RA-04-Forklift Operation

RISK ASSESSMENT Risk Assessment No: 04
Name of the Aspect: Fork Lift Operation Revision No 00

Company Name: Issue date
Assessed By: Risk/Impact Assessment Team (Logistic) Page No Page 223
of 12
Activity Hazard How might Who might N/ AL L S R1 Control measures L S R2 Action by Action
people be be A/ monitore
harmed? harmed? E/ d by
when?
➢ . Make sure the operators do Logistic

Safe Instability Tip-over, Operator E A not load the forklift above the Superviso
Loading Serious L weight specified on the load r
and injury capacity plate. Ensure the data
Unloading plate is legible and help
operators to understand the
difference between the
forklift’s model numbers
painted on the side of the
forklift and the forklift’s load
capacity plate.
➢ Ensure seatbelts are correctly

fitted and worn.
A 3 4 12 ➢ 1 4 4*
Serious Operator L Consider the stability of the
Speeding injury or s and forklift under braking, its
death other stopping distances and
people environmental factors.
around ➢ *
Reduce speed to walking pace
223
of 12
when?
taking into consideration

congestion, vision, other
vehicles and pedestrians etc.
➢ *
Make sure speed limits are
observed and enforced.
➢ *
Operators trained about
braking impact and stopping
distance for their equipment.
A 3 3 9 1 3 3 Superviso
Sprains and Short term Operator L ➢ Consider forklifts with swivel r
strains or long-term s seats and/or closed-circuit
health video systems to reduce neck
effects due ‘craning’ and twisting.
to
➢ Fit mirrors if practicable.
continuous
looking up, ➢ Ensure road surfaces and floor
behind, surfaces are even and in good
uneven condition.
surface. ➢ Ensure the forklift seat is in
good condition and has
sufficient cushioning so that it
supports the back and
minimize vibration and jolting.
224
of 12
when?
➢ Ensure that the cabin is in

good condition.
➢ Allow variety in forklift operator
tasks so that they can change
their posture.
➢ Check that the controls are
comfortable to reach and
operate.
➢ Ensure the forklift is regularly
serviced and maintained
including its controls and
seating.
➢ Ensure your forklifts have:

Slips, Trip While Operator A 2 3 6 o adequate access and 1 3 3 Superviso
and fall getting on s L egress to provide three r
and off points of contact
➢ (hands and feet) while
getting on and off;
225
of 12
when?
o steps with anti-slip

surfaces and enough
space to stand on
firmly;
o grab handles or rails
that allow proper grip,
and are positioned in
an accessible location;
and
o suitable locations for
controls and foot
pedals to eliminate trip
hazards.
➢ Repair or replace broken
steps, rails and handles.
➢ Ensure road surfaces and floor
surfaces are in good condition
(maintain and repair) and clear
of debris and other
obstructions.
➢ Provide a location to park the
forklift that is well lit so
operators can clearly see the
ground surface, and that is not
226
of 12
when?
muddy, slippery, or uneven.
➢ . Provide workers with

information and training on the
correct and safe way to get on
and off forklifts.
➢ Minimize the number of times
that operators need to get on
and off their forklift to help
reduce the number of slips,
trips and falls.
➢ Before driving onto the back of

Driving onto Falling Operator A 4 5 20 a truck, make sure:
Trucks/Doc forklift, s L • the truck’s tray is
k Truck sound, and it can
movement support the forklift and
leading load
serious • the truck wheels are
injury or chocked; the parking
death brake is on; and the
key is secured
• the access ramp is
sufficiently locked so it
227
of 12
when?
won’t come adrift, and

make sure it can
support the forklift and
load.
➢ Procedures should also be

implemented to ensure the
truck is not driven away until
loading is finished.
➢ The truck trailer must be
supported by sturdy supports
or remain attached to the truck
so that it does not collapse or
tilt when the forklift is operating
inside it. If it is attached to a
skeleton trailer, then additional
supports will be needed.
➢ I
If the trailer remains attached
to the truck, ensure a system
is used so the truck does not
pull away from the loading
dock during loading or
unloading
➢ Develop and implement a safe Logistic
Using Forklift Tip- Operator A 4 4 16 work procedure. 1 4 4 Manager
Ramps over, Ramp s and L ➢ Ramps must:
228
of 12
when?
collapse, people o be wide enough and

