How to operate forklift trucks under certain conditions

In confined spaces
Around overhead electrical powerlines
In flammable atmospheres and handling flammable materials
In hazardous areas

Working in confined spaces

Exhaust emissions from forklift trucks operating in confined spaces can lead to carbon monoxide poisoning.

Carbon monoxide is an odourless, colourless and poisonous gas. Precautions must be taken when forklift trucks are used in confined spaces such as cold rooms and freezers to ensure exposure to toxic levels are kept as low as possible.

What to do

Use electric forklift trucks instead of fuel or LP gas-powered types.
Fit a catalytic converter to fuel or LP gas-powered types to catalytically oxidise carbon monoxide to the less toxic gas carbon dioxide.
Fit fuel control devices, to maintain an acceptable fuel-air ratio, and check them daily. Monitor fuel usage rates to detect variations in the fuel-air ratio.
Use exhaust gas analysers as an aid during regular engine tuning.
Monitor and record carbon monoxide levels around workers. Personal or area monitoring can be undertaken.

Around overhead electrical powerlines

Exclusion zones apply when working close to overhead electrical powerlines. Requirements for exclusion zones vary with voltage, and are listed in Appendix B of the Code of Practice for Working Near Exposed Live Parts (PDF, 570 kB). The electrical supply authority should be contacted whenever a forklift truck or any part of its load has to be close to overhead electrical powerlines. Safeguards and precautions required by the authority should be observed.

In the event of a forklift truck contacting a powerline, the operator should:

if practicable, stay where they are and keep others away
wait until the powerline power is shut off before leaving the vehicle
if practicable, move the vehicles off the powerline.

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In flammable atmospheres and handling flammable materials

Great care must be taken when operating a forklift truck in flammable atmospheres or when they are used to handle flammable materials.

Safe work practices are also vital when fuelling forklift trucks or charging batteries.

Potential ignition sources include:

flames or sparks from an exhaust
heat generated by the engine or exhaust
flashback produced by vapours being drawn into the engine
over-revving the engine
excess speeding
sparks and heat generated by brake components
sparks from tynes striking concrete
static electricity discharged by tyres rubbing up against something
an arc from a starter motor or electrical equipment.

Using non-flameproof forklift trucks where flammable dangerous goods are stored or handled without precautions can create an immediate and severe risk of fire or explosion.

Do not allow non-flameproof forklift trucks into an area where mixing, transferring or decanting of fuels and other flammable materials is carried out.

It is not normal practice for a forklift truck to be manufactured as flameproof. Flameproofing a forklift truck is a specialist engineering activity that is carried out after manufacture, such that flameproofing is retrofitted to a normal forklift truck. The degree of flameproofing applied is determined by the flammable zones in which the machine may be required to operate (Zone 1 or Zone 2 only, never Zone 0).

Not all forklift trucks can be economically flameproofed. Generally, it can be economic to flameproof forklift trucks that have compression engines (diesel fuel) or electric engines but not economic to flameproof machines that have spark ignition engines (LPG fuel or petrol).

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What to do in hazardous areas

If you store or handle flammable dangerous goods, you should:

review the MSDS and package labelling to identify the hazardous properties of each flammable dangerous goods
classify areas within the workplace where flammable liquids, gases or solids are stored or handled as hazardous areas according to AS/NZS 60079.10.1-2009 Explosive atmospheres – Classification of areas (non-Queensland Government link)
identify each hazardous area with markings, warning lights and warning signs
separate ignition sources from hazardous areas by an appropriate distance or physical barriers
provide training and supervision to workers about the risk of ignition sources and how to prevent fire or explosion
never use a spark ignition, forklift truck (including petrol and LP gas-powered) in any hazardous area
not use any forklift trucks in any areas where flammable atmospheres exist continually (zone 0 area). These areas should be made free of any sources contributing to the flammable atmosphere, prior to forklift entry
adhere to hot work permits at all times. Hot work permits should include strategies to:
- monitor flammable vapour and gas using calibrated flammable atmosphere devices
- inspect the area and forklift before entry
- ensure adequate ventilation
- remove and shut down processes or materials that may give rise to a flammable atmosphere
use a forklift truck that is either compliant with AS 2359.12:1996 Powered Industrial /Trucks - Hazardous areas (non-Queensland Government link) or non 'spark ignition engine', where flammable atmospheres may be present during normal operation (zone 1 area). Ensure an appropriate hot work permit system is effectively implemented
use either a powered forklift truck that has been modified for use in a zone 2 area; or is not a spark ignition engine forklift and is operated with an effective hot work permit system, where a flammable atmosphere may occur for short periods of time (zone 2 area)
use only forklift trucks specifically designed for use in explosive or flammable areas, and ensure that they comply with the relevant Australian Standards
train all employees on how to eliminate the risks involved in handling flammable atmospheres and materials and potential ignition sources
ensure there is a strictly enforced 'no smoking' policy in refuelling areas or battery charging areas
NOT use naked flames when checking levels of battery cells
handle and store liquid fuel and LP gas in accordance with the relevant Australian Standards
ensure adequate ventilation in workplaces where using forklift trucks powered by LP gas, petrol or diesel fuel
refuel, park and store LP gas-powered forklift trucks in well ventilated areas that are safely away from combustible material and sources of heat or ignition. Ensure that the LP gas cylinder is turned off at the valve when the forklift truck is not in use
ensure LP gas cylinders are removed and replaced by correctly trained employees following procedures that comply with relevant Australian Standards
ensure batteries are recharged and changed by correctly trained employees and in strict accordance with the relevant standard. Before changing or recharging batteries, ensure the park brake is applied and the vent caps are functioning correctly
prevent the build-up of flammable gasses by holding the battery cover open while the battery is on charge
use the correct tools and keep metal objects away from battery cells when changing or charging batteries
not use liquids with a flashpoint of less than 61 deg C for cleaning forklift trucks
follow the recommendations of the flameproofing company about the inspection and maintenance of the flameproofing features for forklifts that have been flamproofed
establish and maintain procedures for diesel forklifts that have been flameproofed to ensure that the spark arrestor tank on the exhaust line is attended to in accordance with the recommendations of the flameproofing company.

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