TRAFFIC

MANAGEMENT
IN WAREHOUSING

PLAN AND CHECKLIST

March 2009

making a difference

New South Wales Government

Acknowledgement: This is a NSW Wholesale Industry Reference Group project in partnership with WorkCover NSW.

Disclaimer
This publication may contain occupational health and safety and workers compensation information. It may include some of your obligations under the
various legislations that WorkCover NSW administers. To ensure you comply with your legal obligations you must refer to the appropriate legislation.
Information on the latest laws can be checked by visiting the NSW legislation website (www.legislation.nsw.gov.au) or by contacting the free hotline
service on 02 9321 3333.
This publication does not represent a comprehensive statement of the law as it applies to particular problems or to individuals or as a substitute for legal
advice. You should seek independent legal advice if you need assistance on the application of the law to your situation.
WorkCover NSW

CONTENTS

PAGE

Introduction

Traffic Management Plan Checklist

Loadshifting Equipment

Barricades/Barriers/Bollards

Layout/Line Marking

Signage/Warning Devices

Training, Systems, Policies, Procedures

Personal Protective Equipment

11

External Traffic Management Requirements

12

Sample Warehouse Traffic Management Action Plan

13

RISK ASSESSMENT MATRIX

14

DEFINITIONS

15

More Information

17

INTRODUCTION
The consequences of being hit by loadshifting equipment and other vehicles can be serious,
resulting in injury or even death. There is a significant cost to the victim, the employer, the
victims family and the community.
This Traffic Management Plan Checklist provides guidance to managers and supervisors
of small to medium businesses on how to develop, implement and maintain safe systems
of work, intended to eliminate or control the risks of collision in a warehousing and/or
storageenvironment.
An important part of managing your business is to ensure the health and safety of your
employees and other people, such as customers, visitors or tradespeople who visit your
workplace.
To ensure you fulfil your obligation for a safe workplace, you need to be aware of what can
cause harm and then take action to ensure no one is at risk while they are in your workplace.
The following questions will help you evaluate how well you are currently managing safety in
your workplace:
Do you talk with your employees about safety issues?

Yes

 No

Do you encourage your employees to report safety problems?

Yes

 No

Do you regularly inspect your workplace to identify safety problems?

Yes

 No

Do you fix identified problems?

Yes

 No

Do you supervise and train employees so that all work is carried out safely? Yes

 No

If you answered no to any of these questions, you may not be meeting all of your
obligations under the Occupational Health and Safety Act 2000 (the OHS Act).
Even if you answered yes to all these questions, this Traffic Management Plan Checklist will
help you to systematically identify the traffic management safety risks in your workplace and
take the necessary steps to make your workplace safer.
When using the Traffic Management Plan Checklist, it is important to involve your
employees, as they are the people most affected by safety issues and can help to identify the
best safety solutions. Involving your workers is one of your obligations under The OHS Act, to
consult with your employees on workplace safety issues, including when developing safe work
procedures.
When you complete the Traffic Management Plan Checklist, it is important to determine how
often it needs to be reviewed. As a guide, it is a good idea to review the Traffic Management
Plan Checklist at least once a year. However, you may also need to review the Traffic
Management Plan Checklist if there are changes to your workplace that may impact on
safety, eg when new equipment is introduced into the workplace, in situations where plant/
processes are modified and during seasonal peak periods.

By completing this Traffic Management Plan Checklist, identifying and controlling any
problem areas and reviewing it regularly, you will be well on your way to meeting your legal
obligations to provide a safe and secure workplace.
Instructions
Simply tick Yes or No to each question and add any comments you consider appropriate.
If the question does not apply to your workplace, tick N/A. If you tick No to any question
you will need to take action to rectify the issue. An action plan template is provided in this
Traffic Management Plan Checklist and may be used to map the necessary steps required to
make your workplace safer.
For more information or assistance, go to www.workcover.nsw.gov.au or contact the WorkCover
Assistance Service on 13 10 50.

TRAFFIC MANAGEMENT PLAN CHECKLIST

Date checklist completed: _______ /_______ /_______
Date checklist to be reviewed
(if not reviewed earlier due to a change to the workplace): _______ /_______ /_______
Name(s) of person(s) who completed checklist: __________________ Title:
Name(s) of person(s) who completed checklist:__________________ Title:
1. LOADSHIFTING EQUIPMENT
Issue
1.1 Is a forklift required
for this job?

YES NO N/A POSSIBLE Control Measure

substitute forklift with
more pedestrian friendly
loadshifting equipment (eg
pallet jacks, walker stackers)
if the above is not
practicable, design the
workplace to eliminate the
need for pedestrian access in
the vicinity of a forklift.

