Been Audited by SafeWork Recently? Here’s What We Learnt About Workplace Traffic Management
We were recently audited by SafeWork NSW at our own site, specifically around our forklift unloading process, pedestrian separation and traffic management plan.
It was a useful reminder that traffic management is not just something for roadworks or major construction sites. If your workplace has forklifts, trucks, delivery drivers, customers or staff moving through the same area, you need a clear way to separate people from mobile plant.
The big lesson?
A process that “works” day-to-day is not always enough. SafeWork will generally want to see clear, visible and repeatable controls that separate pedestrians from forklifts and other mobile plant.
In our case, the main issue was simple: we needed a clearer system for keeping pedestrians and truck drivers away from forklift movement during loading and unloading.
One of the key recommendations was to create a designated driver safety zone, along with clearer loading areas, pedestrian exclusion zones, line marking, signage and temporary barriers.
If you have recently been audited, are preparing for a SafeWork visit, or just want to tighten up your unloading process, here are a few practical things worth reviewing.
The risk: forklifts and pedestrians sharing the same space
Forklifts become part of the daily routine in a busy workplace. That can be the problem.
When a forklift is unloading a truck, there are often multiple things happening at once. The driver may be removing restraints, staff may be walking through the area, customers may be nearby, and the forklift operator may have limited visibility around the load, truck or building.
That is where a basic loading area can quickly become a high-risk zone.
Truck arrives
Where does it park, and is that area clearly marked?
Driver exits
Where does the driver stand while unloading happens?
Forklift starts
How are pedestrians kept away from the forklift operating area?
The goal of a traffic management plan is not to create paperwork for the sake of it. The goal is to make the safe way obvious:
- Where does the truck park?
- Where does the driver stand?
- Where can pedestrians walk?
- Where does the forklift operate?
- How do you stop people entering the unloading area?
What SafeWork is likely to look for
Every site is different, but the general expectation is that you have considered the risk of people being struck by mobile plant and put practical controls in place.
That may include:
- Designated loading and unloading zones
- Physical barriers or exclusion zones
- A clearly marked driver safety zone
- Pedestrian walkways and line marking
- Signage so visitors and delivery drivers know where to go
- Safe work procedures for forklift loading and unloading
- Clear instructions for staff and delivery drivers
Quick self-check
Stand in your loading area and ask yourself this:
If a delivery driver arrived today, would they immediately know where to park, where to stand, and where not to walk?
In other words, it should not rely on “everyone knows what to do”. It needs to be visible, repeatable and easy to follow.
Practical steps you can take
1. Start with a simple site plan
Print a copy of your site layout, or sketch one out. Mark where trucks arrive, where they park, where the forklift travels, where pedestrians walk, and where customers or visitors may enter the area.
This will usually show the problem quickly. If people are walking through the same area the forklift is operating in, you need a better control.
Simple map checklist
- Truck entry and exit points
- Forklift travel path
- Pedestrian walkways
- Customer or visitor access points
- Driver waiting area
- Blind spots and corners
- Loading and unloading zones
2. Create a clear loading and unloading zone
Make it obvious where trucks are expected to park for unloading.
This could be done with line marking, traffic cones, barriers, bollards or signage. The important thing is that staff and drivers can clearly identify the unloading area before the job starts.
3. Add a driver safety zone
This was one of the most practical changes for us.
During forklift unloading, the truck driver should not be standing beside the truck, walking around the forklift, or waiting in a blind spot. A designated driver safety zone gives them a clear place to stand until unloading is complete.
Keep it simple: mark the area, signpost it, and make sure your procedure tells drivers to move there before the forklift starts unloading.
Driver safety zone idea
A driver safety zone can be as simple as a marked box, sign and barrier system that clearly tells the truck driver: “stand here while unloading is happening.”
4. Use barriers to make the exclusion zone obvious
Painted lines are helpful, but temporary physical barriers are often much clearer, especially in shared areas.
Retractable belt posts, traffic cones and cone barrier bars can be used to create a temporary exclusion zone while unloading is happening. Once the job is complete, the area can be opened back up again.
5. Mark pedestrian areas
Line marking is one of the simplest ways to show where people should and should not walk.
Use it to mark pedestrian walkways, driver waiting areas, forklift exclusion zones or loading bays. Bright, clear markings make it easier for staff, visitors and delivery drivers to understand the layout at a glance.
6. Write the process down
A short written procedure is better than a verbal instruction that gets forgotten.
Example unloading process
- Truck parks in the designated unloading bay.
- Driver removes load restraint only when safe to do so.
- Driver moves to the designated driver safety zone.
- Staff member sets up cones, barriers or exclusion zone controls.
- Forklift operator completes a visual pre-start check.
- Forklift unloads the truck.
- Exclusion zone remains in place until unloading is complete.
- Driver only re-enters the loading area once the forklift operator confirms it is safe.
7. Make it easy to follow
The best traffic management plan is the one people can actually use.
Put the procedure near the unloading area. Train your staff. Tell delivery drivers where to stand. Keep barriers and cones close by so they are used every time, not only when someone remembers.
Before
Driver waits near the truck, staff walk through the area, forklift unloads around people, and the process depends on verbal instructions.
After
Truck parks in a marked zone, driver stands in a signed safety zone, barriers go up, forklift unloads inside a controlled area.
Traffic Management Starter Kit
If you are setting up a basic loading area, pedestrian exclusion zone or driver safety zone, these are the types of products that can help.
Retractable Barrier Post
Ideal for creating temporary exclusion zones around loading areas.
Driver Safety Zone Sign
Clearly identifies where truck drivers should stand during unloading.
Line Marking Paint
Useful for marking walkways, loading bays and driver waiting areas.
Reflective Traffic Cones
A simple way to mark temporary no-go zones and guide movement.
Extendable Cone Barrier Bar
Use with cones to create a more visible physical barrier.
Note: Product selection should always be based on your site layout, risk assessment and traffic management requirements.
Final thought
A traffic management plan does not need to be complicated, but it does need to be clear.
If forklifts, trucks, staff, customers or delivery drivers are using the same space, take the time to map it out and put practical controls in place.
Simple starting point
Separate people from mobile plant. Create a driver safety zone. Mark pedestrian areas. Use barriers where needed. Write the process down. Make sure people actually follow it.
If you need help setting up a safer loading area, driver safety zone or pedestrian exclusion zone, contact the All Trades team. We can help you choose practical traffic management products that suit your site.