Fall prevention in Australian workplaces is not just good practice, it’s a legal and moral responsibility.. Falls from height remain a leading cause of workplace injuries and fatalities in Australia, with serious incidents occurring not just on construction sites but in warehouses, transport depots, manufacturing, and office settings. According to Safe Work Australia, many falls happen from heights of less than two metres—highlighting the need for robust fall prevention systems across all industries.

This guide distils the core principles of the Managing the Risk of Falls at Workplaces Code of Practice (PDF) into practical strategies, supported by proven tools such as the Stockmaster range from Spacepac—engineered access equipment designed for workplace safety and compliance.

Why Fall Prevention in Australian Workplaces Must Be a Priority

A common misconception is that only tall structures or scaffolding pose fall hazards. In reality, a fall from a step ladder, platform, loading dock, or mezzanine can be just as dangerous.

Key hazard areas include:

• Unprotected edges 
• Slippery or uneven flooring 
• Ladder use for stock retrieval 
• Climbing onto trucks or machinery 
• Rooftop or mezzanine access 

Every workplace must identify, assess, and control these risks before they lead to injury.

Step 1: Identify Fall Hazards

Effective fall prevention begins with accurately identifying all potential fall hazards in your workplace. Falls don’t just occur from rooftops or scaffolding—they often happen during everyday tasks that may seem routine or low-risk.

A comprehensive fall hazard assessment should examine every location where a person could fall from one level to another, even if the height difference is less than two metres. Many serious injuries in Australia occur from these lower-level falls.

Common fall-risk scenarios include:

• Reaching for stock on high shelving: A frequent cause of strain and imbalance, especially when using unstable step ladders or crates. 
• Accessing elevated plant and equipment: Maintenance work on tanks, conveyor belts, HVAC units, or mezzanines often lacks adequate fall protection. 
• Working on temporary structures or ladders: Tasks such as painting, inspections, or installations are high-risk without enclosed or stabilised platforms. 
• Entering and exiting transport vehicles: Falls from trucks, loading docks, or trailers are common in transport depots—especially in wet or uneven conditions. 

Practical Tip: Look beyond the obvious

Ask your team: 

• “Are workers climbing while carrying loads?” 
• “Are access points protected with rails or gates?” 
• “Are step ladders being substituted for proper mobile platforms?” 

Safer Alternatives: Smart Access Solutions

When traditional ladders or makeshift access points are used, the risk of falls significantly increases. Instead, consider engineered access tools that provide stable, enclosed working areas with fall-resistant features.

Explore safer alternatives like:

• The Stockmaster Tracker – ideal for repeated access to racking in warehouses 
• The Stockmaster Navigator – with enclosed platforms for secure order picking 
• The Stockmaster Mezzalad – designed for mezzanine access without the need for fixed staircases 

These products reduce the need for fall arrest PPE by addressing hazards at the source, aligning with the top levels of the hierarchy of control.

Step 2: Assess the Risk

After identifying potential fall hazards in your workplace, the next step is to evaluate the level of risk associated with each. A thorough risk assessment considers not only the presence of a hazard but the likelihood of it causing harm and the consequences if it does.

This assessment helps you prioritise which risks require immediate action and determine the most appropriate control measures.

Key Risk Assessment Factors

Likelihood

Ask: How probable is it that a fall might occur under current conditions?

• Is the task performed frequently or occasionally? 
• Are workers rushing, distracted, or working in low-visibility areas? 
• Is the walking or climbing surface stable, dry, and clear of debris? 

High-frequency tasks like stock picking or order fulfilment on elevated platforms are inherently riskier—especially if conditions change due to spills, weather, or wear and tear.

Severity

Ask: What would be the outcome if someone were to fall?

• Could it result in minor bruises or a life-threatening injury? 
• How high is the working surface? 
• What lies below—hard flooring, sharp tools, or machinery? 

Even low-level falls (under 2 metres) can result in fractures, concussions, or worse, especially when compounded by poor footing or unguarded edges.

Exposure

Ask: How often are workers exposed to this risk, and for how long?

• Are workers carrying loads while ascending or descending? 
• Are they reaching, bending, or leaning beyond the platform area? 
• Do they work alone in isolated areas? 

The Stockmaster Lift-Truk, for example, reduces exposure by combining order picking and load lifting into a secure, powered platform—minimising overreaching or carrying items up ladders.

Control

Ask: Are current controls effective and appropriate?

• Is the correct access equipment (not just a ladder) being used? 
• Are guardrails or fall arrest systems in place where needed? 
• Are administrative controls, like Safe Work Method Statements, being followed? 

