Part G — Equipment & Plant

Forklift Checklist

Owner

HSE Manager / Document Controller

Review / trigger

Annual review; update on legal, authority, project or client change

Checkpoints

#	Area	Checkpoint / Requirement	Evidence / Acceptance Criteria	Responsible	Frequency
1	Operator competency and authorisation	Operator induction specific to site-specific forklift routes and hazards completed before first independent operation	Site induction record for forklift operators	HSE Officer	Before deployment
2	Operator competency and authorisation	Operator competency reassessed and licence renewed before expiry with no lapse in authorisation	Licence renewal tracking log	HR/HSE Officer	Before expiry
3	Operator competency and authorisation	Trainee operators supervised directly by a certified operator until independent competency signed off	Supervised hours log and competency sign-off	Training Coordinator	During training period
4	Pre-use inspection - visual and mechanical	Windscreen wipers and washer fluid (where fitted) checked functional for outdoor forklift use	Inspection checklist item	Forklift Operator	Daily
5	Pre-use inspection - visual and mechanical	Side-shift and tilt cylinder function tested through full range without jerking or excessive drift	Inspection checklist item	Forklift Operator	Daily
6	Pre-use inspection - visual and mechanical	Instrument panel warning lights and gauges checked functional at start-up	Inspection checklist item	Forklift Operator	Daily
7	Pre-use inspection - visual and mechanical	Counterweight and chassis inspected for cracks, missing bolts or structural damage	Inspection checklist item	Forklift Operator	Daily
8	Pre-use inspection - visual and mechanical	Weekly documented mechanical inspection conducted in addition to daily operator checks, covering fluid levels and belts	Weekly maintenance inspection checklist	Plant Maintenance Team	Weekly
9	Load handling and capacity	Long or wide loads exceeding standard fork spread secured and escorted with banksman during transit	Escort/banksman deployment record	Site Supervisor	As required
10	Load handling and capacity	Double stacking of loads on forklift restricted to loads rated and stable for stacked configuration	Load stacking assessment	Forklift Operator	Before each lift
11	Load handling and capacity	Forklift not used to push, drag or tow loads unless fitted with approved towing attachment	Site rule enforcement and spot check	HSE Officer	Continuous
12	Operating rules and traffic management	Forklift racking storage areas assessed for adequate aisle width matching turning radius of forklift in use	Aisle width measurement against equipment specification	Site Engineer	Before deployment
13	Operating rules and traffic management	Convex mirrors installed at blind corners and junctions along forklift travel routes	Mirror installation and condition check	HSE Officer	Monthly
14	Operating rules and traffic management	Forklift operation on public roads or shared access roads complies with local traffic authority permit conditions	Traffic permit copy on file	HSE Manager	Before use on public roads
15	Operating rules and traffic management	Ramps and inclines used by forklifts assessed for surface condition, drainage and gradient limits before use	Ramp condition inspection record	Site Engineer	Weekly
16	Operating rules and traffic management	Segregation barriers between forklift operating zones and pedestrian walkways maintained in good condition	Barrier inspection checklist	HSE Officer	Weekly
17	Operating rules and traffic management	Reversing camera/proximity sensor system, where fitted, tested for correct alert distance calibration	Sensor calibration test log	Plant Maintenance Team	Monthly
18	LPG/fuel and battery handling	LPG cylinder storage compound sited away from occupied buildings with fire-rated separation distance maintained	Storage compound layout inspection against separation distance standard	HSE Officer	Quarterly
19	LPG/fuel and battery handling	Battery watering (where applicable) performed using distilled water with correct PPE and eye protection worn	Battery maintenance log	Trained Technician	Weekly
20	LPG/fuel and battery handling	Diesel forklift exhaust emissions checked for excessive smoke, catalytic converter/particulate filter maintained	Emission visual check and maintenance record	Plant Maintenance Team	Monthly
21	Maintenance, records and statutory compliance	Forklift downtime and breakdown history reviewed to identify recurring defects requiring corrective action	Maintenance history report and trend analysis	HSE Manager	Quarterly
