Preventing forklifts from injuring people during loading and unloading of trucks

A guide to effective practices

VWA532/02/04.02

WorkSafe Victoria is a division of the Victorian WorkCover Authority

Contents
Introduction Legal obligations How to use this guide Key elements of effective forklift traffic management systems Comparative chart of tasks and issues Key elements of effective forklift traffic management systems Dos and Donts 1. Example of an effective forklift traffic management system for loading and unloading vehicles 2. Example of an implemented effective forklift traffic management system for loading and unloading vehicles Some other important facts to consider WorkSafe Victoria Offices 1 1 1

WorkSafe Victoria Offices

WorkSafe Victoria offers a complete range of health and safety services: Emergency response Advice, information and education Inspections Licencing and certification Publications Head Office Victorian WorkCover Authority Level 24, 222 Exhibition Street Melbourne Victoria 3000 GPO Box 4306 Melbourne Victoria 3001 10 Telephone Fax Toll-free Local offices Ballarat Bendigo Dandenong Geelong Melbourne Mildura Mulgrave Preston Shepparton Traralgon Wangaratta Warrnambool 9641 1555 9641 1222 1800 136 089 Website www.workcover.vic.gov.au Email info@workcover.vic.gov.au WorkCover Advisory Service Level 24, 222 Exhibition Street Melbourne Victoria 3000 Telephone Fax Toll-free 9641 1444 9641 1222 1800 136 089 Publications Telephone Fax 9641 1333 9641 1330

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5337 5443 8792 5226 9628 5021 9565 9485 5831 5174 5721 5562

1400 8866 9000 1200 8115 4001 9444 4555 8260 8900 8588 5600

Introduction
In Victoria, a worker dies on average every week and over half of the forklift related fatalities have been caused by people being hit by a moving forklift. This impact is felt by everyone around them. Families, loved ones, work colleagues, employers and mates. The reality is that almost every one of these deaths could have been prevented if proper forklift operating safety procedures like those outlined in this guide were implemented and followed. No one should die at work. The purpose of this guide is to help employers implement safe and effective forklift traffic management systems, and in doing so to comply with the relevant aspects of the Victorian Occupational Health and Safety Act 1985 and the Occupational Health and Safety (Plant) Regulations 1995. This booklet helps to identify some of the potential risks and provides solutions and tips to help reduce injuries and fatalities resulting from unsafe forklift operations during the loading and unloading of heavy goods vehicles.

Legal obligations
The employers main duty under the Victorian Occupational Health and Safety Act 1985 (OHS Act) is contained in Section 21(1). This section provides that employers (including contractors) are required to: provide and maintain so far as is practicable for employees a working environment that is safe and without risks to health Employers and employees responsible for the safe use of forklifts must be familiar and meet the requirements of the OHS Act along with the Occupational Health & Safety (Plant) Regulations 1995 (particularly regulation 711 714).

How to use this guide

This guide lists effective ways to reduce risks to safety when vehicles are being loaded or unloaded by forklifts. This will help you identify dangerous work practices and provide clear advice on safer work practices. As you read this guide, take a walk around your workplace to look for potential hazards. Then find ways to fix the problem in the short term while you work at long term solutions.

Key elements of effective forklift traffic management systems

Comparative chart of tasks and issues
A comparative chart has been developed to help you. The practices in the green column should be regarded as the target for all workplaces. The practices in the amber column are less effective in reducing risk and should only be treated as an interim solution. Whilst the practices in the red column involve high risk and should not be used in workplaces; an employer who allows high risk practices to be used is almost invariably going to be in breach of Occupational Health & Safety Legislation.

High Risk - Unacceptable Work Practices

Breach of OHS Legislation

Find ways to fix the problem in the short term

Medium Risk - Interim solution only

Find long term solutions

Only acceptable as permanent practices if its clearly not PRACTICABLE to implement higher standard practices in your workplace

Low Risk - Target for all workplaces

Please Note: The OHS Act does not allow a person to avoid putting a risk control measure in place purely on the basis of the cost of the control measure. The term forklift, as used in this guide, applies to counterbalanced industrial trucks that are designed to lift and move loads and typically used to load and unload vehicles. The term loading refers to both the unloading and loading of vehicles unless otherwise specified.

Key elements of effective forklift traffic management systems

Comparative chart of tasks and issues
High Risk
Traffic management plan There is no traffic management plan. Traffic management is dealt with in an ad hoc way. No safe work procedures are in place.

Medium Risk
Traffic is managed by individual safe work procedures at each area of the workplace.