If you’re relying on generic ladders in high-traffic or high-reach zones, it may be time to consider engineered solutions like the Stockmaster Navigator, which provides enclosed, stable access with integrated fall protection.

Why Risk Assessment Matters

A structured fall risk assessment:

• Enables compliance with WHS legislation 
• Identifies where immediate corrective action is needed 
• Provides a baseline for ongoing monitoring and improvement 

It also empowers teams to make informed safety decisions, particularly when selecting equipment or designing workflows.

Remember: the goal is not to make assumptions about safety—but to analyse every factor that increases the chance of harm, then control or eliminate it using the most reliable method available. 

Fall Prevention Strategies for Australian Workplaces

Falls are one of the most common and preventable workplace incidents in Australia. To effectively reduce the risk of injury, businesses should adopt a proactive, multi-layered fall prevention strategy that aligns with Safe Work Australia’s best practices and Work Health and Safety (WHS) regulations.

Here are some key strategies that enhance both compliance and safety:

• Invest in engineered access equipment: Tools like the Stockmaster Tracker and Stockmaster Lift-Truk offer enclosed, stable platforms for safe access—far superior to traditional ladders.

• Eliminate unnecessary climbing by redesigning workflows so that frequently accessed items are stored at waist height.

• Train staff on real-world risks and proper use of access tools such as the Stockmaster Navigator, which allows for safe, single-person elevated tasks.

• Implement Safe Work Method Statements (SWMS) for high-risk activities to ensure hazards are identified, controlled, and documented.

Step 3: Control the Risk – Apply the Hierarchy

Australia’s Work Health and Safety (WHS) Regulations emphasise the hierarchy of control measures:

1. Eliminate the Hazard

Re-engineer the process to remove the need to work at height. Store frequently used materials at waist level or redesign workflows using ground-based tools.

2. Use Engineering Controls

If working at height is unavoidable, use engineered access equipment to reduce risk. The Stockmaster range from Spacepac includes:

• Stockmaster Navigator – A mobile work platform with a fully enclosed cage and single-person operation. Ideal for picking stock in busy warehouse aisles. 
• Stockmaster Tracker – A tilt-and-move safety ladder with wide, non-slip treads and high guardrails—perfect for high-frequency tasks in racking areas. 
• Stockmaster Mezzalad – Designed for safe, structured access to mezzanines, with lockable wheels and fall-protection gates. 
• Stockmaster Lift-Truk – Combines load-lifting and personal elevation for ergonomic order picking and safe lifting from shelving. 

Engineered tools like the Stockmaster range support effective fall prevention in Australian workplaces by eliminating ladder-related risks.

Step 4: Administrative Controls and PPE

When fall hazards cannot be fully eliminated or controlled through engineering measures, the next line of defence involves a combination of administrative controls and, where absolutely necessary, personal protective equipment (PPE).

These measures are essential for mitigating residual risk and ensuring compliance with Australia’s Work Health and Safety (WHS) Regulations.

Administrative Controls: Enforcing Safe Work Processes

Administrative controls don’t eliminate the hazard itself—but they reduce the likelihood of exposure through structured systems, safe procedures, and informed behaviours.

Key administrative strategies include:

• Safe Work Method Statements (SWMS): Required for all high-risk work involving fall hazards. SWMS detail each task step, associated risks, and the control measures in place. They promote consistency and legal compliance on-site. 
• Clear signage and instruction labels: These alert workers to access limitations, fall risks, and correct procedures when using ladders, platforms, or PPE. 
• Site-specific training: Generic induction isn’t enough. Tailored training should include practical, hands-on sessions with actual equipment used on-site—such as the Stockmaster Lift-Truk or Navigator. 
• Routine supervision: Ongoing oversight ensures that safety procedures are being followed, equipment is being used correctly, and any deviation or damage is identified early. 

These controls foster a safety-first culture, especially when backed by regular audits and worker engagement.

PPE – A Last Line of Defence

Personal Protective Equipment should only be used when no higher-level control is reasonably practicable. While PPE can save lives, it is inherently less reliable because it depends heavily on the user’s competency, the fit and condition of the gear, and external factors.

