Forklifts

Learn about forklift risks, safety standards, licensing and practical steps employers, operators and nearby workers can take to prevent injuries.

What are forklifts?

A forklift is a powered vehicle with a mast and forks or other attachments at the front.

These features enable a forklift to lift, lower and move loads, such as pallets, crates and other heavy items.

Most forklifts are controlled by human operators and are used in warehouses, manufacturing plants, construction sites and many other workplaces.

This page focuses on forklifts, a type of powered industrial lift truck.

Manual pallet trucks and telehandlers have different licensing, training and safety requirements. For more details see the licences section and related incident information.

Risks of forklifts

Forklifts are heavy vehicles and can travel at high speed. They often operate near people.

When incidents occur, they can cause serious injury or death.

The three main reasons workers are killed or seriously injured in forklift incidents in NSW are:

  • being hit or crushed by a forklift
  • being hit or crushed by a load that the forklift is moving, and
  • being crushed in a forklift tip-over.

Who is at risk

People are most at risk of being hit by a forklift or its load if they are:

  • walking near it
  • picking stock off a nearby shelf
  • walking in between it and a delivery vehicle
  • stepping into its path, or
  • assisting with loading or unloading.

Falling loads

Most serious injuries and deaths related to a falling load happen:

  • when the load isn’t stable on the pallet
  • because the operator didn’t use an attachment when one was needed, or
  • when workers are helping to stabilise the load or are within exclusion zones.

Tip-overs

In a sit-down counterbalance forklift tip-over or collision, operators are more likely to be killed or seriously injured if they aren’t wearing a seatbelt.

The instinct is to jump clear, but this is often how operators are crushed by the overhead guard instead.

   

Forklifts (mobile plant) are a regulatory priority for SafeWork NSW in 2026-2027. This means SafeWork NSW Inspectors will focus on forklifts when they visit workplaces to check and enforce compliance.


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Legal and licensing requirements

Forklift safety and licensing requirements are:

  • set out in work health and safety legislation, and
  • supported by relevant codes of practice, standards and guidance.

Powered mobile plant

Forklifts are regulated as powered mobile plant under the Work Health and Safety Regulation 2025 (WHS Regulation 2025).

A person who manages or controls a forklift must manage the risks of:

  • the forklift overturning
  • objects falling on the operator
  • the operator being ejected from the forklift
  • the forklift colliding with a person or object, and
  • pressurised parts failing and releasing fluid.

They must also ensure:

  • suitable operator protective devices, such as an overhead guard and seatbelt, are provided, maintained and used
  • a forklift truck is compliant with the relevant Australian Standard, and
  • an unattended forklift cannot move or be operated by an unauthorised person.

Forklift licences

A worker must have the correct high risk work licence (HRW licence) to operate a forklift. There are two licence classes:

  • LF (Forklift truck) for counterbalanced forklift trucks, reach trucks and side-loading forklift trucks.
  • LO (Order-picking forklift truck) for order-picking forklifts.

A person conducting a business or undertaking (PCBU) must develop and maintain a workplace HRW licence register.

Before allowing a worker to operate a forklift a PCBU must:

HRW licences are issued by SafeWork NSW and are valid for five years.

Read more about HRW licences and how to apply.

Manual pallet trucks and telehandlers

Workers do not need a HRW licence to operate manual pallet trucks, just site-specific training.

Workers will only need a HRW licence to operate a telehandler when the telehandler:

  • has a hook attached and is used with a crane jib for lifting loads over three tonnes, or
  • has a slewing function or work box with controls and a boom that extends more than 11 metres.

For all other telehandlers workers will only need site-specific training.

Code of practice

The minimum performance standards for managing forklift risks are detailed in SafeWork NSW’s Managing the risks of plant in the workplace (PDF, 1987.96 KB) (the Code).

Under section 26A of the Work Health and Safety Act 2011, a PCBU must comply with the Code or use another method that provides an equivalent or higher standard of work health and safety.

Please note, other SafeWork NSW Codes of practice may also apply to your workplace.

Australian Standard for forklifts

The AS 2359 (series) — Powered industrial trucks provides technical guidance on forklift design, manufacture, operation and maintenance. The Code identifies it as a relevant standard for managing forklift risks.

