LPG Forklift Operations SWMS
LPG-powered counterbalance forklift operations — LPG cylinder changeover, connection-integrity check, indoor ventilation, CO monitoring, hot-work exclusion, emergency LPG leak response in warehouse and distribution settings.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
LPG-powered counterbalance forklift operations involve cylinder changeover, connection-integrity verification, indoor ventilation management, carbon monoxide monitoring, hot-work exclusion zones and emergency leak response in warehouse and distribution environments. This SWMS addresses obligations under the WHS Act 2011 and WHS Regulation 2025 Chapter 4 Part 4.5 (Plant) and Part 7.1 (Hazardous Chemicals), AS 1596 LP Gas storage and handling, and the requirement for an LF class high-risk work licence under Schedule 3.
Hazards identified
12 hazards covered, sorted by priority.
Flammable vapour cloud ignites causing flash fire and severe burns to operator.
Operators and nearby workers suffer CO poisoning, unconsciousness or death.
Operator crushed beneath overhead guard or thrown from cabin causing fatal injury.
Pedestrian sustains crush injuries, fractures or fatality from impact or run-over.
Valve shears causing uncontrolled gas release and potential ignition or impact injury.
Ignition source triggers LPG vapour explosion injuring multiple workers.
Continuous leak builds flammable atmosphere causing fire or explosion during operation.
Worker struck by falling pallet or stock causing crush or impact injuries.
Unlicensed operation leads to serious incident and regulatory prosecution under WHS Act.
Operator suffers musculoskeletal injury to back, shoulders or hands during lift.
Collision with racking, structures or pedestrians causing damage and injury.
Vehicle fire spreads in warehouse causing burns, smoke inhalation and asset loss.
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Only LF-licensed operators authorised; verify licence and site induction before key issue and log in plant register.
- 2Conduct documented pre-start inspection each shift covering hoses, connections, tynes, brakes, horn and hour meter per AS 2359.2.
- 3Perform LPG cylinder changeover outdoors or in designated ventilated area; soap-test connections and check for leaks before restart.
- 4Install fixed CO monitors with audible alarm at 30ppm in indoor operating areas and ensure mechanical ventilation runs continuously.
- 5Establish 3m hot-work exclusion zone around LPG refuelling and storage; enforce permit-to-work for any ignition source nearby.
- 6Segregate pedestrians using physical barriers, marked walkways and give-way signage; enforce 10km/h site speed limit.
- 7Store spare LPG cylinders upright in ventilated cage compliant with AS 1596 away from ignition sources and exits.
Applicable Codes of Practice
Mandatory framework for forklift risk management, inspection, maintenance and operator competency under WHS Reg Part 4.5.
Governs LPG storage, handling, placarding and emergency planning obligations under WHS Regulation Part 7.1.
Technical standard for safe forklift operation, inspection regimes and operator responsibilities referenced in the model COP.
High-Risk Construction Work triggered
Counterbalance forklift is powered mobile plant requiring documented SWMS before work commences under WHS Regulation 291.
LPG is a Schedule 11 flammable gas; handling and changeover near ignition sources triggers HRCW SWMS requirement.
SWMS must be prepared before work starts, available on site, and reviewed if controls fail; failure breaches WHS Reg 299–303.
Who this is for
- →Warehouse and distribution centre operators running indoor LPG forklift fleets
- →3PL logistics providers and freight handling contractors
- →Manufacturing and food processing sites using LPG counterbalance trucks
What you receive
- ✓Editable DOCX SWMS template fully customisable to your site
- ✓State-specific WHS legislation schedule covering all Australian jurisdictions
- ✓Hazard register with risk matrix scoring and control hierarchy
- ✓Worker sign-on register for SWMS consultation and acknowledgement
Worked example
A Melbourne 3PL warehouse uses six LPG forklifts across two indoor shifts. Following a near-miss CO alarm, the site adopted this SWMS, installed fixed CO monitors at 30ppm alarm threshold, relocated cylinder changeover to a ventilated outdoor cage compliant with AS 1596, and verified all 14 operators held current LF licences. WorkSafe Victoria audited the site three months later and accepted the documented controls without improvement notice.
Related legislation
- WHS Act 2011 (model) sections 19, 28
- WHS Regulation 2025 Part 4.5 (Plant)
- WHS Regulation 2025 Part 7.1 (Hazardous Chemicals)
- AS 1596 Storage and handling of LP Gas
- AS 2359.2 Powered industrial trucks — Operations