Common fall arrest PPE includes:

• Full-body harnesses 
• Self-retracting lifelines (SRLs) 
• Shock-absorbing lanyards 
• Rope grabs, connectors, and anchorage slings 

To be considered effective, PPE must be:

• Task-appropriate: Selected based on the environment, working height, and nature of the task. 
• Fitted correctly: Improperly fitted gear can fail under stress or impair movement. 
• Inspected regularly: Visual checks before each use, and scheduled inspections by a competent person, are mandatory. 
• Supported by a robust system, which includes: 

Anchor Points: The Foundation of Fall Arrest

All PPE must connect to secure, load-rated anchor points that comply with AS/NZS 1891 standards. The placement, type, and integrity of anchors determine the success of a fall arrest system. Improper anchor use is a major cause of system failure.

Rescue Procedures: Don’t Wait Until It’s Too Late

Using PPE without a rescue plan is not just inadequate—it’s dangerous. Suspension trauma can develop in minutes after a fall, and delayed response could result in fatal outcomes.

Your rescue procedures should:

• Clearly outline roles, responsibilities, and communication steps 
• Identify required equipment and trained rescue personnel 
• Include scenario-based drills to test team readiness and speed 

Emergency readiness should be integrated into your safety program, not treated as an afterthought. 

Record Keeping: Track, Verify, Comply

All PPE inspections, training sessions, rescue drills, and equipment maintenance activities must be documented and stored for audit purposes. Record keeping supports:

• Regulatory compliance 
• Incident investigations 
• Scheduling of replacements or servicing 

Outdated or damaged equipment must be removed from service immediately to avoid liability or injury.

Equip Your Team with Safer, Smarter Tools

Administrative controls and PPE are critical components of a layered safety system—but they must be supported by smart access solutions. Tools like the Stockmaster Navigator, Lift-Truk, and Tracker platforms reduce the need for fall arrest PPE by offering engineered-in fall protection through features like:

• Enclosed platforms 
• Anti-slip treads 
• Locking castors 
• Integrated handrails 

These features minimise reliance on behavioural controls and offer a higher standard of safety by design.

Training and Consultation: Building a Safety Culture

Fall prevention begins with people. Even the most advanced equipment and detailed safety procedures are only as effective as the workers using them. That’s why a strong, proactive training and consultation program is vital to any height safety strategy.

Why training matters

To reduce fall incidents, workers must be equipped with more than just gear—they need practical knowledge, hands-on experience, and confidence in what to do before, during, and after a high-risk task.

Effective fall prevention training should cover:

• Understanding of site-specific risks, such as uneven flooring, high racking, or confined spaces.
• Correct use of engineered access solutions, including mobile ladders, order-pickers, and enclosed platforms.
• Inspection of equipment, from PPE to ladders and anchor points.
• Emergency response procedures, particularly how to respond during a fall or rescue situation.

Training should be task-specific—not generic. This means providing workers the opportunity to use tools like the Stockmaster Navigator or Lift-Truk in a supervised environment, so they develop real-world familiarity before using them on the job.

Continuous reinforcement

Training must also be ongoing. As tasks evolve, equipment is replaced, or new risks are identified, refresher training helps keep best practices top of mind and ensures everyone is aligned on procedures. Continuous review is key to maintaining high standards of fall prevention in Australian workplaces.

Consultation: Workers as Partners in Safety

Just as important as training is active consultation with workers. Engaging your team creates a shared responsibility for safety—and leads to better outcomes.

Encourage workers to raise questions such as:

• “Is this ladder still compliant with safety standards?” 
• “Are these guardrails secure and fit for purpose?” 
• “Do we have a rescue plan for this task?” 

Creating a culture where these questions are welcomed—not ignored—allows issues to be identified early, before an incident occurs.

Tools that support safer practices

By involving workers in the selection and use of equipment, businesses can ensure higher engagement and safer use of engineered solutions. For example, platforms like the Stockmaster Navigator allow users to perform elevated tasks in a fully enclosed, stable environment, reducing both the physical and psychological risks of working at height.

Emergency Planning: Be Ready Before It Happens

Even the most robust fall prevention systems can’t completely eliminate risk. That’s why every workplace where there’s a chance of falling—whether from platforms, ladders, mezzanines, or machinery—must have a documented, site-specific emergency response plan.

An effective fall emergency plan is more than a compliance requirement; it’s a critical component of protecting lives and minimising harm in high-risk environments.

What should a fall emergency plan include?

To ensure rapid, safe, and coordinated response, your plan should cover:

Trained first-aid responders

At least one staff member per shift should be trained in administering first aid for fall-related trauma, including the management of suspension trauma associated with harness use.

Dedicated rescue tools

Depending on your work environment, the plan should specify and provide:

• Tripod systems for vertical rescue in confined spaces 
• Rescue winches or rope systems for controlled descent 
• Extension poles or other reach tools for non-entry rescues 

All tools must be readily available, clearly labeled, and regularly maintained.