Low Risk
A comprehensive traffic management plan, dealing with all likely traffic control issues, has been prepared and documented. Everyone affected by the plan understands and applies the traffic management principles. The effectiveness of the plan is regularly reviewed in collaboration with workers. Signs conforming to Australian Standard AS 1319 are prominently displayed at entrance to workplace and in forklift operating areas reminding pedestrians and forklifts drivers about critical parts of the workplaces traffic management system. For example Pedestrian Prohibited Forklift Operating Area; Speed Limited Area. Pedestrian walkways, roadways and forklift operating areas are clearly marked with high visibility self evident lines and signs

Signage for frequently used pedestrian routes and forklift operating areas

No signs or if there are signs they are not in prominent areas or where forklifts are operating. Signs and markings are inconsistent across the workplace and provide insufficient information about intended use.

Signs prominently displayed at entrance to workplace and forklift areas warning of presence of forklifts: For example Forklifts operating in this area. There are no signs specific to the workplaces own traffic management system. Pedestrian walkways and forklift operating areas are marked to show their intended use.

Speed limits

No speed limits enforced or speed limits fail to consider load stability and stopping distance factors.

Speed limits have been determined through a comprehensive risk assessment taking account of stability under braking and stopping distances. Speed limits are enforced through supervision or speed monitoring.

Speed limits have been determined through a comprehensive risk assessment taking account of stability under braking and stopping distances. Forklifts are fitted with speed limiting devices.

High Risk
Informing visiting drivers No information is provided to visiting drivers on safe loading procedures. Staff not trained in loading operations.

Medium Risk
All visiting transport drivers are fully briefed and provided with written information/instructions regarding the loading procedures used at work. Staff involved in loading operations are trained in the workplaces loading procedures only.

Low Risk
All visiting transport drivers are fully briefed and provided with written information/instructions regarding the loading procedures used at work. Everyone involved in loading operations are trained in safe loading operations including: the use of correct equipment to perform the task safely; the use of alternative load shifting equipment and methods; and knowing when use of a forklift is not appropriate for the task. The training aims to improve skills to allow staff to make contributions to enhancing safe work practices.

Forklift barriers

No physical barriers at high risk areas. No proper risk assessment carried out.

Physical barriers at high risk areas e.g. blind corners or places where forklifts are close to pedestrian areas.

Physical barriers protect all marked pedestrian walkways. In addition to physical barriers in areas where pedestrian traffic is common there are large fixed bollards set out from blind corners to protect pedestrians in all areas. Pedestrian crossings are carefully planned, clearly marked, clear of obstructions and speeds are limited to suit required stopping distances and load stability. A priority or give way procedure applies to pedestrian crossings. Prominent signs specify who must give way. Forklift proximity warning systems incorporating temporary pedestrian barriers such as boom gates etc. at crossings.

Pedestrian crossings

No systems in place for pedestrian crossing areas.

A priority or give way procedure applies to pedestrian crossings. Prominent signs specify who must give way. Forklift proximity warning devices only.

High Risk
Safety zones for drivers of trucks and loading crew No markings, bollards, or safety zones for the driver or loading crew.

Medium Risk
A clearly defined safety zone protected by large portable bollards/barriers is provided so that the driver or loading crew can supervise loading at a safe distance from moving forklifts. There are specified exclusion zones around vehicle trailers and forklift operating areas. If there is no risk of the cabin being damaged by a load or the forklift, the driver remains in the truck cabin during loading and unloading operations.

Low Risk
A clearly defined safety zone protected by large fixed bollards/barriers is provided so that the driver or loading crew can supervise loading at a safe distance from moving forklifts and falling loads; or Loading supervision is achieved via remote means such as closed circuit TV and/or radio communications; or The loading supervisors observation post is elevated and visible to the forklift operator at all times. If there is no risk of the cabin being damaged by a load or the forklift, the driver remains in the truck cabin during loading and unloading operations.

Pedestrian Exclusion Zones

Loading crew or other pedestrians are permitted to move in close proximity to working forklifts or the vehicle loading activity.

There is no acceptable interim alternative.

A clearly defined pedestrian exclusion zone is designated around the vehicle being loaded. The extent of the exclusion zone is determined from a comprehensive risk assessment of all loading operations. A minimum exclusion zone size should be established for a distance equal to the height of the load from the ground plus an additional allowance for the nature of the load e.g. potential to bounce, roll or splash contents. Lines or large bollards delineate the exclusion zone. All forklift movements are stopped if pedestrians e.g. loading crew need to enter the exclusion zone.

High Risk
Number of loading crew and monitoring of their location Large number of people in the loading crew around the loading area and there is no system to monitor their presence.

Medium Risk
There is no acceptable interim alternative.

Low Risk
Loading crew is limited to minimal numbers to keep communications simple and make it easier to monitor where the crew is located. Where there has to be a large number of people in the loading crew, specific monitoring systems are in place so that forklift operator is certain of the location of any member of the crew while the forklift is in operation.

Loading crew

Personnel are permitted on the vehicle tray when the forklift is moving the load. No procedure in place related to visibility of people near working forklifts. Loading crew may not always be in view of forklift operator. High visibility clothing is not worn or is ineffective.

