Forklift Operations JSA Template
This Job Safety Analysis template covers day-to-day forklift operations: pre-start inspection, load assessment, travelling on designated routes, pedestrian separation, stacking and racking, and LPG refuelling or battery charging. It suits counterbalance and reach forklifts working in warehouses, factories, yards and on construction sites across Australia. Delivered as an editable Microsoft Word document, it is designed to be tailored to your site, your plant and your people before use.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
This JSA breaks routine forklift operations into eight sequential steps, from the daily pre-start inspection through load assessment, travel on designated routes, stacking into pallet racking, refuelling or battery charging, and final parking and shutdown. The dominant risks in forklift work are consistent across Australian workplaces: tip-over from overloading or turning too fast, pedestrians struck in shared traffic areas, loads falling during racking operations, and fire or chemical exposure during LPG cylinder changes and battery charging. Each step in this template pairs those specific hazards with hierarchy-of-controls measures and before-and-after risk ratings, giving operators and supervisors a practical document to brief at toolbox talks and adapt to their own site layout, plant and traffic management plan.
Forklift use in a warehouse, factory or yard is not construction work, so no SWMS duty arises in those settings. Where a forklift operates on a construction site, work in an area with movement of powered mobile plant is high-risk construction work under regulation 291 of the model WHS Regulations (Victoria: OHS Regulations 2017), and a SWMS must be prepared in addition to this JSA. This JSA supplements a SWMS with task-level detail; it does not discharge the SWMS duty.
Hazards identified
16 hazards covered, sorted by priority.
Arises at step: Complete the daily pre-start inspection. Initial risk HIGH, reduced to LOW with the listed controls in place.
Arises at step: Complete the daily pre-start inspection. Initial risk HIGH, reduced to LOW with the listed controls in place.
Arises at step: Check the work area and traffic management arrangements. Initial risk HIGH, reduced to MEDIUM with the listed controls in place.
Arises at step: Check the work area and traffic management arrangements. Initial risk MEDIUM, reduced to LOW with the listed controls in place.
Arises at step: Assess the load before lifting. Initial risk HIGH, reduced to LOW with the listed controls in place.
Arises at step: Assess the load before lifting. Initial risk MEDIUM, reduced to LOW with the listed controls in place.
Arises at step: Pick up the load. Initial risk HIGH, reduced to LOW with the listed controls in place.
Arises at step: Pick up the load. Initial risk MEDIUM, reduced to LOW with the listed controls in place.
Arises at step: Travel with the load to the destination. Initial risk HIGH, reduced to MEDIUM with the listed controls in place.
Arises at step: Travel with the load to the destination. Initial risk HIGH, reduced to MEDIUM with the listed controls in place.
Arises at step: Stack the load or place it into racking. Initial risk HIGH, reduced to MEDIUM with the listed controls in place.
Arises at step: Stack the load or place it into racking. Initial risk HIGH, reduced to LOW with the listed controls in place.
Arises at step: Refuel LPG or recharge the battery. Initial risk HIGH, reduced to LOW with the listed controls in place.
Arises at step: Refuel LPG or recharge the battery. Initial risk HIGH, reduced to LOW with the listed controls in place.
Arises at step: Park and shut down the forklift. Initial risk MEDIUM, reduced to LOW with the listed controls in place.
Arises at step: Park and shut down the forklift. Initial risk MEDIUM, reduced to LOW with the listed controls in place.