22	Maintenance, records and statutory compliance	Spare/pool forklifts held in reserve are subject to the same inspection regime as those in active daily use	Reserve fleet inspection log	Plant Maintenance Team	Weekly
23	Maintenance, records and statutory compliance	Forklift key control procedure in place preventing unauthorised access when equipment not in use	Key control log/register	Site Supervisor	Daily
24	Maintenance, records and statutory compliance	Subcontractor-supplied forklifts verified for valid certification and colour tag before entering site	Gate verification checklist for subcontractor equipment	HSE Officer	Before mobilisation
25	Warehouse and racking interface	Racking structures inspected for damage from forklift impact, damaged racking reported and repaired before reload	Racking inspection checklist with damage log	Warehouse Supervisor	Monthly
26	Warehouse and racking interface	Racking load capacity signage displayed and verified against actual loads placed by forklift operators	Load capacity signage and load verification check	Warehouse Supervisor	Monthly
27	Warehouse and racking interface	Pedestrian crossing points within warehouse marked and given right-of-way priority over forklift movement	Crossing point marking inspection	HSE Officer	Monthly
28	Warehouse and racking interface	Loading bay dock levellers and wheel chocks used correctly during truck loading/unloading by forklift	Dock leveller and chock usage observation	Warehouse Supervisor	Every operation
29	Emergency preparedness for forklift operations	Emergency stop procedure known to operators, including safe shutdown sequence in event of malfunction	Operator toolbox talk record on emergency procedure	HSE Officer	Annually
30	Emergency preparedness for forklift operations	Spill kit available near battery charging/fuelling areas for hydraulic fluid or fuel leaks	Spill kit inventory check	HSE Officer	Monthly
31	Emergency preparedness for forklift operations	Forklift overturn/tip-over emergency response procedure (stay in seat, brace) communicated to all operators	Toolbox talk attendance record	HSE Officer	Annually
32	Emergency preparedness for forklift operations	First aid and emergency contact numbers posted on or near forklift operating areas	Signage inspection	HSE Officer	Quarterly
33	Housekeeping and environmental controls	Forklift parking and charging areas kept free of combustible storage and clutter	Housekeeping inspection checklist	Site Supervisor	Weekly
34	Housekeeping and environmental controls	Oil/hydraulic fluid drips from forklifts cleaned promptly to prevent slip hazard on travel routes	Housekeeping inspection and incident-free record	Forklift Operator	Daily
35	Housekeeping and environmental controls	Used batteries and oil filters from forklift maintenance disposed of via licensed hazardous waste contractor	Waste transfer manifest	Environmental Officer	As generated
36	Housekeeping and environmental controls	Forklift wash-down area, where provided, fitted with oil/water separator maintained in working order	Separator maintenance and inspection record	Facilities Contractor	Monthly
37	Housekeeping and environmental controls	Noise levels from forklift operation assessed where operating near noise-sensitive site boundaries	Noise monitoring record	Environmental Officer	Quarterly
38	Warehouse and racking interface	Forklift travel speed within racking aisles restricted to walking pace with speed limiter set where fitted	Speed limiter calibration record and observation	Warehouse Supervisor	Monthly
39	Emergency preparedness for forklift operations	Forklift fitted with seatbelt interlock preventing hydraulic/traction function until seatbelt fastened, tested functional	Interlock function test log	Plant Maintenance Team	Monthly
40	Emergency preparedness for forklift operations	Drills conducted simulating forklift-pedestrian near-miss scenario to validate traffic management controls	Drill record and lessons-learned report	HSE Manager	Annually
41	Operator competency and authorisation	Operator fatigue management addressed through shift length limits and mandatory rest breaks for forklift duties	Shift roster and rest break log	Site Supervisor	Weekly
42	Load handling and capacity	Loads with obstructed operator view handled with a banksman directing movement at walking pace	Banksman deployment record for obstructed-view loads	Banksman	As required