There is no acceptable interim alternative.

No personnel are on the vehicle tray during any movement of the load by a forklift. The forklift driver checks that loading crew and the truck driver are in the safety zone before entering the pedestrian exclusion zone. Forklift drivers stop work immediately if the location of the truck driver or any member of the loading crew cannot be confirmed or any pedestrian enters the exclusion zone. High visibility clothing is worn by anyone required to move or work in the vicinity of forklifts or other traffic.

Visibility of people near working forklifts

There is no acceptable interim alternative.

Parking areas for multiple vehicles

No special arrangements in place when more than one vehicle is being loaded.

Portable physical barriers used around forklift operating zones where more than one vehicle is being loaded. Warning systems are used to alert forklift drivers if they have moved into another exclusion zone.

Fixed physical barriers or scheduling of operations make it impossible for a forklift that is not supposed to be involved in a loading operation to intrude into another designated exclusion zone while loading operations are underway. Loading operators are under constant supervision and loading procedures are enforced.

Supervision

Loading operations are not supervised or planned.

Supervision of loading operation occurs on a needs only basis.

High Risk
Training forklift operators Forklift operators are not licensed and trainees are not constantly and directly supervised. Operators have not been specifically trained in all activities undertaken.

Medium Risk
There is no acceptable interim alternative.

Low Risk
Forklift operators are licensed or they are trainees under constant direct supervision. Competencies are regularly reviewed and updated. Task (workplace) specific training is provided on all activities to be undertaken.

Using a forklift to lift people

People are lifted on the tynes of a forklift without a safety cage.

Forklifts are only used to lift people where no other method is practicable. People are only lifted in safety cages that comply with the Australian Standard. A key control procedure is implemented to ensure that only competent forklift operators have access to the keys and forklift. This procedure is managed by the forklift operators.

Forklifts (other than specialised order picking forklifts) are not used to lift people.

Controlling who uses forklifts

There is no specific procedure or control of who operates the forklift.

A key control procedure is implemented to ensure that only competent forklift operators have access to the keys and forklift. Managers or supervisors are in control over access to keys to the forklift. There is a daily pre-start up maintenance check done by the driver. Suitably qualified or competent persons perform regular inspections and maintenance. Comprehensive record of maintenance is kept and is available to operators. Logbooks are maintained by operators. All documentation is regularly monitored and the information from the documents is integrated into a risk control system. Seat belts are fitted to new forklift vehicles and retrofitted to older units. Wearing of seat belts is compulsory and the practice is supervised.

Maintenance of forklifts

There is no regular maintenance performed by suitably qualified or competent persons and no documentation is kept.

Forklifts are well maintained by competent staff but information in maintenance records and logbooks are not integrated into a risk control system.

Fitting and wearing of seat belts or other forms of driver restraint

Seat belts are not worn or are not fitted to forklifts, there is no driver restraint and no related supervision.

Seat belts are fitted to new forklifts but not to older units. Supervision is inconsistent. Wearing of seat belts is compulsory on new forklifts but not on older units.

High Risk
Use of alternative load lifting equipment Appropriate load shifting/handling equipment is not available.

Medium Risk
There is no acceptable interim alternative.

Low Risk
Load shifting or handling equipment is provided for use as an alternative where the use of a forklift may be particularly hazardous. Only attachments confirmed by the manufacturer as suitable for the particular forklift and tasks are used. Safe working load and radius charts for the forklift and attachment combination are displayed on the forklift. The attachments are regularly inspected for damage or wear.

Attachments

Appropriate load lifting attachments are not available for forklift operations or they are not engineered to appropriate standards.

Purpose built lifting attachments are used and these are marked with the safe working load, an engineers report is available and the attachments are regularly inspected for damage or wear.

Incident reporting

Forklift related incidents are not reported or investigated.

There is no acceptable interim alternative.

All forklift related incidents are reported, investigated and acted upon to prevent future incidents. Reporting and response involves health and safety representatives. Use of smart forklift vehicles that utilise engineering and technology to improve safety e.g. use of automatic pedestrian proximity warning devices and speed limiting devices. Automatic dock levellers used at all loading points. Edges of loading docks clearly defined with high visibility markings. Automatic trailer braking chocks and parking brakes used. Dock designed to allow vehicle to drive through rather than reverse in.

Use of engineering solutions for critical safety controls

No use of engineering or technological safety oriented systems.

Minimum engineering and technology to improve safety but not all available systems are exploited. e.g. only reversing warning systems used.

Loading docks

Loading ramps are manufactured without obvious regard to loading forces, necessary width or edge guarding. Loading ramp not secured to loading dock or trailer. Trailer movement prevented only by parking brakes. No edge marking on docks or ramps.

