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Forklifts - What are the OHS risks?

Medium-sized forklifts weigh about the same as an average dump truck and, when loaded, frequently weigh up to five tonnes – making them extremely dangerous when used incorrectly, for both operators and pedestrians.

Pedestrian risks

More than half the people involved in forklift accidents are pedestrians. Even when travelling at low speeds, forklifts present significant risks to pedestrians, who can be crushed by a forklift even if it is barely moving. Being hit by a load is also a common cause of workplace deaths and injuries.

A traffic management plan can minimise some risks associated with forklifts. Safety of pedestrians is the most important aspect of a workplace traffic management plan. Normal ‘rules of the road’ should apply to all site traffic movements, including, in most cases, a set speed limit.

Operator risks

For forklift operators, jumping or falling from a forklift when it tips over is a major risk, as they can be crushed between the forklift and the ground. Forklifts are prone to overturning at speed because of their high centre of gravity. This risk exists even if the forklift is not carrying a load: 75 per cent of side tip-overs take place when the forklift is empty.

Operators can also suffer serious injuries if they slip or fall while getting on and off forklifts. Since forklifts are classified as high risk plant, operators are required to have an appropriate State or Territory Certificate/Licence to operate the plant.

As a general rule, LPG powered forklifts have their gas tanks on the counterweight at the rear of the forklift. The mounting cradle can be 1200mm or more from ground level. A full LPG tank made from steel weighs around 40kg and an aluminium tank about 25kg, so manually lifting the container to that height requires significant physical effort – especially given that during the lift the bottle must be rotated 90 degrees. This can constitute a muscular stress hazard.

Charging and changing forklift batteries is potentially hazardous. Hydrogen gas is explosive and is freely generated during charging. In areas where the hydrogen concentration could exceed one per cent, the ventilation system needs to be spark free.

Risk from emissions

Exhaust emissions from forklifts operating in confined spaces can lead to carbon monoxide poisoning. Carbon monoxide is an odourless, colourless and poisonous gas. Precautions must be taken when using forklifts in confined spaces such as cold rooms and freezers to prevent exposure to toxic levels.