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Forklift Gas And Fuel Risk Assessment

Forklift Gas And Fuel 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 Gas And Fuel Risk Assessment

Product Overview

Identify and control organisational risks associated with Forklift Gas and Fuel operations through a structured, management-level WHS Risk Management framework that focuses on planning, systems and governance rather than task-by-task instructions. This Risk Assessment supports officers and PCBUs in demonstrating Due Diligence, meeting WHS Act obligations, and reducing operational liability linked to fuel, LPG and battery-powered forklift fleets.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance & WHS Duties: Assessment of officer due diligence, PCBU responsibilities, consultation duties, and overarching WHS governance for gas, fuel and battery-powered forklift operations.
  • Procurement & Design of Forklifts and Fuel Systems: Management of specification, selection and commissioning of forklifts, LPG systems, fuel tanks and associated plant to ensure compliance with Australian Standards and manufacturer requirements.
  • Fuel & LPG Storage, Handling and Refuelling Infrastructure: Evaluation of fixed and portable fuel/LPG storage, decanting points, bowsers, cylinder cages and ventilation to minimise fire, explosion and environmental risks.
  • Battery Charging Systems for Electric Forklifts & Stackers: Assessment of charging room design, ventilation, electrical safety, hydrogen gas build‑up, spill containment and segregation from ignition sources.
  • Operating Environment & Traffic Management: Management of interactions between forklifts, pedestrians and vehicles in areas where refuelling, cylinder change‑outs or battery charging occur, including zoning, signage and exclusion controls.
  • Operator Competency, Licensing & Fuel/Gas Awareness: Protocols for verifying high-risk work licences, competency in fuel and LPG hazards, and ongoing training and supervision for operators and spotters.
  • Refuelling, LPG Cylinder & Battery Replacement Procedures: Standardisation of safe systems of work for changing cylinders, refuelling, connecting/disconnecting hoses and swapping batteries, including isolation and lock‑out requirements.
  • Inspection, Maintenance & Integrity of Fuel and Battery Systems: Controls for scheduled inspections, leak detection, pressure testing, electrical checks and defect management for tanks, lines, valves, chargers and batteries.
  • Incident Reporting, Emergency Preparedness & Spill Response: Planning for gas leaks, fuel spills, fires, explosions and battery failures, including emergency equipment, drills, communication protocols and post‑incident review.
  • Change Management & Continuous Improvement: Systems for managing changes in fuel types, storage locations, equipment upgrades, layout alterations and contractor use, supported by monitoring, audits and performance review.

Who is this for?

