Forklifts and material handling equipment (MHE) are essential tools in most Australian warehouses. From lifting and transporting heavy goods to optimising storage systems, they play a critical role in daily operations. However, when not used correctly or maintained properly, forklifts and MHE pose significant risks to workers and the warehouse environment.

In Australia, forklift and MHE safety is not just an operational priority—it is governed by strict health and safety regulations. Warehouses must adhere to these regulations to reduce the risk of accidents, improve operational efficiency, and create a safe workplace for all employees.

In this article, we’ll explore the key aspects of forklift and material handling equipment safety in Australian warehouses, including regulations, best practices, and tips for maintaining a safe working environment.

The Importance of Forklift and MHE Safety

Forklifts and MHE are integral to warehouse operations, but they are also involved in a disproportionate number of workplace accidents. According to Safe Work Australia, forklifts alone account for a significant percentage of workplace injuries, including fatalities. These incidents often occur due to:

• Collisions: Forklifts and pedestrians may share space in busy warehouse aisles.
• Overturning: Forklifts can tip over, especially when carrying uneven or unstable loads.
• Crush Injuries: Workers can be injured if they are struck or trapped by a moving forklift.
• Load Instability: Improperly loaded or unsecured goods can cause accidents during handling or transportation.

By adhering to warehouse safety guidelines and providing proper training, warehouses can reduce the likelihood of such accidents, protect employees, and maintain a more productive and efficient environment.

Regulations Governing Forklift and MHE Safety in Australia

In Australia, forklift and material handling equipment safety is regulated by several key standards and codes, which are designed to ensure the safe operation, maintenance, and use of these machines.

1. Work Health and Safety (WHS) Act 2011
   The Work Health and Safety Act 2011 is the primary piece of legislation governing workplace safety across Australia. It places a duty of care on employers to ensure, as far as reasonably practicable, the health and safety of their workers. This includes providing a safe working environment free from risks associated with forklifts and material handling equipment.
   
2. Safe Work Australia Code of Practice: Forklifts
   Safe Work Australia provides a comprehensive Code of Practice for forklift safety, which outlines the requirements for forklift operation, training, maintenance, and inspections. It covers safe operating procedures, the use of personal protective equipment (PPE), and guidelines for maintaining equipment in good working order.
   
3. Australian Standard AS2359: Powered Industrial Trucks
   AS2359 outlines the requirements for powered industrial trucks, including forklifts. It covers topics such as the design, construction, and operation of forklifts, as well as safety features and equipment standards that must be met for safe use.
   
4. Workplace Safety Codes of Practice
   Many states and territories in Australia have specific safety codes and regulations related to forklifts and MHE, such as the Workplace Health and Safety Queensland (WHSQ) guidelines, or SafeWork NSW regulations. These provide further clarification on forklift safety and the roles of employers and employees in maintaining a safe environment.
   

Best Practices for Forklift and MHE Safety

To ensure the safety of workers and the protection of goods and equipment, warehouses must implement best practices for forklift and material handling equipment safety. These practices should cover everything from the safe operation of forklifts to regular maintenance and staff training.

1. Operator Training and Certification

One of the most critical aspects of forklift safety is ensuring that operators are properly trained and certified. In Australia, forklift operators must hold a valid High Risk Work (HRW) Licence for operating forklifts and other specified equipment. The training programme includes theoretical and practical components that teach operators how to safely operate equipment, assess and control risks, and respond to emergencies.

• Ensure all operators have current HRW licences issued by a Registered Training Organisation (RTO).
• Provide refresher courses to ensure operators stay up to date with safety practices, regulations, and new equipment.
• Include hands-on training for new employees to give them experience under supervision before operating forklifts independently.

2. Pre-Operation Inspections and Maintenance

Regular inspections and maintenance are essential to keep forklifts and material handling equipment in good working condition and to identify potential safety hazards before they cause accidents.

• Conduct daily pre-operation checks of forklifts, including inspecting tyres, brakes, forks, and load capacity.
• Implement a preventative maintenance schedule to ensure equipment is serviced regularly and parts are replaced before they fail.
• Keep detailed inspection and maintenance logs to track the condition and service history of each forklift or piece of MHE.

3. Proper Load Handling and Stability

Incorrectly loaded materials or overburdened forklifts are a leading cause of forklift accidents. To maintain safety, ensure all loads are correctly positioned, balanced, and within the capacity of the forklift.

• Always check the load capacity of the forklift and ensure it’s not exceeded.
• Load materials with the heaviest items at the bottom and lighter items on top to ensure stability.
• Ensure loads are securely fastened to prevent items from shifting during transportation.
• Use load backrests to prevent goods from falling off the forklift during movement.

4. Safe Operating Procedures and Speed Limits

Implementing safe operating procedures is essential to reducing accidents and ensuring smooth operations. This includes enforcing speed limits, maintaining proper distance between forklifts, and ensuring good visibility throughout the warehouse.

• Set speed limits in warehouse aisles to reduce the risk of collisions. A good practice is to keep speeds below 5 km/h in pedestrian areas.
• Enforce a no-overtaking policy in narrow aisles to reduce the risk of accidents.
• Use horns or warning lights to signal when forklifts are approaching blind corners or intersections.

5. Pedestrian Safety and Warehouse Design

Pedestrian safety is a key concern in any warehouse where forklifts and MHE are in operation. By clearly defining pedestrian pathways and establishing strict safety zones, warehouses can prevent accidents involving workers on foot.

• Mark dedicated pedestrian walkways with clear signage and floor markings to separate workers from forklift traffic.
• Install barriers or bollards around high-risk areas, such as loading docks, to prevent forklifts from accidentally striking pedestrians.
• Provide warning lights, horns, or alarms on forklifts to alert pedestrians when they are approaching.
• Ensure adequate lighting in all areas to improve visibility, especially in aisles and corners.

6. Personal Protective Equipment (PPE)

Forklift operators and warehouse workers should always wear the appropriate PPE to protect themselves from injury. This includes hard hats, high-visibility clothing, gloves, and safety boots.

• Require high-visibility vests or jackets to ensure forklift operators and pedestrians are clearly visible.
• Enforce the use of safety boots to protect feet from heavy or falling objects.
• Ensure that gloves are worn when handling materials or operating forklifts to prevent injury from sharp edges or rough surfaces.

Conclusion: A Culture of Safety for Forklift and MHE Operations

Forklift and material handling equipment safety is vital to the overall health and wellbeing of warehouse workers. By following Australian safety regulations, providing ongoing training, and adopting best practices for equipment operation, maintenance, and pedestrian safety, warehouses can minimise the risk of accidents and ensure a safer working environment.

Warehouses that prioritise forklift safety not only comply with legal requirements but also enhance operational efficiency, protect their workforce, and reduce costs associated with accidents, downtime, and damaged goods.

Creating a culture of safety involves everyone in the warehouse, from management to operators and support staff. When safety becomes part of everyday practice, the result is a more productive, compliant, and risk-free workplace for all.