Product Overview

Summary: This Forklift Operation Safe Operating Procedure provides a clear, step-by-step framework for operating forklifts safely and efficiently in Australian workplaces. It helps businesses control high-risk plant hazards, meet WHS obligations, and protect workers, visitors, and property from incidents involving powered industrial trucks.

Forklifts are among the most common—and most dangerous—pieces of mobile plant in Australian workplaces, frequently involved in serious crush injuries, collisions and property damage. This Forklift Operation Safe Operating Procedure sets out a practical, repeatable method for planning, conducting and monitoring forklift activities in warehouses, yards, loading docks, construction sites and manufacturing environments. It gives operators and supervisors a shared, plain-English reference that aligns with Australian WHS requirements and recognised industry good practice.

The SOP guides users through pre-start inspections, safe route planning, load assessment, lifting and stacking techniques, traffic management, interaction with pedestrians, and shutdown/parking requirements. It also embeds critical controls such as exclusion zones, spotter use, reversing protocols and communication standards. By implementing this procedure, businesses can reduce the likelihood of serious incidents, demonstrate due diligence to regulators and insurers, and improve the overall efficiency and professionalism of their materials handling operations.

Key Benefits

• Reduce the risk of collisions, tip-overs and crush injuries involving forklifts and pedestrians.
• Ensure consistent, compliant forklift operation across shifts, sites and labour-hire personnel.
• Support WHS due diligence by documenting how high-risk plant is operated and controlled.
• Improve productivity by standardising load handling, travel routes and stacking practices.
• Strengthen induction and refresher training with a clear, auditable reference document.

Who is this for?

• Forklift Operators
• Warehouse Supervisors
• Logistics and Distribution Managers
• Site Supervisors
• Operations Managers
• WHS Managers and Advisors
• Transport and Freight Coordinators
• Manufacturing Supervisors
• Construction Site Managers

Hazards Addressed

• Collision between forklifts and pedestrians or other vehicles
• Forklift tip-over due to overloading, unstable loads or unsafe driving
• Crush injuries between forklifts and fixed structures or racking
• Falling loads during lifting, stacking or transport
• Poor visibility and blind spots, particularly when reversing or in congested areas
• Slips, trips and falls when mounting or dismounting the forklift
• Exposure to exhaust emissions from internal combustion forklifts in enclosed areas
• Noise and vibration exposure during extended forklift operation
• Property damage to racking, stock, plant and building structures

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Applicable Forklift Types
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Licensing, Authorisation and Training Requirements
• 5.0 Required PPE and Safety Equipment
• 6.0 Pre-Start Checks and Forklift Condition Inspection
• 7.0 Work Area Assessment and Traffic Management Controls
• 8.0 Safe Mounting, Dismounting and Operator Positioning
• 9.0 Load Assessment, Capacity and Stability Requirements
• 10.0 Safe Lifting, Carrying, Stacking and Unloading Procedures
• 11.0 Travelling, Speed Limits, Corners, Ramps and Reversing
• 12.0 Working Around Pedestrians, Spotters and Other Mobile Plant
• 13.0 Operating in Special Conditions (confined spaces, docks, outdoors, poor visibility)
• 14.0 Parking, Shutdown and Securing the Forklift
• 15.0 Hazard Identification, Risk Controls and Prohibited Practices
• 16.0 Incident, Near Miss and Damage Reporting Requirements
• 17.0 Maintenance, Fault Reporting and Tag-Out Procedures
• 18.0 Recordkeeping, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (including provisions for high risk plant and traffic management)
• 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 – Code of Practice: Traffic Management in Workplaces
• AS 2359 series: Powered industrial trucks
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)
• ISO 45001: Occupational health and safety management systems (where adopted by the business)