Telehandler Operations SWMS
Telehandler operations including pallet-fork work, man-basket operation, suspended-load lifts, slew-handler configurations, outrigger set-up and high-reach work on construction sites.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Telehandlers are versatile mobile plant used across Australian construction sites for pallet-fork work, suspended-load lifts via jib or hook attachments, man-basket personnel lifting, and high-reach material placement. Their hybrid nature — part forklift, part mobile crane — means operators must comply with multiple regulatory frameworks simultaneously, including powered mobile plant duties, lifting-equipment standards, and where applicable, working-at-heights provisions when operating from a man-basket. Slew-handler and rotating telehandler configurations introduce additional load-chart and stability complexities that distinguish them from rigid telehandlers.
Under the model Work Health and Safety Act 2011 and the WHS Regulation 2025, a Person Conducting a Business or Undertaking (PCBU) must manage risks associated with powered mobile plant under Regulation 213–219, and ensure the plant is not used unless the operator holds the relevant high-risk work licence (TL for non-slewing >3t, or CN/CV for slewing-mode operation depending on capacity). Telehandler operations also fall within Schedule 3 High Risk Construction Work, mandating a written SWMS before work commences under Regulation 299.
This SWMS has been prepared to satisfy Regulations 299–303 and to align with the Safe Work Australia Code of Practice: Managing the Risks of Plant in the Workplace, the Code of Practice: Construction Work, and AS 2550.1/2550.10 for safe use of cranes and elevating work platforms. It documents hazards, controls, consultation and review obligations to enable lawful use of telehandlers on Australian sites.
Hazards identified
12 hazards covered, sorted by priority.
Operator crush fatality; load ejection onto ground workers
Plant overturn, load fall, fatal crush injuries to spotters and ground crew
Crush injury, fatality, dropped-object strike on workers below
Fall from height resulting in fatal or serious injury
Electrocution of operator and ground personnel; arc-flash burns
Crush injury, run-over fatality
Sudden plant tilt, load drop, structural collapse of plant
Falling fork, jib or basket causing impact injuries or fatality
Unlicensed operation, regulatory prosecution, increased likelihood of incident
High-pressure fluid injection injury, burns, sudden boom drop
Collision with structures, workers or other plant
Reduced reaction time, hearing loss, musculoskeletal injury
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Verify operator holds the correct HRW licence class — TL for non-slewing telehandlers >3t, or CN/CV for telehandlers operated in slew/crane mode — and verify VOC for the specific make/model before mobilisation, in line with WHS Regulation 81 and Schedule 3.
- 2Complete a documented pre-start inspection each shift covering tyres, outriggers, load-moment indicator (LMI), boom condition, hydraulic hoses, attachment locking pins, ROPS/FOPS structure, lights, alarms and seatbelt; isolate and tag-out any defective machine under AS 2550.1.
- 3Read and apply the manufacturer's load chart for every lift — confirm boom angle, extension, attachment, frame-level and outrigger configuration; never exceed 87% of rated capacity when lifting suspended loads in accordance with AS 2550.10.
- 4Set up on firm, level ground; deploy outriggers fully on engineered timber or composite pads sized to keep ground bearing pressure within the soil's capacity, and re-check level before each lift.
- 5Maintain minimum approach distances to overhead powerlines as specified in the relevant state code (e.g. 3m up to 132kV, 6m up to 330kV, or as directed by the network operator) and use a trained spotter where exclusion zones may be approached.
- 6Use only engineered, compliant man-baskets designed for the specific telehandler, with a current design registration where applicable, full harness anchor points, secondary retention to the boom, and never travel the machine with personnel in the basket.
- 7Establish exclusion zones around the telehandler and suspended loads using hard barriers or spotters; prohibit personnel from walking under suspended loads and use tag lines for load control.
- 8Use a qualified dogger (DG licence) for any suspended load lift where the load is out of the operator's view or where slinging judgement is required, in accordance with WHS Regulation 81.
- 9Conduct attachment changeover with the boom lowered and hydraulics depressurised; verify quick-hitch pins are fully engaged and locked, and perform a visual and crowd-back test before lifting.
- 10Implement a documented traffic management plan separating telehandler routes from pedestrian access; fit and use reversing alarms, flashing beacons and a trained spotter where line-of-sight is limited.
- 11Toolbox-brief all crew on the SWMS daily, record sign-on, and stop work and review the SWMS if conditions, attachments, loads or personnel change.
- 12Maintain plant service records, LMI calibration certificates and annual major inspections per AS 2550.10; remove from service any telehandler exceeding manufacturer service-life or with unresolved defects.
Applicable Codes of Practice
Primary code for hazard identification, guarding, isolation, inspection and operator competency requirements for powered mobile plant including telehandlers.
Defines High Risk Construction Work and SWMS preparation, content and review obligations applicable to telehandler use on construction sites.
Sets safe-use principles applied when telehandlers lift freely suspended loads via jib or hook attachments.
Applies to telehandler-mounted work platforms (man-baskets) used for elevating personnel.
Design, manufacture and configuration standard for telehandlers including load charts and attachment compatibility.
Applies where telehandler man-baskets are used to elevate workers, requiring fall-prevention controls and harness use.
High-Risk Construction Work triggered
A telehandler is powered mobile plant under WHS Regulation 5; any construction-related operation falls squarely within Schedule 3 item 13 and requires a SWMS before work commences.
Telehandler operations frequently involve placing precast panels, structural steel or working from a man-basket above 2m, triggering the falls-related and lifting limbs of Schedule 3.
