Pallet Jack Operation SWMS

Pallet jack operations account for a significant proportion of foot and ankle crush injuries in Australian warehouses, with both manual and powered pallet jacks presenting risks from uncontrolled movement, load instability, and operator positioning. Powered pallet jacks operating on ramps, dock levellers, and uneven surfaces create tip-over and runaway risks that are often underestimated. Manual pallet jacks involve sustained pushing and pulling forces that contribute to musculoskeletal injuries when used for extended periods or over long distances. This SWMS template covers manual and powered pallet jack operation with controls mapped to the Managing Risks of Plant and Hazardous Manual Tasks codes of practice.

Legal Requirements

regulation

WHS Regulation 2025 Part 5.2 — Plant; Part 4.2 — Hazardous Manual Tasks

hrcw category

Work involving powered mobile plant, hazardous manual tasks

code of practice

Managing Risks of Plant in the Workplace; Hazardous Manual Tasks (binding July 2026)

section 26a binding

Yes — Both codes binding July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Foot and ankle crush from pallet jack wheels during manoeuvring	Fractures, crush injuries, amputations of toes	Likely
Load instability and pallet collapse during transport	Struck-by injuries from falling product	Possible
Runaway powered pallet jack on ramps and dock levellers	Crush injuries, struck-by injuries, property damage	Possible
Musculoskeletal injury from sustained pushing and pulling forces with manual pallet jacks	Shoulder injuries, back strain, repetitive strain	Likely
Pedestrian collision in warehouse aisles and blind corners	Lower limb injuries, falls, crush injuries	Possible

Controls (Hierarchy of Controls)

Require steel-capped safety boots for all personnel operating or working near pallet jacks

Inspect pallet load stability before transport — refuse to move unstable or poorly stacked pallets

Prohibit use of manual pallet jacks on ramps exceeding 5 degrees gradient — use powered equipment

Limit manual pallet jack transport distance to 20 metres — use powered jacks for longer distances

Maintain pallet jack wheels, bearings, and hydraulic systems to prevent uncontrolled movement

Train all pallet jack operators in correct operation including safe positioning of feet during manoeuvring

Install convex mirrors at blind corners and aisle intersections to prevent pedestrian collisions

Recent Prosecutions

Pallet jack crush injury — NSW$95,000

A worker suffered bilateral foot fractures when a loaded pallet jack ran over both feet after the operator lost control on a dock leveller incline. The pallet jack brake mechanism had not been maintained and the operator had received no training on ramp procedures.

2024 — SafeWork NSW Prosecution Database

What Your SWMS Must Include

✓Pre-use inspection checklist for manual and powered pallet jacks covering wheels, brakes, and hydraulics

✓Ramp and dock leveller procedure specifying gradient limits and powered equipment requirements

✓Maximum transport distance for manual pallet jacks before powered equipment is required

✓Load stability assessment procedure including pallet condition and stacking requirements

✓Operator training requirements covering foot positioning, ramp procedures, and pedestrian awareness

Need a compliant Pallet Jack SWMS?

Our WHS consultants develop pallet jack SWMS with ramp procedures, maintenance schedules, and operator training frameworks that reduce foot and ankle injury rates.