1.2 Have you studied

the loadshifting
equipment and
pedestrian movement
in the workplace
to identify the risk
of collision with a
pedestrian?

study the loadshifting

equipment and pedestrian
movement in the workplace

1.2a Have you

implemented control
measures to address
the risks identified in
the above study?

mark No Go for exclusion

zones for both pedestrians
and powered loadshifting
equipment based on
pedestrian and equipment
movements, braking
distance, stability and loads
being handled

identify the potential for

collisions with loadshifting
equipment and pedestrians,
columns, racking and other
vehicles.

change layout
change equipment.
1.2b Have you
implemented
appropriate measures
to monitor the
effectiveness of the
controls?

ensure there is an
appropriate level of
supervision provided to see
control implemented
ensure there are appropriate
arrangements in place so
that incidents and near
misses are reported
ensure arrangements are
in place to modify controls
where necessary based on
feedback from incident and
near miss reports.

Action to be taken

1. LOADSHIFTING EQUIPMENT (CONTINUED)

Issue
1.3 Have you determined
parking areas
for loadshifting
equipment?

YES NO N/A POSSIBLE Control Measure

Action to be taken

ensure loadshifting
equipment has its own
clearly marked parking and/
or recharging areas
design work processes
so that no loadshifting
equipment is required to
park on pedestrian walkways.

1.4 Are daily

pre-operational
checks being
completed for these
components?

falling object protection

brakes
seat belts (where fitted)
lights
warning devices
steering
tyres
controls
horn
mast and hydraulics
chains
hand brake
load capacity plate

Notes










5

2. BARRICADES/BARRIERS/BOLLARDS
Issue
2.1 Are physical
separation structures
installed to keep
pedestrians out
of loadshifting
areas? (they may be
essentially visual in
nature or only strong
enough to resist
accidental actions by
the pedestrian)

YES NO N/A POSSIBLE Control Measure

enclose designated
loadshifting equipment
operating areas with physical
barriers to prevent pedestrian
access
if employees work within
loadshifting equipment
operating areas eg desks,
counters, goods dispatch
areas or workstations:
relocate them away from
traffic areas
erect physical barriers
to protect such areas,
egsteel railings.

2.2 Are pedestrian

crossings clearly
marked?

clearly designate pedestrian

crossings by installing inward
opening pedestrian gates as
a calming device to ensure
people stop and look before
crossing
have right of way procedures
in place and enforced,
clearly indicating who must
give way
pedestrian crossings on the
pavement.

2.3 Are adequate bollards

and safety railings
being used to reduce
the risk of vehicle
and pedestrian
collision in the
battery charging area
and waste bin work
zones?

clearly delineate the battery

charging area for electric
loadshifting equipment by
installing adequate bollards/
safety railings
separate access paths for
vehicles and pedestrians,
eg vehicles access from the
end and pedestrians from
the side barricading and
markings to match
ensure clear visibility around
waste bin areas to avoid
pedestrians stepping out into
traffic from blind spots
install barriers/bollards to
protect other vulnerable
equipment, pits or places
where employees work.

2.4 Do entry and exit

points to the building
protect pedestrians
from being struck by
vehicles?

install barriers or bollards

at the entry and exit points
of the building to prevent
pedestrians walking into the
path of oncoming vehicles
where buildings or walkways
open directly onto roadways
or traffic zones, erect
permanent barriers to ensure
pedestrians do not step into
the path of passing vehicles
use bollards/barriers to
prevent vehicles obstructing
emergency exits.

Action to be taken

3. LAYOUT/LINE MARKING
Issue
3.1 Is there an
effective workplace
layout to separate
pedestrian and
powered loadshifting
equipment traffic?

YES NO N/A POSSIBLE Control Measure

Action to be taken

clearly line mark pedestrian

walkways, roadways and
loadshifting equipment
operating areas based on
speed limits, stopping
distances and efficient
workflow
minimise the cross flow of
traffic, intersections and
blind spots
line mark customer pick-up
parking areas
make sure customer pick-up
parking areas are positioned
close to pedestrian walkways
and provide access without
crossing driveways or loading
dock vehicle paths
clearly define areas where
powered loadshifting
equipment is used as
pedestrian exclusion zones
and clearly exclude powered
loadshifting equipment from
pedestrian walkways/work
areas
use line markings and/or
marker posts in docking areas
to indicate distances from
dock, ie 1 metre increments
advising driver of proximity to
dock, reducing the need for
assistance reversing
provide line marking for:
traffic flow markings
loadshifting equipment
parking
driver designated safe
areas
car parking
keep clear zones
lane numbering where
multiple docks exist
speed humps.