43	Operating rules and traffic management	Forklift movement suspended during periods of heavy rain, sandstorm or reduced visibility per site weather procedure	Weather stand-down log	Site Manager	As occurs
44	Housekeeping and environmental controls	Forklift tyre pressure and condition monitored to prevent uneven wear from overloading or poor yard surfaces	Tyre condition log cross-referenced with load records	Plant Maintenance Team	Monthly
45	Maintenance, records and statutory compliance	Forklift attachments (clamps, rotators) subject to separate maintenance and inspection schedule from base unit	Attachment-specific maintenance record	Plant Maintenance Team	Quarterly
46	Operator competency and authorisation	Forklift operator holds valid, current forklift operator licence/certificate of competency	Licence copy checked against operator ID	HSE Officer	Before deployment
47	Operator competency and authorisation	Operator authorisation list maintained on site, only listed operators permitted to operate forklifts	Authorised operator list posted at yard/office	Site Supervisor	Monthly
48	Operator competency and authorisation	Operator medically fit, with valid medical fitness certificate where required by site policy	Medical fitness certificate on file	HR/HSE Officer	Annually
49	Operator competency and authorisation	Refresher training conducted for operators involved in any forklift incident or after extended absence	Refresher training record	Training Coordinator	As required
50	Pre-use inspection - visual and mechanical	Daily pre-use inspection checklist completed by operator before first use each shift	Signed daily pre-use checklist	Forklift Operator	Daily
51	Pre-use inspection - visual and mechanical	Tyres/wheels checked for damage, correct pressure and no excessive wear	Inspection checklist item	Forklift Operator	Daily
52	Pre-use inspection - visual and mechanical	Forks inspected for cracks, bends, wear at heel and correct locking pins in place	Inspection checklist item with fork condition noted	Forklift Operator	Daily
53	Pre-use inspection - visual and mechanical	Mast and chains inspected for damage, correct lubrication and smooth operation through full range	Inspection checklist item	Forklift Operator	Daily
54	Pre-use inspection - visual and mechanical	Hydraulic system checked for leaks, hoses free from cuts or abrasion	Inspection checklist item	Forklift Operator	Daily
55	Pre-use inspection - visual and mechanical	Brakes (service and parking) tested functional before moving off	Inspection checklist item, brake test result recorded	Forklift Operator	Daily
56	Pre-use inspection - visual and mechanical	Steering operates smoothly with no excessive play	Inspection checklist item	Forklift Operator	Daily
57	Pre-use inspection - visual and mechanical	Horn, reverse alarm and warning lights/beacon tested functional	Inspection checklist item	Forklift Operator	Daily
58	Pre-use inspection - visual and mechanical	Seatbelt present, undamaged and operator confirmed wearing it before operation	Inspection checklist item and observation	Forklift Operator	Daily
59	Pre-use inspection - visual and mechanical	Overhead guard (FOPS) and load backrest extension intact and undamaged	Inspection checklist item	Forklift Operator	Daily
60	Pre-use inspection - visual and mechanical	Fuel/battery level checked and LPG cylinder or battery secured correctly with no leaks	Inspection checklist item	Forklift Operator	Daily
61	Pre-use inspection - visual and mechanical	Mirrors and reversing camera (if fitted) clean and correctly adjusted	Inspection checklist item	Forklift Operator	Daily
62	Pre-use inspection - visual and mechanical	Data plate/capacity plate legible and matches attachments in use	Visual check against data plate	Forklift Operator	Daily
63	Pre-use inspection - visual and mechanical	Any defects found during pre-use inspection reported immediately and equipment tagged out of service	Defect report form and tag-out record	Forklift Operator	As found
64	Load handling and capacity	Load weight verified not to exceed rated capacity shown on data plate, adjusted for attachment and lift height	Load weight check against capacity chart	Forklift Operator	Before each lift
65	Load handling and capacity	Load centre of gravity considered, load positioned against backrest and evenly distributed on forks	Visual check before travel	Forklift Operator	Before each lift
66	Load handling and capacity	Forks fully inserted under load before lifting, load raised only enough to clear ground during travel	Observation during operation	Forklift Operator	Every lift
