PLT/Specific Plant/TBT-PLT-012

Forklift Truck Safety

Plant & Equipment › Specific Plant › Forklift Truck Safety

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Location		Date

Forklift trucks are used on construction sites for material handling in stores, loading areas, and warehouse environments.
Overturning is the most common cause of fatal forklift incidents — caused by overloading, excessive speed, and turning with raised loads.
Operators must hold a valid CPCS, NPORS, or RTITB certification for the specific forklift type before operating.
The load must be carried low with forks tilted back during travel — raised loads shift the centre of gravity dangerously high.
Pedestrian segregation around forklift operating areas is essential — a forklift striking a person causes fatal injuries.
The rated capacity decreases as the load centre moves forward — longer loads may exceed the capacity even if within the weight limit.
Pre-use checks must cover forks, mast, hydraulics, tyres, brakes, lights, seat belt, and all safety devices daily.
Forklifts must not be used to lift personnel unless a purpose-designed, secured work platform attachment is fitted.
Seat belts must be worn at all times — in an overturn, an unbelted operator is thrown from the cab and crushed by the ROPS.
Forklift operations near edges, ramps, and dock levellers require additional care to prevent the truck driving over the edge.

Overturn crushing	A forklift overturning pins the unbelted operator beneath the cage — the seat belt keeps you inside the ROPS protection zone.
Pedestrian strikes	Forklifts have limited forward visibility with a raised load — pedestrians in the path are struck without the operator seeing them.
Load centre effect	Longer loads move the centre of gravity forward, reducing capacity — a forklift can tip forward even with an apparently light load.

Don't

Hold a valid CPCS, NPORS, or RTITB forklift card before operating on site.
Carry loads low with forks tilted back during all travel movements.
Maintain pedestrian exclusion zones around all forklift operating areas.
Check the load weight and centre against the truck's rated capacity before lifting.
Complete the daily pre-use inspection of forks, mast, hydraulics, and brakes.
Wear the seat belt at all times during forklift operation.
Use only purpose-designed secured platforms for lifting personnel on forks.
Reduce speed on turns, ramps, and near edges to prevent overturn.
Sound the horn at blind corners and intersections with pedestrian routes.
Shut down the engine and remove the key when leaving the forklift unattended.

DON'T operate a forklift without a valid competency card for the specific type.
DON'T travel with the load raised — carry it low with forks tilted back.
DON'T allow pedestrians in the forklift operating area without segregation barriers.
DON'T exceed the rated capacity — check the load weight and centre before every lift.
DON'T skip the pre-use check — fork and mast failures drop loads without warning.
DON'T drive without the seat belt — an overturn without it is almost always fatal.
DON'T lift people on bare forks — only purpose-designed secured platforms are permitted.
DON'T speed around corners — the shift in centre of gravity causes overturn.
DON'T approach blind corners without sounding the horn to warn pedestrians.
DON'T leave the forklift running unattended with the key in the ignition.

See also: Plant and Pedestrian Segregation | Plant Pre-Use Inspections

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