3.2 Is there effective line

marking to separate
pedestrian and
powered loadshifting
equipment traffic?

4. SIGNAGE/WARNING DEVICES
Issue
4.1 Is there adequate
lighting and visibility
to minimise the risk
of collision?

YES NO N/A POSSIBLE Control Measure

install eye ball convex
mirrors to provide clear
visibility of approaching
loadshifting equipment and/
or pedestrians
all loadshifting equipment
to carry high visibility and/or
reflective markings
pedestrians within vehicle
access areas to wear high
visibility clothing or vests
provide additional lighting.

4.2 Is there clear warning

of loadshifting
equipment hazards?

loadshifting equipment
have fitted and maintained
reversing beepers and/or
flashing lights
clearly mark such things as
cabling or ducting with high
visibility materials
have signs conforming to the
Australian Standard AS1319
Safety Signs for the
Occupational Environment
prominently display clear
warning signs in relevant,
well lit areas to remind
persons of the traffic
management hazards and
requirements.
Signageexamples:
Pedestrians Prohibited
Loadshifting Equipment
Operating Area
Loadshifting Equipment
Prohibited
Pedestrian Safety Zone
Beware loadshifting
equipment operating
within the area
Vehicles must give way to
pedestrians or a priority
or right of way procedure
that applies to pedestrian
crossings.

Action to be taken

5. TRAINING, SYSTEMS, POLICIES, PROCEDURES

Issue
5.1 Are operators
adequately trained
and licensed where
required?

YES NO N/A POSSIBLE Control Measure

Action to be taken

make sure operators are

adequately trained and
competent, even for
machines that do not require
a Certificate of Competency
do NOT allow other people
(eg visitors, delivery drivers,
etc) to operate machinery
without assessing their
competency and sighting
relevant Certificates of
Competency
make sure learner operators
are properly supervised and
complete logbooks
induct operators into the
operation of new plant
have operation manuals for
plant available for operators
to read
keep copies of loadshifting
operators Certificates of
Competency.

5.2 Have employees

undergone a site
safety induction prior
to being permitted
to use loadshifting
equipment?

conduct a work environment

induction

5.3 Are safe work

procedures in
place for operators
of loadshifting
equipment?

Consult with staff and consider

incorporating the following into
your safe work procedures:

conduct a traffic
management site induction.

pre-use inspection
procedures to check for
obvious defects
means to ensure loads do not
exceed the capacity of the
equipment
loadshifting equipment key
control procedures to ensure
only competent operators use
the equipment
loadshifting equipment to
cease work if pedestrians
enter a pedestrian exclusion
zone
loadshifting equipment
operators to keep the tynes
as close to the floor as
practical when travelling and
operating within the site
loadshifting equipment
operators to ensure that their
load (mast) has appropriate
rearward tilt prior to moving
pallet/stock and not travel
with tynes extended
loadshifting equipment
operators should lower their
loads before turning in the
direction of travel

5. TRAINING, SYSTEMS, POLICIES, PROCEDURES (CONTINUED)

Issue
5.3 Are safe work
procedures in
place for operators
of loadshifting
equipment? (cont)

YES NO N/A POSSIBLE Control Measure

sound loadshifting
equipments horn (warning
device) when crossing
intersections, pedestrian
walkways and access and
egress points for pedestrians
no loadshifting equipment is
to be used to move or shunt
another piece of equipment
no tampering or modifying
of loadshifting equipment
bystaff
Out of Service/Danger tag
system clearly understood
and carried out by
loadshifting operators
ensure operators of
loadshifting equipment
travel in reverse if the load
obstructs their view.

5.4 Have procedures and

training on traffic
management been
given to employees
and any visitors to
the workplace?

ensure pedestrians are aware

of traffic management rules,
including not walking behind
loadshifting equipment when
in operation and staying on
designated walkways and
pedestrian areas
ensure all contractors and
visitors working on site
receive induction regarding
traffic management and are
signed in
ensure non-inducted visitors
are supervised at all times
when walking through the site
monitor and assess
employees compliance with
the traffic management
procedures.

5.5 Have you clearly

identified pedestrian
walkways and traffic
directions?

develop a site plan clearly

identifying pedestrian
walkways and traffic
directions
review the site plan regularly
(at least annually), have
it dated and signed off
by the OHS Committee/
Representative and Site
Manager.