67	Load handling and capacity	Mast tilted back slightly when travelling with elevated load to stabilise load	Observation during operation	Forklift Operator	Every lift
68	Load handling and capacity	Unstable, damaged or unbanded loads not lifted until properly secured	Pre-lift load condition check	Forklift Operator	Before each lift
69	Load handling and capacity	Attachments (fork extensions, clamps) rated and approved for use, not exceeding combined capacity limits	Attachment certification check	HSE Officer	Before use
70	Operating rules and traffic management	Forklift travel routes defined, signed and segregated from pedestrian walkways where practicable	Site traffic management plan and signage inspection	HSE Officer	Monthly
71	Operating rules and traffic management	Speed limits for forklift operation clearly posted and enforced across the site	Speed limit signage inspection	HSE Officer	Monthly
72	Operating rules and traffic management	Forklift operated with load lowered and mast tilted back when travelling, forks 150-200mm above ground	Observation during operation	Forklift Operator	Every trip
73	Operating rules and traffic management	Operator sounds horn at blind corners, doorways and pedestrian crossing points	Observation during operation	Forklift Operator	Continuous
74	Operating rules and traffic management	No personnel permitted to ride on forks, attachments or load; personnel-lifting only via approved cage with interlock	Site rule enforcement and spot check	HSE Officer	Continuous
75	Operating rules and traffic management	Forklift not operated on gradients or surfaces exceeding manufacturer-rated incline limits	Ground condition assessment before task	Forklift Operator	Before each task
76	Operating rules and traffic management	Exclusion zone maintained around forklift during loading/unloading of trucks	Barricading/banksman positioning check	Banksman	Every operation
77	Operating rules and traffic management	Banksman/spotter deployed for reversing in congested areas or where visibility is restricted	Banksman deployment record	Site Supervisor	As required
78	Operating rules and traffic management	Forklift parked with forks lowered flat to ground, engine off and parking brake applied when unattended	Parking area inspection	Forklift Operator	End of use
79	Operating rules and traffic management	Mobile phone use prohibited while operating forklift	Site rule enforcement and spot check	HSE Officer	Continuous
80	LPG/fuel and battery handling	LPG cylinder changeover conducted only by trained personnel in designated, ventilated area away from ignition sources	Changeover procedure observation	Trained Technician	As required
81	LPG/fuel and battery handling	Battery charging station for electric forklifts ventilated with eyewash station and fire extinguisher available	Charging bay inspection checklist	Facilities Contractor	Monthly
82	LPG/fuel and battery handling	No smoking or naked flame signage posted at fuelling/charging areas and enforced	Signage inspection and compliance check	HSE Officer	Monthly
83	Maintenance, records and statutory compliance	Forklift undergoes scheduled preventive maintenance per manufacturer service intervals	Maintenance service record	Plant Maintenance Team	Per service schedule
84	Maintenance, records and statutory compliance	Forklift subject to third-party statutory inspection/certification where required by local authority (equivalent to LOLER regime for lifting attachments)	Third-party inspection certificate on file	Third Party Inspector	Annually
85	Maintenance, records and statutory compliance	Colour-coded inspection tag current and matches site quarterly colour coding scheme	Tag colour verified against current scheme	HSE Officer	Weekly
86	Maintenance, records and statutory compliance	Incident/near-miss involving forklift reported, investigated and corrective actions tracked to closure	Incident report and CAPA closure record	HSE Manager	As occurs
87	Maintenance, records and statutory compliance	Forklift fire extinguisher mounted, inspected and within service date	Fire extinguisher inspection tag check	HSE Officer	Monthly
88	Maintenance, records and statutory compliance	Daily pre-use checklists retained and available for audit for minimum defined retention period	Document control register showing retention	Document Controller	Ongoing

Each checkpoint records Status (Yes / No / N/A), Comments, Corrective Action and Sign-off. Switch to Complete in-app to fill it here, or download the blank version to complete on site.

Back to checklist library

Turn this into evidence you can hand over