Forklift Operation SWMS — Warehousing

Forklift incidents remain the number one cause of workplace death in Australian warehousing, with pedestrian-forklift collisions, tip-overs, and load drops accounting for the majority of fatalities and serious injuries. Warehouses processing hundreds of forklift movements per shift face compounding risks as traffic density increases in confined aisle spaces. The WHS Regulation 2025 introduces Australia's first DPM workplace exposure limit at 0.1 mg/m3, directly affecting warehouses operating diesel forklifts indoors. This SWMS template covers counterbalance, reach, and order picker forklift operations with controls mapped to the Managing Risks of Plant in the Workplace Code of Practice binding from July 2026.

Legal Requirements

regulation

WHS Regulation 2025 Part 5.2 — Plant; Part 5.3 — High Risk Plant; Part 8A — WEL

hrcw category

Work involving powered mobile plant (forklift — HRWL required)

code of practice

Managing Risks of Plant in the Workplace (binding July 2026 under Section 26A)

section 26a binding

Yes — Plant code binding July 2026. Non-compliance is admissible as evidence of breach.

hrwl required

Yes — LF class high risk work licence required for all forklift operators

Hazards

Hazard	Consequence	Likelihood
Pedestrian struck by forklift in warehouse aisles and intersections	Fatal crush injuries, traumatic brain injury, spinal cord injury	Possible
Forklift tip-over from overloading, uneven surfaces, or excessive speed on turns	Operator fatal crush injury, bystander crush	Unlikely
Load drop from forks during travel, stacking, or destacking operations	Crush injuries, fatalities from falling loads	Possible
Collision with racking causing structural damage or collapse	Racking cascade collapse, multiple casualties	Unlikely
Diesel particulate matter exposure from diesel forklifts operating indoors	Lung cancer, respiratory disease, cardiovascular disease	Likely

Controls (Hierarchy of Controls)

Implement physical pedestrian segregation barriers with designated crossing points in all forklift operating areas

Enforce speed limits appropriate to warehouse layout with speed limiting devices on all forklifts

Conduct daily pre-operational forklift checks using documented checklists covering brakes, steering, forks, and safety devices

Verify LF class high risk work licence for every forklift operator before permitting operation

Install forklift-racking collision protection including upright protectors, end-of-aisle guards, and guide rails

Transition diesel forklifts to electric or LPG alternatives in enclosed warehouse areas to eliminate DPM exposure

Implement traffic management plan with one-way aisles, intersection protocols, and loading zone controls

Recent Prosecutions

Forklift fatality — distribution centre NSW$500,000

A pedestrian worker was struck and killed by a forklift at an intersection in a distribution centre that had no physical segregation between pedestrian walkways and forklift operating zones. The site processed over 200 forklift movements per shift.

2024 — SafeWork NSW Prosecution Database

What Your SWMS Must Include

✓Traffic management plan showing forklift routes, pedestrian zones, crossing points, and speed limits

✓Pre-operational check procedure and daily checklist for each forklift type

✓HRWL verification procedure confirming current LF class licence before each operator commences

✓Racking collision reporting and damage classification procedure

✓DPM exposure management plan for any diesel forklifts operating in enclosed areas

Need a compliant Forklift Operation SWMS?

Our WHS consultants develop forklift SWMS with traffic management plans, pedestrian segregation designs, and DPM controls that satisfy regulator expectations.