5.6 Are external delivery

drivers aware of your
sites traffic safety
procedures?

develop a truck docking

procedure to ensure delivery
trucks engage trailer braking,
chocks and parking brakes at
all times during unloading
ensure risks of drive-offs
during loading and unloading
are minimised (eg driver
not permitted to stay inside
vehicle while being loaded/
unloaded or ignition key put
on a hook inside the dock).

10

Action to be taken

6. PERSONAL PROTECTIVE EQUIPMENT

Issue
6.1 Do pedestrians and
drivers (internal and
external) wear high
visibility clothing in
traffic areas?

YES NO N/A POSSIBLE Control Measure

Action to be taken

provide high visibility

clothing that meets the
Australian Standard
AS/NZS 4602 High
Visibility Safety Garments
and is appropriate for their
specific use day or night
ensure pedestrians and
delivery drivers wear high
visibility clothing (day or
night) in traffic areas
provide high visibility
clothing (eg vests) for visitors
or other employees accessing
traffic areas from other areas
of the workplace, eg office
staff entering warehouses.

6.2 Do you have a policy

regarding appropriate
footwear in the
workplace?

write a policy regarding

appropriate footwear in
the workplace and clearly
define the term Appropriate
Footwear for each area of
the workplace
ensure persons accessing
vehicle areas wear closed-in
and/or safety footwear.

Notes















11

7. EXTERNAL TRAFFIC MANAGEMENT REQUIREMENTS

Issue

YES NO N/A POSSIBLE Control Measure

7.1 Do you have external

controlled speed
limits in place for
trucks, customers or
visitors vehicles to
the site?

install traffic-calming devices

to reduce the speed of
vehicles, especially when
approaching pedestrian
or loadshifting equipment
operating zones eg boom
gates and self closing gates.

7.2 Have you provided

safe access and
egress to and
from your site for
pedestrians?

provide line markings,

signage and barriers for safe
pedestrian walkways.

7.3 For common areas

where pedestrians
and vehicles are
required to operate
within the same area,
have you provided
adequate safety
control measures?

provide line markings on

the ground to indicate
appropriate parking lanes,
driver safe zones and
walkways for drivers of
vehicles being loaded and
unloaded

Action to be taken

clearly define safety zones

protected by bollards/barriers
so that drivers or unloading
crew can supervise unloading
at a safe distance from
loadshifting equipment and
falling loads.

Notes












12

SAMPLE WAREHOUSE TRAFFIC MANAGEMENT ACTION PLAN

Action
Required

Priority Person
Responsible

1. Re-do line
High
marking of
Med
all pedestrian Low
walkways

M. Brown

Est Completion Completed by Comments

Date
Signature/Date
January 2009

Check all
pedestrian
walkway areas
within the
warehouse

High
Med
Low
High
Med
Low
High
Med
Low
High
Med
Low
High
Med
Low
High
Med
Low
High
Med
Low
High
Med
Low
High
Med
Low
High
Med
Low
High
Med
Low
High
Med
Low

13

RISK ASSESSMENT MATRIX

HOW DANGEROUS IS THE HAZARD YOU HAVE IDENTIFIED?
FOR EACH HAZARD THINK ABOUT THE FOLLOWING:
WORKCOVER HAZPAK MATRIX

HOW LIKELY IS IT TO HAPPEN?

HOW BAD IS IT LIKELY TO BE? VERY LIKELY:

Could happen
at any time
++

Kill or cause permanent

disability or ill health

Long term illness or

serious injury

LIKELY:
Could happen
some time
+

UNLIKELY:
Could happen,
but very rarely

VERY
UNLIKELY:
Could happen,
but probably
never will

!!!

Medical attention and

several days off work
!!

First aid needed

!

The numbers show how important it is to do something.

1 top priority: immediate action required
6 low priority: take action when possible.

Example
Hazard: Plate glass door at foot of steps
Judge severity: Someone falling down the steps could smash through the glass and be
very seriously injured. So it is a !!! hazard. (Look in the second row of numbers.)
Judge likelihood: This could easily happen at any time. So it is ++ very likely. (Look in
the first column of numbers.)
Second row, first column is priority number 1. So it is extremely important to fix this
hazardsoon.