Because two HRCW categories apply, a written SWMS compliant with WHS Regulation 299 must be prepared before work starts, kept available at the workplace, made accessible to inspectors, and reviewed if controls fail or conditions change. Failure to prepare, comply with or produce the SWMS is an offence under Regulations 300–303 with category 2/3 penalties for the PCBU and officers under sections 32–33 of the WHS Act 2011.
Who this is for
- →Construction PCBUs and principal contractors hiring or operating telehandlers on site
- →Civil and structural subcontractors using telehandlers for material handling or precast placement
- →Plant hire companies supplying telehandlers with operators (wet hire) to construction sites
- →Site managers, project engineers and HSE advisors responsible for plant SWMS authorisation
- →Licensed telehandler operators and doggers required to sign on to a documented SWMS
- →Auditors and WHS consultants reviewing plant safety documentation for compliance
What you receive
- ✓Editable Microsoft Word (DOCX) SWMS template fully populated for telehandler operations
- ✓State-specific legislation schedule covering NSW, VIC, QLD, WA, SA, TAS, ACT and NT WHS/OHS instruments
- ✓Comprehensive hazard register with 12 pre-assessed hazards, consequences and risk priority ratings
- ✓Worker sign-on register for daily toolbox briefings and SWMS acknowledgement
- ✓Pre-start inspection checklist aligned to AS 2550.1 and manufacturer requirements
- ✓Load-chart verification record and lift-plan template for suspended-load operations
- ✓HRW licence and VOC verification log for operators and doggers
- ✓SWMS review and amendment log to satisfy Regulation 302 currency obligations
Worked example
A licensed TL telehandler operator on a Sydney commercial fit-out project is tasked with lifting bundled steel purlins from a delivery truck onto a level-3 slab edge using a fork-mounted jib attachment. Before mobilising, the operator and site supervisor open this SWMS at the morning pre-start, confirm the operator's HRW licence covers slew-mode operation (CV), verify the dogger's DG ticket, and sign the worker register. The operator completes the documented pre-start inspection, identifies a slow hydraulic creep on the boom-extend cylinder, and tags the machine out of service — exactly the response the SWMS prescribes. A replacement telehandler arrives; the operator recommences the pre-start, sets up on engineered outrigger pads after the supervisor confirms the slab-edge ground has been compacted and proof-rolled, and uses the load chart to confirm the 1.4t purlin bundle is within 80% of rated capacity at the planned 9m boom extension. The dogger directs the lift via UHF radio while a spotter maintains the 3m exclusion zone from a nearby 11kV overhead service. The lift completes without incident, and the SWMS sign-on, lift-plan record and pre-start checklist are filed in the site HSE register, available for SafeWork NSW inspection.
Related legislation
- Work Health and Safety Act 2011 (Cth model) — sections 19, 32, 33
- Work Health and Safety Regulation 2025 — Chapter 4 Part 4.5 (Plant), Regulations 213–219
- Work Health and Safety Regulation 2025 — Chapter 6 (Construction Work), Regulations 291–303
- Work Health and Safety Regulation 2025 — Schedule 3 (High Risk Construction Work)
- Work Health and Safety Regulation 2025 — Schedule 4 (High Risk Work Licences) — TL, CN, CV, DG classes
- Occupational Health and Safety Regulations 2017 (VIC) — Part 3.5 Plant (Victorian equivalent)
- Electrical Safety Regulation 2013 (QLD) and equivalent state powerline approach-distance instruments
Frequently asked questions
Which high-risk work licence does a telehandler operator need in Australia?
It depends on the configuration. A non-slewing telehandler with a rated capacity over 3 tonnes generally requires a TL (telehandler) class licence under Schedule 4 of the WHS Regulation. When the telehandler is operated in slew/rotating mode lifting freely suspended loads, the operator typically requires a CN (non-slewing crane >3t) or CV (vehicle-loading crane) class, depending on capacity and configuration. The dogger directing suspended lifts requires a DG licence. Always confirm the licensing pathway with the regulator in your state.
Is a SWMS legally required for telehandler operations on a construction site?
Yes. Telehandler operation falls within High Risk Construction Work under Schedule 3 of the WHS Regulation — specifically powered mobile plant (item 13) and, where lifts occur near falls greater than 2m, item 7. Regulation 299 requires a written SWMS prepared before work starts, kept available, and reviewed if controls fail or conditions change.
Can a telehandler legally lift personnel in a man-basket?
Only where it is the safest practicable option, the basket is purpose-designed and compatible with the specific telehandler, the assembly complies with AS 2550.10, the telehandler has appropriate interlocks (or equivalent administrative controls), workers wear compliant fall-arrest harnesses anchored to designated points, and the machine remains stationary during elevation. The lift must be documented in the SWMS and a lift plan, and supervised by a competent person.
How often must this SWMS be reviewed?
Under Regulation 302, the SWMS must be reviewed and revised if the controls are revealed to be inadequate, if there is an incident, if the work changes, or if a HSR requests review. Best practice is to review at least annually, on every project mobilisation, and whenever attachments, ground conditions or load characteristics change materially.
What ground-bearing assessment is required before deploying outriggers?
The PCBU must verify that the supporting surface can carry the maximum imposed point load through the outrigger pad without exceeding the soil's allowable bearing pressure. On backfilled ground, near excavations, or over services, a competent person (typically a structural or geotechnical engineer) should confirm bearing capacity and pad sizing. Compliant timber, steel or composite outrigger pads must be used and condition-checked each shift.
Does this SWMS cover both rigid and slewing/rotating telehandlers?
Yes. The hazards, controls and load-chart references in this SWMS cover rigid (fixed-frame) telehandlers and slewing/rotating telehandlers in both forklift and crane modes. Operators must apply the correct load chart and licence class for the configuration in use, and the SWMS sign-on must record the specific machine, attachment and lift mode for the shift.