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Administrative — Complete the manufacturer's daily pre-start checklist before first use each shift: tyres, forks, lift chains, hydraulics, brakes, steering, horn and warning lights
- 2Isolation — Remove any defective forklift from service — key out, 'Danger — Do Not Operate' tag attached, unit quarantined until repaired by a competent person
- 3Administrative — Record defects in the plant maintenance log and report them to the supervisor before the unit is next allocated
- 4Administrative — Check seatbelt latching, webbing condition and overhead guard integrity as mandatory pre-start items
- 5Isolation — Quarantine the unit until the seatbelt or guard is repaired — these are no-go defects, not items to work around
- 6Isolation — Separate pedestrian walkways from forklift routes with physical barriers and marked exclusion zones per the site traffic management plan
- 7Engineering — Fit and use convex mirrors, blue-spot projection lights and a flashing beacon at blind intersections and doorways
- 8Administrative — Enforce site speed limits, right-of-way rules and horn use at intersections; stop and make eye contact before passing near pedestrians
- 9Elimination — Clean up spills and remove debris from the route before operating rather than driving around them
- 10Administrative — Inspect the intended route at the start of the shift; barricade and report damaged floor surfaces
- 11Administrative — Confirm load weight and load centre against the forklift's data plate and load chart before every non-routine lift
- 12Administrative — Never add counterweight, carry passengers or use a second forklift to compensate for an over-capacity load — arrange suitable plant instead
- 13Substitution — Transfer goods onto a sound pallet before lifting instead of raising a cracked or broken one
- 14Engineering — Shrink-wrap or strap loose items so the load acts as a single stable unit
- 15Administrative — Quarantine damaged pallets in a marked area so they are not reused
- 16Isolation — Keep an exclusion zone around the lift area — no person on the far side of racking or a vehicle while tines are being inserted
- 17Administrative — Sight the far side as clear, insert tines fully under the load, then tilt the mast back before lifting
- 18Administrative — Centre the load across both tines and seat it against the load backrest before raising
- 19Administrative — Lower, reposition and re-lift any load that sits skewed — never correct a bad pick at height
- 20Administrative — Travel with tines 100–150 mm off the ground and the mast tilted back; never travel with the load raised
- 21Administrative — Travel in reverse or use a spotter when the load unavoidably obstructs forward view
- 22Engineering — Use reversing cameras and proximity detection where fitted to the unit
- 23Administrative — Slow right down before turns, never turn on a ramp, and keep the load facing uphill on every grade
- 24Administrative — Keep the seatbelt fastened at all times; if the forklift tips, stay in the seat, brace and lean away from the direction of fall — never jump
- 25Isolation — Maintain an exclusion zone below and behind the racking bay while a load is being placed or retrieved at height
- 26Administrative — Square the forklift to the racking, raise and place smoothly, and confirm the pallet is fully seated on both beams before withdrawing the tines
- 27Engineering — Fit rack upright protectors and end-of-aisle guards in forklift-trafficked aisles
- 28Administrative — Report every rack strike immediately, no matter how minor, and comply with the bay load signage
- 29Isolation — Unload and tag out any struck or visibly damaged bay until it is inspected by a competent person
- 30Administrative — Change cylinders with the engine off, in a well-ventilated area away from ignition sources, drains and pits
- 31Administrative — Inspect the O-ring, connect hand-tight and check for leaks (smell, sound, soapy water) before restarting
- 32Isolation — Store spare cylinders upright and secured in a ventilated cylinder cage away from the building
- 33Engineering — Charge only in the designated ventilated charging bay, clear of combustibles and ignition sources
- 34Administrative — Switch the charger off before connecting or disconnecting leads; no smoking or naked flames in the charging area
- 35PPE — Wear a face shield and chemical-resistant gloves when handling battery connections or topping up electrolyte
- 36Administrative — Park on level ground clear of exits, walkways and fire equipment; apply the park brake, select neutral and remove the key
- 37Isolation — Secure keys in a controlled location so only licensed, authorised operators can access the unit
- 38Administrative — Fully lower the tines and tilt forward until they sit flat on the floor before leaving the seat
Applicable Codes of Practice
Traffic management and pedestrian separation controls for forklift steps.