This Risk Assessment is designed for Business Owners, Operations Managers, Fleet Managers and Safety Professionals responsible for planning, approving and overseeing forklift gas, fuel and battery operations across warehouses, logistics hubs and industrial sites.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Legislative Compliance
  • • Failure of PCBU and officers to understand and discharge WHS Act 2011 duties in relation to LPG and petrol/diesel for forklifts
  • • Absence of a documented WHS management plan specifically addressing gas and fuel for forklifts and other powered industrial trucks
  • • Inadequate integration of forklift gas and fuel risks into the organisation’s overall risk management framework and WHS consultation processes
  • • Lack of clarity around responsibilities between host employer, labour‑hire providers, contractors and site controllers for fuel storage, change‑out and emergency response
  • • Non‑compliance with relevant Australian Standards and codes of practice for storage and handling of flammable and combustible liquids and LP Gas
2. Procurement, Design and Specification of Forklifts and Fuel Systems
  • • Selection of forklifts with inappropriate fuel type (LPG, petrol, diesel, battery electric) for the environment, such as internal combustion units used in poorly ventilated or hazardous areas
  • • Purchase or lease of forklifts, order pickers, pallet stackers and truck‑mounted forklifts without adequate engineering controls for fuel system integrity and fire protection
  • • Use of non‑compliant or incompatible LPG cylinders, regulators, hoses and fittings for forklifts
  • • Insufficient consideration of battery type, charging system and ventilation when procuring electric forklifts and pallet stackers
  • • Failure to specify requirements for counterbalance design, load capacity and stability in conjunction with fuel tank location and weight
  • • Inadequate assessment of how forklifts transporting scrap metal or operating on uneven surfaces may increase tipping risk when fuel tanks are full or partially full
3. Fuel and LPG Storage, Handling and Refuelling Infrastructure
  • • Inadequate design and management of LPG cylinder storage areas for forklifts leading to fire, explosion or gas exposure
  • • Non‑compliant storage of petrol or diesel used for forklifts and truck‑mounted forklifts (e.g. unbunded, poor segregation, inappropriate containers)
  • • Lack of segregation between fuel storage/refuelling points and battery charging areas for electric forklifts, creating ignition and explosion risks
  • • Poorly designed refuelling and gas‑change stations with inadequate ventilation, traffic separation, signage and spill management
  • • Uncontrolled ignition sources such as smoking, hot work or vehicles near gas and fuel storage
  • • Inadequate housekeeping around fuel and gas storage leading to accumulation of combustible materials or damaged cylinders and containers
4. Battery Charging Systems for Electric Forklifts and Pallet Stackers
  • • Inadequately designed battery charging areas for electric forklifts, order pickers and pallet stackers leading to hydrogen accumulation, fire or explosion
  • • Poor ventilation and lack of monitoring of charging rooms used for high‑reach forklifts and order pickers
  • • Absence of systems for managing electrolyte spills, damaged batteries or incorrect charging setups
  • • Uncontrolled ignition sources, including forklift traffic, hot work or electrical equipment not rated for hazardous atmospheres within charging areas
  • • Inadequate separation between battery charging areas and LPG/fuel storage or refuelling points
  • • Insufficient training and procedures for safe battery charging, battery replacement, and isolating equipment before maintenance
5. Operating Environment, Traffic Management and Fuel‑Related Interactions
  • • Poorly planned traffic management systems resulting in forklifts refuelling or changing LPG cylinders in congested or pedestrian‑heavy zones
  • • Inadequate separation between forklift operating routes (including scrap metal transport routes) and fuel or LPG storage areas
  • • Use of internal combustion forklifts in confined or poorly ventilated areas causing accumulation of exhaust gases and potential ignition of vapours
  • • Inappropriate locations for stopping, parking, and dismounting from forklifts near fuel storage or battery charging areas
  • • No systematic assessment of how gradients, uneven ground and load characteristics (e.g. scrap metal, high‑reach loads) affect tipping risk when combined with fuel tank placement and weight
  • • Limited controls for order picker forklifts and pallet stackers operating near refuelling or battery charging zones, increasing collision and impact risks
6. Operator Competency, Training and Licensing for Fuel and Gas Risks
  • • Forklift, order picker and pallet stacker operators lacking formal licensing, verification of competency or role‑specific training on gas and fuel hazards
  • • Inadequate training on the impact of counterbalance, load distribution and fuel tank location on forklift stability and tipping risk
  • • Poor understanding of correct mounting and dismounting techniques, particularly when forklifts are positioned near fuel storage, refuelling or charging points
  • • Limited knowledge of safe operation of high‑reach, truck‑mounted and order picker forklifts in proximity to fuel and LPG infrastructure
  • • Operators and spotters unaware of emergency procedures for fuel leaks, LPG leaks, battery failures or fires associated with forklifts
  • • Insufficient supervision and monitoring of new or labour‑hire operators to ensure compliance with site‑specific fuel and gas procedures
7. Procedures for Refuelling, LPG Cylinder Management and Battery Replacement
  • • Absence of clear, documented procedures for refuelling forklifts and changing LPG cylinders leading to unsafe practices
  • • Inconsistent practices between shifts, sites and labour‑hire workers concerning gas cylinder connection, leak checking and storage
  • • Improvised or ad‑hoc methods for replacing or recharging batteries on electric forklifts, order pickers and pallet stackers
  • • Failure to ensure forklifts are safely parked, isolated and stabilised before refuelling, LPG change‑out or battery replacement
  • • Over‑reliance on informal on‑the‑job instruction with no verification that workers understand fuel and gas procedures
  • • No systematic process for controlling and tracking keys, access cards or approvals for those performing fuel, LPG or battery change tasks
8. Inspection, Maintenance and Integrity Management of Fuel and Battery Systems
  • • Lack of systematic inspection and preventative maintenance for forklift fuel systems, LPG components and batteries
  • • Use of damaged or out‑of‑test LPG cylinders on forklifts and truck‑mounted forklifts
  • • Undetected leaks, corrosion, chafed hoses, loose fittings or damaged tanks due to absence of structured inspection programs
  • • Inadequate maintenance of battery systems leading to overheating, gassing, electrical faults or loss of capacity on high‑reach forklifts, order pickers and pallet stackers
  • • Poor record keeping for defects, repairs and scheduled maintenance on forklifts and associated fuel infrastructure
  • • Reliance on operators alone to identify major fuel and gas defects without competent technical oversight
9. Incident Reporting, Emergency Preparedness and Spill Response
  • • No structured system for reporting, investigating and learning from fuel leaks, LPG releases, fires, near misses or battery failures involving forklifts
  • • Inadequate emergency response planning for fuel and gas incidents, including evacuation, first aid and communication with emergency services
  • • Insufficient availability of suitable spill response equipment and fire protection for fuel and LPG‑related emergencies
  • • Workers untrained in recognising early warning signs of gas leaks, overheating batteries, fuel system defects or tipping events linked to fuel load
  • • Lack of scenario‑based drills incorporating forklift fuel fires, LPG leaks or battery incidents near charging and refuelling infrastructure
  • • Failure to coordinate emergency arrangements with neighbouring businesses or shared facilities where fuel and LPG risks may be interdependent
10. Change Management, Monitoring and Continuous Improvement
  • • Uncontrolled introduction of new forklifts, fuels, battery technologies or storage configurations without risk assessment
  • • Failure to review and update WHS controls when work practices change, such as expansion of scrap metal transport, increased use of high‑reach forklifts or new battery charging equipment
  • • Inadequate monitoring of leading and lagging indicators related to forklift fuel and gas safety performance
  • • Lack of consultation with workers and health and safety representatives when changing procedures or infrastructure related to fuel, LPG or battery charging
  • • Drift from established procedures over time due to production pressure, poor supervision or conflicting KPIs
  • • Inconsistent application of lessons learned from incidents or audits across multiple sites or business units

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • Safe Work Australia – Managing Risks of Plant in the Workplace Code of Practice: Guidance on controlling risks associated with plant, including forklifts and associated fuel systems.
  • Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace Code of Practice: Requirements for storage, handling and use of fuels, LPG and battery electrolytes.
  • Safe Work Australia – Managing the Risk of Falls and Powered Mobile Plant in the Workplace (relevant guidance): Controls for powered mobile plant interactions, traffic management and operating environments.
  • AS 2359 (Series) – Powered Industrial Trucks: Requirements for the design, safe use, maintenance and inspection of forklifts.
  • AS/NZS 1596: The storage and handling of LP Gas.
  • AS 1940: The storage and handling of flammable and combustible liquids.
  • AS/NZS 3012: Electrical installations — Construction and demolition sites (referenced for safe temporary electrical and charging installations).
  • AS 3780: The storage and handling of corrosive substances (relevant to battery electrolytes and charging areas).
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

$79.5

Safe Work Australia Aligned