BlueSafe
Forklift Work Platform Risk Assessment

Forklift Work Platform Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Forklift Work Platform Risk Assessment

Product Overview

Identify and control organisational risks associated with Forklift Work Platform operations at a management level, with a structured focus on governance, planning, equipment selection and WHS systems. This Risk Assessment supports compliance with the WHS Act, demonstrates Due Diligence, and helps protect your business from operational and legal liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, WHS Duties and Consultation: Assessment of PCBU obligations, officer due diligence, consultation with workers and HSRs, and clarity of roles and responsibilities for forklift work platform use.
  • Design, Procurement and Suitability of Forklift and Work Platform: Management of equipment selection, compatibility of forklifts and work platforms, engineering controls, and verification that plant is designed and rated for elevating personnel.
  • Risk Management, Planning and Work Authorisation: Systems for hazard identification, risk assessment, job planning, permits and formal authorisation before any person is lifted on a forklift work platform.
  • Training, Licensing, Competency and Supervision: Requirements for high risk work licensing, competency assessment, refresher training, and supervision arrangements for operators and spotters.
  • Procedures, Safe Systems of Work and Documentation: Development and control of documented procedures, work instructions, exclusion zones, communication protocols and record-keeping to support consistent safe practice.
  • Plant Maintenance, Inspection and Pre‑Use Verification Systems: Preventive maintenance programs, pre‑start checks, inspection regimes, defect reporting and isolation processes for forklifts and work platforms.
  • Site Layout, Traffic Management and Segregation: Planning of work areas, pedestrian and vehicle separation, signage, lighting, ground conditions and overhead obstructions where work platforms are used.
  • Contractor, Labour Hire and Supplier Management: Controls for engaging contractors and labour hire workers, verification of competencies, information exchange, and management of hire or leased plant.
  • Emergency Preparedness and Incident Management: Development of rescue plans for elevated persons, emergency lowering procedures, communication systems, and post‑incident investigation processes.
  • Monitoring, Review, Consultation and Continuous Improvement: Ongoing performance monitoring, safety meetings, audits, corrective actions and periodic review of forklift work platform controls.

Who is this for?

