mechanical failure from inadequate pre-start checks and maintenance
• Manual handling and musculoskeletal injuries from incorrectly securing loads or adjusting forks
• Exposure to noise, dust, and vibration during extended forklift operation
• Fatigue and reduced alertness during long shifts or high‑pressure production periods

Included Sections

• 1.0 Purpose and Scope – Forklift Operation in Timber Mills
• 2.0 References, Legislation and Definitions
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Operators, Spotters, Maintenance)
• 4.0 Competency, Licensing and Training Requirements for Forklift Operators
• 5.0 Timber Mill and Yard Traffic Management Requirements
• 6.0 Pre-Start Inspections and Forklift Safety Checks
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Load Assessment, Fork Positioning and Stability for Timber Products
• 9.0 Safe Driving Practices in Yards, Sheds and Production Areas
• 10.0 Stacking, Unstacking and Storage of Timber Packs and Logs
• 11.0 Truck Loading and Unloading Procedures (Flatbeds, Curtainsiders, Containers)
• 12.0 Operating Near Log Yards, Kilns, Saws and Other Mobile Plant
• 13.0 Working Around Pedestrians, Visitors and Restricted Zones
• 14.0 Environmental Considerations (Weather, Lighting, Surface Conditions, Dust)
• 15.0 Parking, Shutdown and Isolation of Forklifts
• 16.0 Hazard Identification, Risk Assessment and Control Measures
• 17.0 Incident, Near Miss and Damage Reporting Requirements
• 18.0 Emergency Procedures (Collisions, Tip-Overs, Spills and Injuries)
• 19.0 Inspection, Maintenance and Fault Reporting for Forklifts
• 20.0 Recordkeeping, Review and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations – Part 4.5 Powered Mobile Plant
• Safe Work Australia – General Guide for Industrial Lift Trucks
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing the Risks of Falls at Workplaces
• AS 2359 series: Powered industrial trucks
• AS/NZS 4801: Occupational health and safety management systems (superseded but still widely referenced)
• AS/NZS 45001: Occupational health and safety management systems – Requirements with guidance for use
• Relevant state and territory High Risk Work Licensing requirements for forklift operation (e.g. LF licence)