 

If you are a small business owner in NSW, the $1,000 SafeWork small business rebate can help you purchase eligible safety items to make your workplace safer.


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Managing the risks

Under WHS laws, a PCBU must eliminate risks to health and safety so far as is reasonably practicable or otherwise minimise them.

Use the hierarchy of controls to select the most effective measures that are reasonably practicable:

  1. Eliminate the risk where possible.
  2. If the risk cannot be eliminated, minimise it by:
    • substituting the hazard
    • isolating people from it, or
    • using engineering controls.
  3. Use administrative controls and personal protective equipment only to manage any remaining risk.

A combination of controls may be needed.

Select the headings below to see more details.

         
Separate pedestrians and forklifts

The safest workplaces physically separate people from moving forklifts, for example with guardrails or overhead walkways. Where that is not possible:

  • schedule work so forklifts and people are not in the same area at the same time
  • clearly mark walkways, pedestrian crossings and safe work zones
  • provide dedicated loading and unloading areas and exclusion zones for delivery drivers
  • keep people out of striking distance and never lift a load over a person
  • require people working nearby to use pedestrian pathways, stay visible and wait for the operator to acknowledge them before approaching or crossing, and
  • provide good standards of lighting and visibility.

Give visitors, contractors and delivery drivers clear instructions before they enter forklift areas. Use:

