Worker crushed by loads when operating a pallet jack on a slope (13 September 2023)
A 49-year-old man was seriously injured while moving a loaded pallet down a concrete ramp with another worker. The man was using a manual pallet jack to move a pallet of 48 bags of rapid screed grout, each weighing 20kg and with a total weight of approximately 960kg. The pallet jack and load rolled away from the workers, causing one of the men to be crushed between the uncontrolled loaded pallet and another pallet of goods.
Safety information
Each year people suffer serious and fatal injuries in NSW due to incidents involving the uncontrolled movement (roll away) of mobile plant.
While the use of a pallet jack may be simple, the operation of a manual pallet jack is a hazardous manual task as high forces are often required to move or stop the load. If operating on inclined floors the forces required to maintain control of the load and to ensure it can be safely brought to a stop are greater.
Consider ‘reasonably practicable’ control measures to manage the risks associated with moving loads on slopes using manually operated mobile plant including pallet jacks, to reduce the risk of workers and others being struck or crushed by loads.
Ensure:
- you refer to the manufacturer’s information to ensure the pallet jack is safely operated and to assist in implementing suitable controls when used on unlevel floors such as:
- the maximum allowable slope
- the correct direction of travel
- safe operator position/location (including other workers that may be assisting)
- how to stop the pallet jack in an emergency (for example lowering the forks so that the pallet contacts the ground).
- workers are provided with information, training and supervision for the tasks they undertake
- the correct plant is available for use, taking the task, risk assessments and site conditions into consideration
- the use of electric powered pallet jacks, or manual powered pallet jacks fitted with brakes, if operating on uneven surfaces is a regular practice
- all plant used is fit for purpose and serviced as per the manufacturer's specifications.
Related guidance material
- Choosing and using trolleys – WorkSafe Vic
- Working with or around mobile plant
- Code of Practice: Managing the risks of plant in the workplace (PDF, 1987.96 KB)
- Hazardous manual tasks (PDF, 1499.23 KB)
- Workplace traffic management – Safe Work Australia
- AFITA-011 – Using hand pallet trucks on an incline – Australian Forklift & Industrial Truck Association