Serious around strong enough to take
injury the forklift and load
o be maintained in good
condition
o have good traction in
wet weather
o have side rails to
prevent wheels slipping
off
o allow a smooth weight
transfer on and off the
ramp
o have a gradient that

does not exceed the
angle recommended
for safely operating the
forklift. All variable level
ramps that a forklift is
required to work on
must be provided with
locking and interlocking
facilities.
229
of 12
when?
o have portable ramps

secured according to
the manufacturer’s
instruction and the
appropriate load rating
attached.
o If the load obstructs

your view while
travelling up an incline,
get another worker to
guide you from a safe
position. Ensure all
other people are in full
view at all times. If you
lose sight of them, stop
immediately.
o Drive in reverse if a
bulky load obscures
your forward view.
However, the load
must lead when
travelling up inclines.
Use another worker,
safely positioned, as a
spotter in this instance.
230
of 12
when?
➢ T
Battery Serious Operator E The use and maintenance of
Charging injury or s, the vehicles, associated
death due to business, battery chargers, and
electrocutio equipmen equipment should be
n, fire and t and restricted to designated
explosion stock personnel trained in their
operation.
o D
Do not locate battery
chargers within storage racks.
o W
Within facilities equipped with
automatic sprinklers provide
automatic sprinklers to
protect battery charging
areas.
o B
Battery chargers should be
installed on a concrete floor,
or securely wall mounted
against a noncombustible
structure.
o P
Provide barriers to protect
231
of 12
when?
battery chargers from vehicle

impact.
o T
The charging area should be
kept clean, tidy and free from
rubbish.
o S
Smoking, use of open flames
and other ignition sources
should be prohibited in
battery charging areas.
o W
There charging is carried out
in enclosed areas, provide
adequate natural or
mechanical ventilation to
avoid the accumulation of
hydrogen gas. As hydrogen is
lighter than air, ventilation will
be needed at high points of
the wall or roof.
232
of 12
when?
A 3 5 15 USE tested and certified MEWP to

Working at Serious Worker L use for the activity.
height to injury or Operator should be competent and
paste sticker death due to certified
and material fall from Area to be barricaded
quality height Worker to be trained for working at
height
Full body safety harness anchorage in
a rigid point
Adequate supervision
Moving Sudden Serious Pedestria 3 4 12 Safe work Practices 1 4 4 Superviso Immedia

forklift Pedestrian Injury, n Designated walkways for pedestrians r te
inside the crossing Hit in the including Training orientate programs for
ware pedestrian, logistic operators
house Falling Load team & Provide signage’s
visitors Abdicated supervision
Signature: ___________ Signature: ___________
Name: Name:
233
of 12
when?
Designation: Logistic Manager Designation:
Probability (Likelihood) Severity Risk Matrix Risk Rating

Methodology:
Low 1-5
Very unlikely 1 Negligible 1 Risk Likelihood
1. Identify Hazards
Rating 1 2 3 4 5 2. List Hazard Effects (Risk
1 1 2 3 4 5 event)
Unlikely 2 First-aid injury 2
6-14 3. Calculate initial risk factor
2 2 4 6 8 10
Severity
Medium i.e. probability x severity

3 3 6 9 12 15 4. Decide Control measures
Likely 3 Minor injury 3 5. Calculate residual risk factor
4 4 8 12 16 20
6. Evaluate acceptability of risk
5 5 10 15 20 25 and act accordingly.
Very likely 4 Major 4
High 15-25
Certain or Imminent 5 Fatality 5
Legend:
N: Normal A: Abnormal E: Emergency
AL: Applicability of legal requirements
L: Likelihood R1: Initial Risk Rate
S: Severity R2: Residual Risk Rate
234

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RISK ASSESSMENT Risk Assessment No: 04

Name of the Aspect: Fork Lift Operation Revision No 00

➢ . Make sure the operators do Logistic

➢ Ensure seatbelts are correctly

taking into consideration

➢ Ensure that the cabin is in

➢ Ensure your forklifts have:

o steps with anti-slip

muddy, slippery, or uneven.

➢ . Provide workers with

➢ Before driving onto the back of

won’t come adrift, and

➢ Procedures should also be

collapse, people o be wide enough and

o have a gradient that

o have portable ramps

o If the load obstructs

battery chargers from vehicle

A 3 5 15 USE tested and certified MEWP to

Moving Sudden Serious Pedestria 3 4 12 Safe work Practices 1 4 4 Superviso Immedia

Signature: ___________ Signature: ___________

Designation: Logistic Manager Designation:

Probability (Likelihood) Severity Risk Matrix Risk Rating

Medium i.e. probability x severity

Certain or Imminent 5 Fatality 5

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