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Forklift Safety in the Workplace: Learning from a Tragic Incident

A Tragic Reminder of Workplace Risks

Last week, a 25-year-old worker in Sydney was killed in a forklift incident, just weeks into his new role. Read the news report here (7News).

This heartbreaking event is a sobering reminder of the risks faced by workers around high-risk machinery like forklifts. It’s a situation no family, colleague, or workplace should ever have to endure.

Here at Modus, our hearts go out to his family, friends and co-workers. Everyone should be able to go to work and come home safe.

Understanding Forklift Safety

In media reports, a co-worker expressed his belief regarding forklifts:

“They’re machines — they can definitely be dangerous — but if you know how to operate one and you’ve got your licence, which I do, I don’t see that they’re a dangerous piece of equipment.”

This highlights a dangerous misconception.

A licence is only the first step. Real safety comes from structured supervision, ongoing mentoring, and fostering a strong workplace safety culture. Forklifts are classified as high-risk machinery precisely because their operation in busy, mixed-use environments can have serious consequences if proper safeguards are not in place.

The dangers of forklifts according to SafeWork NSW

SafeWork NSW identifies three leading causes of forklift-related fatalities and serious injuries:

  • Being struck or crushed by a moving forklift
  • Being hit by a shifting or unstable load
  • Being involved in a tip-over incident

These are not unforeseeable accidents; they are known risks that can be mitigated through structured controls and thoughtful workplace design.

Practical Ways to Improve Safety

Forklift safety is not achieved through one-off measures but through layers of protection. Physical separation between forklifts and pedestrians is one of the most effective controls, whether through barriers or clear walkways. Where separation isn’t possible, strict adherence to well-marked pedestrian routes is vital.

Safe load handling, proper use of seat belts, and clear traffic management rules also play an important role. But rules alone are not enough. Workplaces need to foster open conversations between operators, supervisors and relevant staff to identify and address risks.

Creating Safer Workplaces

Building a culture of safety means going beyond compliance. It’s about designing workplaces where risks are minimised, providing supervision and mentoring for new or young workers, ensuring that every single person understands and follows clear procedures.

Incidents like this Sydney tragedy underline why proactive attention to traffic and pedestrian safety in workplaces is essential. Every worker has the right to return home safely at the end of the day.

Further Guidance and Resources

For more information on forklift safety and workplace risk management, SafeWork NSW provides detailed guidance on forklift safety best practices. National statistics and insights from Safe Work Australia also illustrate why this remains an area of focus across many industries.

Unsure if your site, warehouse or loading dock could be improved? Here are some free resources to find out.