Warehouse Forklift Pedestrian Separation Audit

Inspection template for evaluating warehouse controls that separate forklifts and pedestrians, including floor markings, physical barriers, crossings, and safety signage.

Inspection Scope and Area Identification

• Inspection area identified and walk-through route defined
  Enter the warehouse zone, aisle range, dock area, or work cell covered by this audit.
• Date and time of inspection recorded
  Capture when the inspection was performed.
• Inspector identified and authorized to perform inspection
  Enter the inspector name and role, such as supervisor, safety lead, or competent person.
• Forklift traffic areas and pedestrian routes included in scope
  Confirm the inspection covers all active travel paths, staging areas, and crossing points in the selected zone.

Floor Markings and Traffic Direction

• Pedestrian walkways clearly marked and continuous
  Walkway lines are visible, continuous, and guide pedestrians away from forklift travel lanes.
• Forklift travel lanes clearly marked
  Forklift lanes are visible and distinguishable from pedestrian routes throughout the area.
• Floor markings are legible, intact, and not obscured
  Markings are not faded, peeling, blocked by pallets, or hidden by debris or stored materials.
• Restricted or no-go zones marked where forklift-pedestrian separation is required
  Hazard zones, blind corners, dock edges, and loading areas are marked to prevent pedestrian entry.
• Marking condition rating
  Rate the overall condition and visibility of floor markings in this area.

Physical Barriers and Separation Controls

• Physical barriers installed where separation is required
  Guardrails, bollards, chain barriers, or equivalent controls are present in high-risk mixed-traffic areas.
• Barriers are intact, secure, and not bypassed
  Barriers are free of damage, properly anchored, and not routinely crossed, moved, or defeated.
• Barrier openings are controlled and limited to authorized access
  Any gates or openings are used only for authorized pedestrian or material movement and are closed when not in use.
• Barriers provide adequate protection at blind corners and dock edges
  Protection is present where visibility is limited or where a pedestrian could be exposed to moving equipment.
• Barrier condition rating
  Rate the overall condition, placement, and effectiveness of physical separation controls.

Crossings, Intersections, and Visibility

• Designated pedestrian crossings present at required locations
  Crossings are provided where pedestrians must cross forklift routes, such as aisle intersections or dock access points.
• Crossings are clearly marked and easy to identify
  Crosswalks, stop lines, or directional indicators are visible and distinguish crossing points from travel lanes.
• Sightlines at intersections and corners are unobstructed
  Racks, pallets, product, shrink wrap, or equipment do not block visibility for operators or pedestrians.
• Crossing controls are used consistently by pedestrians and forklift operators
  Observed behavior supports the posted traffic pattern, including stopping, yielding, or using designated crossing points.
• Visibility at crossings rating
  Rate how well the crossing design supports safe interaction between pedestrians and forklifts.

Safety Signage, Rules, and Communication

• Forklift warning signs posted where pedestrians enter traffic areas
  Signs warn of powered industrial truck traffic at entrances, crossings, and shared-use areas.
• Pedestrian instruction signs posted and legible
  Signs instruct pedestrians to use designated routes, crossings, or restricted access points as applicable.
• Traffic-control signs are unobstructed and readable
  Signs are not blocked by product, equipment, dust, glare, or poor placement.
• Area rules and right-of-way expectations are communicated to workers
  Workers appear aware of local traffic rules, including pedestrian priority or stop-and-yield requirements where posted.
• Signage adequacy rating
  Rate the overall adequacy of signage and communication controls in the inspected area.

Housekeeping, Obstructions, and Corrective Actions

• Aisles, crossings, and pedestrian paths are free of obstructions
  No pallets, trash, tools, cords, or stored materials block the intended separation or force pedestrians into forklift lanes.
• Temporary changes to traffic flow are controlled and communicated
  If routes are altered due to maintenance, staging, or construction, temporary controls are in place and communicated.
• Deficiencies documented with corrective actions
  List any deficiencies, non-conformances, corrective actions, responsible person, and target completion date.
• Follow-up required
  Select the follow-up status for identified issues.