  • site inductions
  • designated waiting areas
  • exclusion zones, and
  • agreed loading and unloading procedures.
Plan workplace traffic
  • Put a traffic management plan (PDF, 614.31 KB) and site safety rules in place.
  • Train workers, contractors and visitors in traffic management and site safety.
  • Install warning signs, dome mirrors at intersections and blind corners, and controlled pedestrian crossings where needed.
  • Set and enforce speed limits, including walking pace near people.
  • Operators must look in the direction of travel, keep forks lowered, slow down and sound the horn at intersections, blind spots, doorways, aisle ends and passages.
  • If a load blocks the operator’s view, drive in reverse or use a trained spotter where reversing is not practical.
  • For loading docks, ramps and trailers, develop and implement safe systems of work to manage the risks associated with:
    • dock edges
    • gradients
    • bridge plates, and
    • vehicle movement.
  • Make sure trailers are secured against movement before loading or unloading.
Select suitable forklifts and attachments
  • Use a forklift with the right capacity for the load. If a load is not on a pallet or skid with proper lifting pockets, a suitable attachment may be needed.
  • Before buying, hiring or commissioning a forklift, check that it is suitable for the workplace, surfaces, loads and tasks. Read more about buying a new or second-hand forklift.
  • Check the manufacturer’s instructions, capacity plate, load rating plate, safety features, maintenance history and any attachments.
  • Supply attachments suited to the size, shape and weight of the load that have been assessed by a competent person to ensure it is the correct attachment.
  • Check the manufacturer approves the attachment use with the model of forklift.
  • Have the forklift's load capacity plate updated where required, as attachments can reduce a forklift's lifting capacity.
  • Consult the transport company or supplier before delivery if a load may need an attachment.
  • Train operators to fit and use attachments safely.
Inspect and maintain forklifts
  • Complete and record pre-start checks:
    • at the start of each shift, and
    • whenever an operator changes to a different forklift.
  • Check the forklift and attachments, including safety devices, tyres, forks, restraints and the load-rating plate.
  • Record and report faults or damage.
  • Isolate and remove the forklift from service if a fault could affect safe operation.
  • Maintain forklifts to the manufacturer’s recommendations or in accordance with the WHS Regulation 2025.
  • Use a competent person to inspect and service the forklift and keep maintenance, inspection and repair records.
  • Before maintenance starts:
    • isolate the forklift, and
    • control risks from raised parts, stored energy, unintended movement and other mobile plant utilising the area
Secure loads
  • Match the forklift’s load capacity to the load.
  • Make sure palletised loads are stable, short and squat, or secured. Read the pallet racking fact sheet for more details.
  • Do not place a load directly on the forks unless it is designed to be lifted that way.
  • Use a backrest extension for high or segmented loads and stillage bins where appropriate.
  • The back rest extension must support at least two thirds of the load being lifted or shifted.
  • Ensure segmented loads are suitably secured.
  • Travel with the load only high enough for ground clearance and keep people out of striking distance.
  • Before using a work box, make sure:
    • the work box is approved for the forklift, compatible with its capacity, securely attached and inspected
    • the forklift has been modified for lifting people
    • hydraulic flow restrictors are fitted
    • the side-shift and tilt-shift functions are locked out, and
    • the modifications are recorded on the plant load-rating plate
  • Set up reliable communication between the operator and the person in the work box and have emergency arrangements in place.
Ensure licensing, training and supervision
  • Make sure operators hold a current, valid high risk work licence and regularly check that it remains valid.
  • Develop and maintain a workplace HRW licence register.
  • A trainee may operate a forklift only when:
    • enrolled with a registered training organisation, and
    • directly supervised by an appropriately licensed, experienced person.
  • Provide refresher training regularly and after an incident or near miss.
  • Supervise workers, give feedback and reinforce safe behaviour.
  • Consult workers and health and safety representatives when identifying hazards and selecting controls. Read more about consultation at work.
  • Make sure required high-visibility clothing and other personal protective equipment is worn.
Use restraints and protective devices
  • Provide, maintain and use a suitable combination of protective devices, such as an overhead guard and seatbelt.
  • Include seatbelt use in site rules and consider a seatbelt interlock (required by the Australian Standard).
  • If a tip-over happens, the operator should not jump. They should brace their feet, hold on and lean away from the point of impact (required by the Australian Standard).
  • Consider proximity sensors, reverse lights and sensors, flashing lights, beepers, speed-limiting devices, reverse cameras and additional mirrors.
  • Manage tip-over risks from kerbs, gutters, rough or sloping ground, loading docks, speed bumps and bad weather.
  • Change LPG cylinders and charge batteries in designated, ventilated areas away from ignition sources. Secure cylinders in the correct orientation, inspect batteries and leads for damage, and have procedures for leaks and spills.
Review controls
  • Review traffic management and other controls regularly and:
    • before changes to the workplace layout, plant, loads or work activities, or
    • after an incident, near miss, fault or worker feedback.
  • Talk to workers and health and safety representatives and use their feedback to improve controls.
  • Check that people follow site rules, exclusion zones, speed limits and safe operating procedures.
  • Make sure unattended forklifts cannot move or be operated by an unauthorised person.
  • When parking a forklift, use a firm, level surface, apply the handbrake, switch off the motor and remove the key.
Respond to incidents
  • After a collision, tip-over, dropped load, serious fault or near miss, stop work and isolate the forklift and affected area.
  • Provide first aid, make the site safe and report the incident through workplace procedures.
  • Notify SafeWork NSW immediately if the event is a notifiable incident.
  • Preserve the incident site where required or directly after helping an injured person or making the site safe.
    

Further information and resources

Use these resources to help you identify forklift hazards, manage risks and reinforce safe work practices in your workplace.

Reports

The NSW Forklift Safety Report – February 2023 summarises forklift-related incidents in NSW between 2017-2022 and findings from SafeWork NSW’s compliance campaign, with practical actions for businesses.

Toolbox talk

Forklift safety: Toolbox talks (PDF, 372.88 KB) will help you educate workers about the three main causes of forklift deaths and serious injuries in NSW.

Checklists

Use the Self-Assessment Checklist: Safety around moving plant (PDF, 171.08 KB) to assess forklift safety measures in your workplace.

Learn what to consider when buying a new or second-hand forklift, including safety features, required information and your WHS obligations.

Fact sheets

The pallet racking fact sheet explains how to safely design, install, use and maintain standard pallet racking.

Safe Work Australia’s Forklifts - Information sheet explains how to manage the risks of operating powered forklifts in the workplace.

Posters

Reinforce forklift safety in your workplace by displaying these A2 posters:

Videos

Use these videos in inductions, training sessions and toolbox talks to show common forklift hazards and reinforce safe work practices.

Related incident information

These incident information releases explain risks and recommended controls for other equipment used to move loads:


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