Product Overview

Summary: This Safe Operating Procedure sets out a clear, step-by-step approach for operating forklifts safely within metal fabrication workshops, yards and warehouses. It focuses on controlling high-risk interactions between mobile plant, heavy steel products and people, helping Australian businesses meet WHS duties while maintaining efficient material handling and production flow.

Forklift use in metal fabrication environments presents a unique combination of risks: heavy and irregular steel loads, congested workshop layouts, overhead lifting equipment, hot work areas and frequent interaction with pedestrians. This Forklift Operations in Metal Fabrication SOP provides a practical, workshop-ready procedure that addresses these specific challenges, from pre-start checks and load handling to traffic management and coordination with cranes and welding bays. It is designed to integrate seamlessly into existing WHS systems and toolbox talks, giving operators and supervisors a shared, consistent way of working.

The document helps metal fabrication businesses demonstrate due diligence under Australian WHS legislation by clearly defining how forklifts are to be used, who is authorised to use them, and what controls must be in place before, during and after operation. It tackles common pain points such as near misses in tight aisles, damage to fabricated components, unstable or over-length loads, and confusion around right-of-way between pedestrians, forklifts and overhead cranes. With this SOP in place, you can improve safety performance, reduce downtime from incidents and equipment damage, and support a higher standard of training and contractor management across your site.

Whether you operate a small fabrication workshop or a large multi-bay facility with indoor and outdoor storage, this SOP provides a structured framework for planning forklift movements, managing high-risk tasks like loading trucks with steel bundles or plate, and coordinating with other high-energy activities such as cutting, grinding and welding. It is written in clear, practical language suitable for frontline workers while still aligning with relevant Australian Standards and industry best practice.

Key Benefits

• Reduce the risk of collisions, crush injuries and near misses between forklifts, pedestrians and other plant in metal fabrication areas.
• Ensure consistent, compliant forklift operation aligned with Australian WHS legislation and relevant Standards.
• Improve load stability and product protection when handling heavy, awkward or over-length steel components and fabricated assemblies.
• Streamline training and induction for new forklift operators, labour hire workers and contractors entering the workshop or yard.
• Minimise equipment damage, unplanned downtime and costly rework arising from unsafe lifting, stacking and transport of metal products.

Who is this for?

• Workshop Managers
• Fabrication Supervisors
• Forklift Operators
• Yard Hands and Storepersons
• WHS Managers and Coordinators
• Production Managers
• Safety Representatives and HSRs
• Operations Managers in Metal Fabrication
• Maintenance Supervisors
• Training and Induction Coordinators

Hazards Addressed

• Collision between forklifts and pedestrians in workshops, yards and loading zones
• Crush injuries from forklifts contacting fixed structures, racking, steel stacks or vehicles
• Load instability and dropped loads when handling long, uneven or banded steel products
• Tipping of forklifts due to overloading, poor load placement or uneven surfaces
• Struck-by hazards from protruding or over-length loads in narrow aisles or doorways
• Interaction between forklifts and overhead cranes or hoists in shared work zones
• Reduced visibility due to large loads, poor lighting or blind corners within the workshop
• Noise, fumes and heat interaction with welding, cutting and grinding activities
• Manual handling strains from incorrect assisting of forklift operations (e.g. steadying loads by hand)
• Property damage to racking, fabricated components, vehicles, doors and building structures

Included Sections

• 1.0 Purpose and Scope – Forklift Operations in Metal Fabrication
• 2.0 Definitions and Abbreviations (e.g. rated capacity, load centre, exclusion zone)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Licensing, Authorisation and Training of Forklift Operators
• 5.0 Pre-Start Inspections and Fault Reporting
• 6.0 Workshop and Yard Traffic Management Requirements
• 7.0 Load Assessment, Planning and Stability for Metal Products
• 8.0 Safe Operating Procedure – Driving, Manoeuvring and Parking
• 9.0 Handling Long, Oversized and Irregular Steel Loads
• 10.0 Interaction with Overhead Cranes, Hoists and Other Plant
• 11.0 Working Around Pedestrians, Contractors and Visitors
• 12.0 Loading and Unloading Trucks and Delivery Vehicles
• 13.0 Operating on Ramps, Dock Areas and Outdoor Surfaces
• 14.0 Use of Attachments (e.g. jib attachments, slippers, clamps) and Limitations
• 15.0 Housekeeping, Stacking and Storage of Steel Materials
• 16.0 Personal Protective Equipment (PPE) Requirements
• 17.0 Hazard Identification, Risk Assessment and Control Measures
• 18.0 Emergency Procedures, Incident Response and Reporting
• 19.0 Maintenance, Tag-Out and Isolation of Faulty Forklifts
• 20.0 Recordkeeping, Audit and Review of Forklift Operations SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (Cth and relevant state/territory variants)
• Safe Work Australia – General Guide for Industrial Lift Trucks
• Safe Work Australia – Code of Practice: Managing the Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks in Warehousing and Storage (where applicable to steel storage)
• AS 2359 series: Powered industrial trucks
• AS/NZS 4801: Occupational health and safety management systems (superseded but still widely referenced)
• ISO 45001: Occupational health and safety management systems (where adopted by the business)