High-Risk Construction Work triggered
Forklift use in a warehouse, factory or yard is not construction work, so no SWMS duty arises in those settings. Where a forklift operates on a construction site, work in an area with movement of powered mobile plant is high-risk construction work under regulation 291 of the model WHS Regulations (Victoria: OHS Regulations 2017), and a SWMS must be prepared in addition to this JSA. This JSA supplements a SWMS with task-level detail; it does not discharge the SWMS duty.
Who this is for
- →Warehouse and distribution centre operators formalising forklift procedures
- →Manufacturing and production facilities running counterbalance or reach trucks
- →Construction and civil contractors operating forklifts on site alongside other trades
- →Transport, freight and container yard businesses
- →Small businesses that need a professional forklift JSA without writing one from scratch
What you receive
- ✓Editable Microsoft Word (DOCX) template — one-off purchase, yours to keep and reuse
- ✓Eight pre-filled job steps from pre-start inspection through to parking and shutdown
- ✓Hazard, control and risk-rating tables using the hierarchy of controls, with before-and-after ratings
- ✓PPE, training and emergency response sections ready to tailor to your site
- ✓Worker sign-off page for toolbox talks and acknowledgement records
- ✓Australian WHS terminology and Australian spelling throughout
Worked example
This JSA breaks routine forklift operations into eight sequential steps, from the daily pre-start inspection through load assessment, travel on designated routes, stacking into pallet racking, refuelling or battery charging, and final parking and shutdown. The dominant risks in forklift work are consistent across Australian workplaces: tip-over from overloading or turning too fast, pedestrians struck in shared traffic areas, loads falling during racking operations, and fire or chemical exposure during LPG cylinder changes and battery charging. Each step in this template pairs those specific hazards with hierarchy-of-controls measures and before-and-after risk ratings, giving operators and supervisors a practical document to brief at toolbox talks and adapt to their own site layout, plant and traffic management plan.
Related legislation
- Work Health and Safety Act and Regulations of your state or territory (in Victoria, the OHS Act 2004 and OHS Regulations 2017)
- How to Manage Work Health and Safety Risks Code of Practice
- Where the task is high-risk construction work: the SWMS provisions of your jurisdiction (a JSA supplements, and does not replace, a required SWMS)
Frequently asked questions
What licence do I need to operate a forklift in Australia?
A high risk work licence class LF is required to operate a forklift truck, and class LO for order-picking forklift trucks, issued under the model WHS Regulations by your state or territory regulator. An operator must also be familiarised on the specific make and model they will use — the licence alone does not cover site- and plant-specific training.
Do I still need a SWMS if I use this JSA?
Sometimes, yes. In a warehouse, factory or yard, forklift work is not construction work, so no SWMS duty arises and this JSA is an appropriate risk-management tool. On a construction site, however, work in an area with movement of powered mobile plant is high-risk construction work under regulation 291 of the model WHS Regulations (in Victoria, the equivalent duties sit under the OHS Regulations 2017), and a SWMS is legally required. In that case this JSA supplements the SWMS with task-level detail — it does not replace it or discharge the SWMS duty.
Can I edit the template to match my site and forklifts?
Yes — the template is a standard Microsoft Word (DOCX) file. You can add or delete steps, change hazards and controls, insert your logo and company details, and adjust the PPE and training lists to reflect your plant, layout and traffic management plan. You should tailor it before use; a generic document that does not reflect your actual workplace has limited value in managing risk.
What is the difference between a JSA and a SWMS?
A JSA is a general risk-management tool that breaks one task into sequential steps and identifies the hazards and controls for each step. A SWMS is a specific document required by WHS law for the 18 categories of high-risk construction work defined in regulation 291. A JSA can be used for any task in any industry; a SWMS is only mandatory for high-risk construction work, where it must be prepared before the work starts.
How often should this JSA be reviewed?
Review it before work starts whenever the task, plant, load types or site layout change, after any incident, near miss or rack strike, and at a set interval such as annually. It should also be briefed at toolbox talks so operators can raise conditions the document does not yet cover — the worker sign-off page in the template supports this.