Fix

After you have identified the risks in your workplace, you need to control them so far as is reasonably practicable to ensure your workplace is safe.

Some examples of common control measures include:

 Overturning and tipping

• purchase or lease forklifts with safety enhancing features (e.g. suitable restraints and a seat belt interlock device to keep the operator secured at all times)
• require suppliers to provide detailed information on all stability limitations and capacities at different lift heights and positions
• ensure seatbelts are worn by installing intelligent systems preventing forklifts being started unless a seatbelt is fastened
• don’t overload forklifts – ensure that the load weighs less than the maximum capacity indicated on the ‘load capacity data plate’
• use dual-wheeled forklifts that provide greater lateral stability when lifting loads above 4.5 metres
• avoid parking or stacking a forklift on an incline, and don’t operate it on gradients with the load elevated more than necessary

Speed and stopping distances

• purchase or retrofit forklifts with speed limiting devices
• reduce the speed limits around the workplace
• if forklifts have speed limiting devices, set the maximum speed to the speed limit
• plan forklift travel paths taking into account pedestrian movements, travelling speed, the weight of the load and the road surface 
• display speed limit signs so that they can be easily seen by forklift operators
• ensure speed limits are followed by providing regular supervision and enforce these limits

Getting on and off

• purchase forklifts that are ergonomically designed to reduce the effort required to operate controls, steer and brake
• ensure forklifts are equipped with good footing, anti-slip surfaces and grab handles
• reduce the number of times workers need to get on and off their forklift
• ensure forklift operating and parking areas are free of uneven surfaces and obstructions
• use visual aids such as closed circuit video systems to reduce neck craning and twisting
• ensure the operator’s seat and cabin are in good condition
• provide information and training on correct techniques for getting on and off forklifts using three points of contact
• instruct operators not to jump from forklifts

 Handling loads

• ensure loads have known weights marked on them
• if you are unsure about the load’s weight, weigh it
• fit load detecting equipment on forklift tynes so that operators can ensure the load is within the forklift's load limit (listed on the load capacity plate)
• check the load before starting the engine and reload it if it’s not stable
• remove any damaged pallets
• only use attachments on designated forklifts and make sure the attachment is secured correctly to the forklift 
• when using attachments that could affect the forklift’s stability, reduce the maximum load weight for the forklift (this is called de-rating)  
• follow the manufacturer’s recommendations for carrying and lowering loads
• never carry passengers on the forklift or load

Dangerous environments

• use electric forklifts rather than petrol, diesel or LPG-powered forklifts in confined or poorly ventilated spaces
• test the exhaust emission levels in the tail pipe of the forklift truck – the exhaust gas should contain not more than 0.2% (2000 ppm) carbon monoxide when idling and 0.1% (1000 ppm) when operating without a load
• fit a catalytic converter to fuel or LP gas powered type to catalytically oxidize carbon monoxide to the less toxic gas carbon dioxide
• never use a spark ignition, including petrol and LP gas powered forklifts, in any area where flammable liquids, gases or solids are stored and there is potential for flammable atmospheres to be present

Pedestrians

• install intelligent pedestrian sensing systems to ensure separation of pedestrians from operational forklifts
• implement an effective traffic management plan designating exclusion zones for pedestrians and forklifts
• enforce exclusion zones within a three metre radius of a forklift (this distance should be expanded when the height of the forklift load or the speed travelled increases)
• don’t allow forklifts to operate near areas where people commonly walk, such as around time clocks, tearooms, cafeterias, amenities and entrances
• clearly mark pedestrian walkways and install physical barriers wherever possible
• provide alarms and horns as well as flashing lights to warn pedestrians of approaching forklifts
• use overhead dome mirrors at intersections and blind corners to increase visibility
• avoid placing bins, racks or storage units where they could obstruct a forklift operator’s view