This Risk Assessment is designed for Business Owners, Operations Managers, Safety Managers and WHS Advisors responsible for planning, approving and overseeing forklift work platform activities within their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Consultation
  • • Failure of PCBUs and officers to understand and discharge primary duties under the WHS Act 2011 in relation to forklift work platforms
  • • Lack of formal WHS governance structure overseeing high‑risk plant and work at height activities
  • • Inadequate consultation with workers and Health and Safety Representatives (HSRs) about the introduction and ongoing use of forklift work platforms
  • • No clear allocation of roles, responsibilities and accountabilities between PCBUs in multi‑PCBU workplaces (e.g. host employer, labour hire provider, contractor)
  • • Poor change management when introducing, modifying or expanding the use of forklift work platforms
  • • No process for reviewing WHS performance indicators specific to forklift work platform use
2. Design, Procurement and Suitability of Forklift and Work Platform
  • • Procurement of forklifts that are not designed or rated to safely use work platforms for elevating persons
  • • Use of non‑compliant, homemade, or modified work platforms without engineering certification
  • • Incompatibility between specific forklift models and specific work platforms (e.g. capacity, attachment method, load centre)
  • • Absence of manufacturer’s instructions, design registration details or engineering verification for the work platform
  • • Failure to consider site‑specific conditions (ground conditions, gradients, overhead obstructions, traffic volumes) when selecting equipment
  • • Use of second‑hand or hired equipment without adequate verification of compliance and maintenance history
3. Risk Management, Planning and Work Authorisation
  • • Absence of a formal risk management process specific to using work platforms on forklifts
  • • Ad hoc or informal planning of tasks at height, leading to use of work platforms in unsuitable conditions
  • • No documented criteria for when forklift work platforms are permitted versus when other access methods (e.g. EWP, fixed scaffolds) must be used
  • • Inadequate pre‑task review of adjacent activities, traffic flows, and overhead hazards (e.g. powerlines, services, racking)
  • • Lack of formal work authorisation or permit process for high‑risk tasks using forklift work platforms
  • • Failure to review risk controls after incidents, near misses or significant changes to operations
4. Training, Licensing, Competency and Supervision
  • • Forklift operators holding no licence or an inappropriate High Risk Work Licence for the class of forklift being used
  • • Operators and workers in the platform not trained in safe use, emergency procedures or site‑specific rules
  • • Supervisors lacking competency to monitor, correct and enforce safe systems of work involving forklift work platforms
  • • No system to verify and record ongoing competency, refresher training and licence currency
  • • Inconsistent induction for labour hire workers, contractors and short‑term staff
  • • Reliance on informal, on‑the‑job instruction without structured competency assessment
5. Procedures, Safe Systems of Work and Documentation
  • • Lack of documented procedures governing planning, set‑up and use of forklift work platforms
  • • Procedures that are overly generic, outdated or not aligned with actual site conditions and equipment
  • • Workers unaware of or not following documented safe systems of work
  • • Inadequate instructions for abnormal or non‑routine situations (e.g. breakdowns, restricted spaces, after‑hours work)
  • • Reliance on verbal directions or custom and practice rather than controlled documents
  • • No formal system for version control and communication of updates to procedures
6. Plant Maintenance, Inspection and Pre‑Use Verification Systems
  • • Failure to maintain forklifts and work platforms to manufacturer’s specifications and WHS Regulation requirements
  • • Absence of scheduled inspections for lifting attachments, locking mechanisms, safety chains and guard rails
  • • No systematic pre‑use verification that plant is fit for purpose and correctly configured for elevating persons
  • • Inadequate management of defects, leading to operation with compromised safety features
  • • Incomplete records of maintenance, inspection and repairs, making it difficult to verify plant safety
  • • Use of damaged or modified equipment without engineering review
7. Site Layout, Traffic Management and Segregation
  • • Inadequate separation between forklifts using work platforms and pedestrians or other mobile plant
  • • Poorly planned travel routes requiring forklifts with elevated platforms to move through congested or shared areas
  • • Insufficient signage, line marking and physical barriers to control the movement of plant and people
  • • Blind spots, tight turning areas and racking layouts that increase collision risks when persons are elevated
  • • Lack of coordination between different work groups and contractors using mobile plant in the same area
  • • Operating forklift work platforms in unsuitable ground or surface conditions (e.g. uneven, soft, contaminated surfaces)
8. Contractor, Labour Hire and Supplier Management
  • • Contractors and labour hire workers operating forklifts or using work platforms without equivalent training and competency to direct employees
  • • Assumptions between PCBUs that another party is managing key risks such as maintenance, training or supervision
  • • Suppliers delivering or installing plant without appropriate induction to site‑specific controls
  • • Inconsistent application of site rules and procedures to external parties
  • • Limited oversight of third‑party maintenance providers performing critical work on forklifts and work platforms
9. Emergency Preparedness and Incident Management
  • • Lack of specific emergency procedures for incidents involving persons in elevated forklift work platforms
  • • Workers and supervisors not trained in how to respond to plant failures, medical events or falls from the platform
  • • Absence of appropriate rescue equipment or arrangements, leading to delayed response
  • • Ineffective communication systems between platform occupants, operators and emergency responders
  • • Inadequate incident reporting and investigation processes for events involving high‑risk plant
  • • No coordination of emergency plans with neighbouring PCBUs or emergency services where shared sites exist
10. Monitoring, Review, Consultation and Continuous Improvement
  • • Static WHS systems that do not adapt to operational changes, new equipment or emerging risks
  • • Limited worker input into the effectiveness of controls for forklift work platforms
  • • Inadequate monitoring of leading and lagging indicators for plant and work at height risks
  • • Failure to learn from incidents in the same or similar industries using forklift work platforms
  • • Audit and inspection programs not targeting high‑risk activities such as elevating persons on forklifts

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

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 controlling risks associated with plant, including forklifts and work platforms.
  • Model Code of Practice – Work health and safety consultation, cooperation and coordination: Requirements for consultation and coordination between PCBUs, workers and contractors.
  • Model Code of Practice – How to manage work health and safety risks: Framework for risk management, including identification, assessment and control of hazards.
  • AS 2359 (Series) – Powered industrial trucks: Requirements for the safe design, operation and maintenance of forklifts.
  • AS 2550.10: Cranes, hoists and winches – Safe use – Mobile elevating work platforms (referenced for elevating personnel principles where relevant).
  • AS/NZS ISO 45001:2018: Occupational health and safety management systems – Requirements with guidance for use.
  • 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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