14

DEFINITIONS
WHOLESALE TRAFFIC MANAGEMENT
Traffic Control Bollards, Barriers, Railings and Barricades
A physical barrier installed to separate pedestrians or property from loadshifting equipment
and other vehicles.
Competent Person
A person who has acquired through training, qualification or experience, or a combination of
them, the knowledge and skills to carry out that task.
Personal Protective Equipment (PPE)
Safety devices or safeguards worn by workers to protect against environmental hazards. PPE
includes such items as helmets, safety goggles, hearing protectors, face shields, sun screens,
respirators, harnesses and lanyards, arm guards, smocks, gloves, high visibility clothing and
safety boots.
Plant
Any machinery, equipment (including scaffold), appliance, implement or tool and any
component or fitting thereof or accessory thereto.
Risk Assessment
A process that estimates the effects or consequences of hazardous events on people,
property and the environment. The process would consider the likelihood of occurrence and
the severity of the consequences.
Safe Work Method Statement or Job Safety Analysis
A statement that:

describes how work is to be carried out

identifies the work activities assessed as having safety risks

identifies the safety risks

describes the control measures that will be applied to the work activities, and includes
a description of the equipment used in the work, the standards or codes to be complied
with, the qualifications of the personnel doing the work and the training required to do
the work.

15

Scheduled Work
Scheduled Work is defined in the Occupational Health and Safety Regulation 2001, Part 9.1,
Clause 266 and includes some types of cranes and loadshifting equipment used in warehouses.
Pedestrian
A person travelling on foot.
Loadshifting Equipment plant designed to lift and/or move loads

Powered: eg motorised pallet mover/jack, forklift truck, walk-behind forklift, stock picker/
order picker, overhead crane, vehicle mounted crane

Manual: eg manual pallet jack, trolley, wheeled pallet.

Dock
Any area designated for the physical receipt and/or despatch of goods.
Delivery Vehicle
Any vehicle delivering or picking up items from a workplace (eg bicycle, motorcycle, car, van,
ute, truck etc).
Safety Zone
Designated work area protected by a physical barrier separating pedestrians and loadshifting
equipment.
Certificate of Competency
Certification determining competency to operate specific machinery, which is scheduled
under Clause 266 of the Occupational Health and Safety Regulation 2001 (eg specified
types of forklift, crane, hoist etc). Also commonly called a Ticket or a Licence.
Site Plan
Building and perimeter layout detailing the flow of work processes and all necessary movements
of people, loadshifting equipment, vehicles, material and equipment of different types.
Traffic-calming Devices
Methods used to bring traffic movement to a momentary halt or reduce the speed of vehicles
eg boom gates, self closing gates, speed humps, chicanes.

16

MORE INFORMATION
GUIDE TO OBTAINING MORE INFORMATION
WorkCover NSW
Phone: 13 10 50
http://www.workcover.nsw.gov.au/
WorkCover NSW publications are available on the WorkCover website or by calling the
Publications Hotline on 1300 799 003. Some useful publications are:

Making your forklift work for you

Forklift Truck: National Certificate of Competency

Plant Guide 2001

OHS Legislation
Occupational Health and Safety Act 2000
Occupational Health and Safety Regulation 2001
http://www.legislation.nsw.gov.au/
Australian Standards
Standards Australia
Phone: 1800 035 822
http://www.standards.org.au/
Australian Standards are available from SAI Global www.saiglobal.com/shop
Email: sales@sai-global.com or phone 13 12 42
WorkSafe VIC
Forklift Safety Reducing the Risk
http://www.worksafe.vic.gov.au/wps/wcm/resources/file/ebcad2435c446c8/forklift_safety.pdf
ACT WorkCover
A Guide to Forklift Safety July 2005
http://www.workcover.act.gov.au/pdfs/guides_cop/Forklift_Safety_Booklet.pdf
Worksafe WA
Guidance Note Safe Movement of Vehicles at Workplaces
http://www.docep.wa.gov.au/worksafe/PDF/bulletins/safe_movement_vehicl.pdf
Shop, Distributive and Allied Employees Association (NSW Branch)
InfoSheet8 Working with Forklifts
http://www.sdansw.org.au/www/forms/forklifts.pdf
Safety-Engineer.com
Forklift Safety by Design
http://www.safety-engineer.com/forklift.shtml

17

Health & Safety Executive UK

Improving the Safety of Workers in the Vicinity of Mobile Plant
http://www.hse.gov.uk/research/crr_htm/2001/crr01358.htm
Workplace Transport Safety
http://www.hse.gov.uk/pubns/indg199.pdf
Monash University Accident Research Centre (MUARC)
Forklift Trucks and Severe Injuries: Priorities for Prevention
www.monash.edu.au/muarc/reports/muarc030.html

Notes























18

Notes






























19

Notes






























20

Catalogue No. WC05856 WorkCover Publications Hotline 1300 799 003

WorkCover NSW 92-100 Donnison Street Gosford NSW 2250
Locked Bag 2906 Lisarow NSW 2252 WorkCover Assistance Service 13 10 50
Website www.workcover.nsw.gov.au
ISBN 978 1 74218 075 5 Copyright WorkCover NSW 0209