Loading ramps (bridging plates) properly engineered, full width of vehicle being loaded and fitted with raised edge guarding having high visibility markings. Loading ramps locked to loading dock trailer brakes applied and wheels chocked against movement. Edges of loading docks clearly defined with high visibility markings.

Key elements of effective forklift traffic management systems Dos and Donts
Do
develop and implement traffic management plans for both forklift and heavy vehicle movements. provide specified pedestrian exclusion zones around vehicle tray or trailer and forklift operating areas. require the forklift driver to stop work immediately if they lose sight of the truck driver or any member of the loading crew. supervise work to ensure that procedures are followed. have specific workplace training in competency in safe forklift operation, use of attachments and safe loading practice. report and investigate all forklift related incidents. provide safety areas where pedestrians involved in the loading activity are clearly visible to the forklift driver. instruct and brief all visitors, including visiting truck drivers, on company procedures.

Dont
allow pedestrians in forklift operating areas. allow drivers to supervise the loading process while standing in the forklift truck operating zone, including on the opposite side of the vehicle and on the tray. lift people on the tynes of a forklift. access pedestrian exclusion zones while a forklift is moving in the area or moving a load. stand beside a vehicle on the opposite side to where a forklift is moving or adjusting a load. stand on the tray of a vehicle while a forklift is moving or adjusting a load.

1. Example of an effective forklift traffic management system for loading and unloading vehicles
The following example will assist you with developing an effective forklift traffic management system. Remember, keeping pedestrians and truck drivers at a safe distance from operating forklifts is the only way to prevent death and injury.

Truck loading/unloading - Exclusion Zones

One way traffic is safer. Removable bollards in front of the truck enable it to move forward after being loading.

Safety Zone for Driver

The driver must be in full view to a forklift operator. All loading or unloading activity must stop if the driver cannot be seen or needs to enter exclusion zone to inspect load. Alternatively, if it is safe to do so, the system of work can provide for the driver to stay in the truck cabin during loading and unloading.

Bollards/Witches Hats/ Paint marking the Pedestrian

Exclusion Zone.

Pedestrian Exclusion Zone

A minimum exclusion zone should be established for a distance equal to the height of the load from the ground plus an additional allowance for the nature of the load e.g. potential to bounce, roll or splash contents. All forklift movements within the zone must be stopped before pedestrians enter this area.

Truck cabin

Truck trailer
This is a total exclusion zone during loading or unloading activity.

Forklift

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2. Example of an implemented effective forklift traffic management system for loading and unloading vehicles
As outlined in this guide the key to effective forklift traffic management systems is to separate pedestrians and operating forklifts and to keep drivers in a safety zone. The following is an example of how one operator has adapted the principles outlined in this guide and implemented the following traffic management system. This system has significantly reduced the level of risk and increased productivity.

Safety Zone for Driver

Forklift runners take pallets from edge of exclusion zone to their destinations.

Pedestrian Exclusion Zone

Truck cabin Truck trailer
This is a total exclusion zone during loading or unloading activity.

Forklift

Pallets are taken to the edge of exclusion zone by a single forklift.

Pedestrian Exclusion Zone

A pedestrian exclusion zone has been established for a distance equal to the height of the load from the ground plus an additional allowance for the nature of the load. Forklift movements within this zone are stopped before pedestrians enter.

Safety Zone for Driver

The driver must be in full view to a forklift operator. All loading or unloading activity must stop if the driver cannot be seen or needs to enter exclusion zone to inspect load. Alternatively, if it is safe to do so, the system of work can provide for the driver to stay in the truck cabin during loading and unloading.

Bollards/Witches Hats/Paint
Bollards marking the perimeter of the pedestrian exclusion zone have been installed.

Forklifts
Only one forklift operates in the pedestrian exclusion zone.

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Some other important facts to consider

Forklifts and the loads they carry are heavy; a laden forklift travelling at 15km/hr may take 12 metres or more to stop in an emergency. Rear wheel steering can cause the rear of the forklift to swing out unexpectedly and crush or run over the feet of bystanders. Forklift wheels carry very high loads and will inflict serious injuries to feet. Forklifts are designed to lift only palletised loads or equipment that has purpose-built slots to engage the tynes. Talk to your supplier about special purpose attachments for safely lifting other loads e.g. drum lifters, wide load spreader tynes. Loads that have steel to steel contact with the tynes are especially dangerous as they slip unexpectedly during movement. Forklifts can become unstable and roll over when turning or braking at speed, particularly if travelling with the load raised. Seatbelts or operator restraints should always be used. Drivers being thrown from the seat and crushed by the forklift in a rollover has been the cause of many fatal injuries. Forklifts placing or removing loads from other vehicles or material stacks can disturb adjacent material causing these to fall on bystanders. Remember keeping pedestrians at a safe distance from operating forklifts is the only way to prevent death & injury.

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