Flammable atmospheres and materials
Hazardous areas
Ways to control hazards
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
- static electricity discharged by tyres rubbing up against something
- an arc from a starter motor or electrical equipment
Using unprotected 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 unprotected forklift trucks into an area where mixing, transferring or decanting of fuels and other flammable materials is carried out
Hazardous areas
Where flammable dangerous goods are stored or handled the occupier should:
- Review MSDS and package labelling to identify the hazardous properties of each flammable dangerous goods.
- Areas where flammable liquids, gases or solids are stored or handled should be classified as hazardous areas according to Australian Standard AS 2430 Series Classification of hazardous 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, including petrol and LP gas powered forklift trucks in any hazardous area.
- Do 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
- Where flammable atmospheres may be present during normal operation (zone 1 area) use a forklift truck that is either compliant with Australian Standard AS 2359.12:1996 Powered Industrial /Trucks – Hazardous areas(non-Queensland Government link) or non 'spark ignition engine'. Ensure an appropriate hot work permit system is effectively implemented.
- Where a flammable atmosphere may occur for short periods of time (zone 2 area) 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.
More information on dangerous and flammable goods.
Ways to control hazards
- When working in explosive or flammable areas, use only forklift trucks specifically designed for use in these areas, and ensure that they comply with the relevant Australian Standards
- All employees must attend training 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.
- Naked flames are not be used 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.
- Removing and replacing LP gas cylinders should only be carried out by correctly trained employees. Procedures must comply with relevant Australian Standards.
- The re-charging and changing of batteries should only be carried out by correctly trained employees and in strict accordance with the relevant standard. Before changing or re-charging batteries, ensure the park brake is applied and the vent caps are functioning correctly.
- To prevent the build-up of flammable gasses, hold the battery cover open while the battery is on charge.
- When changing or charging batteries, use the correct tools and keep metal objects away from battery cells.
- Do not use liquids with a flashpoint of less than 61EC for cleaning forklift trucks.
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