Accessible rescue kits

Emergency gear should be:

• Clearly located and signposted 
• Complete with all required PPE, slings, connectors, and anchor straps 
• Routinely inspected and replaced as needed 

Delay due to missing or damaged equipment can result in serious injury or death.

Scheduled rescue drills

Rescue plans only work if they’re practiced. Conduct regular simulations under real-site conditions:

• Test team readiness 
• Validate timing and tool availability 
• Identify bottlenecks or procedural gaps 

Workers must know who to contact, what to use, and how to act in case of a fall.

Products that support safer emergencies

Proactive planning also means choosing equipment that reduces the risk of entrapment or complex rescues. The Stockmaster Lift-Truk is one such example. Its powered elevation system, enclosed platform, and ergonomic design make it safer for both day-to-day operation and emergency situations by:

• Minimising fall exposure during order picking 
• Providing stable, enclosed access that reduces tip risk 
• Supporting smooth evacuation if an incident occurs 

In emergency planning, time is everything. The fewer variables you leave to chance—equipment access, trained personnel, and clearly rehearsed plans—the more likely you are to save lives. 

Step 5: Review and Improve Continuously

Workplace safety—especially when it comes to fall prevention—is never static. As operations evolve, so too must your approach to hazard control. A one-time setup is not enough. Regular review ensures your systems stay effective, relevant, and compliant with current Work Health and Safety (WHS) regulations.

When should you review your fall prevention strategy?

• After a near miss or incident: These are critical learning opportunities. Investigate what failed, what was missing, and how similar risks can be mitigated.
• When introducing new equipment, processes, or layouts: Changes in tools, workflow, or warehouse design can create new fall risks or expose gaps in existing controls.
• Following worker feedback or safety audits: Workers on the floor often spot issues management may overlook. Audits can also uncover outdated practices or unsafe equipment.

Why continuous improvement matters

Falls can happen unexpectedly—even in well-managed environments. But when review and improvement are built into your safety culture, you reduce risk exposure, increase employee confidence, and create a more resilient workplace.

Use these reviews to identify and phase out outdated or unsafe equipment, like worn-out step ladders or makeshift access tools. Replace them with engineered alternatives that offer greater protection and stability.

For example, the Stockmaster Tracker provides superior safety features such as non-slip steps, built-in handrails, and lockable wheels. These features reduce fall risk while improving mobility and access—making it a practical upgrade over conventional ladders in warehouses or logistics hubs.

Regular evaluations also support:

• Regulatory compliance audits 
• Insurance and liability risk assessments 
• Worker confidence and buy-in 

In short, review isn’t just about compliance—it’s about evolving safety to match the demands of your business. 

Final Thoughts: Smarter Tools, Safer Outcomes

Fall prevention is more than a regulatory checkbox—it’s a fundamental part of responsible business. Every fall that is prevented protects a life, preserves a livelihood, and reinforces a culture of care within your organisation.

When employers invest in safer systems and smarter tools, the benefits are measurable and far-reaching:

• Fewer injuries: Reducing the risk of falls directly translates to fewer medical incidents, compensation claims, and lost time injuries (LTIs).
• Reduced downtime: Safer environments lead to uninterrupted operations and faster job completion, particularly in logistics, warehousing, and manufacturing.
• Higher productivity: Workers who feel safe are more focused, confident, and efficient in performing their tasks—especially when using equipment designed for both access and ergonomics.
• Enhanced reputation: Demonstrating a strong commitment to safety strengthens your position with clients, stakeholders, and auditors. It shows you value people over shortcuts.

To build a workplace where fall risks are properly managed:

1. Identify and assess hazards at all working levels—not just rooftops, but ladders, mezzanines, loading docks, and confined spaces.
2. Eliminate or control risks using reliable, engineered solutions like mobile access platforms or enclosed workstations.
3. Train and engage workers continuously so they understand both the “how” and “why” of your safety procedures.
4. Prepare for emergencies by establishing rescue plans and practicing response scenarios with the right tools on hand.
5. Continuously review and upgrade your safety systems based on feedback, equipment wear, and changes in your operations.

Tools like the Stockmaster range support these strategies with purpose-built access and handling solutions that prioritise both safety and usability. Whether it’s reducing ladder use or improving warehouse picking efficiency, these platforms offer a scalable and compliant path toward safer outcomes.

Ultimately, fall prevention isn’t just about avoiding penalties—it’s about protecting people and empowering productivity through smarter choices. When safety becomes part of how you work, not just a rule you follow, everyone benefits.

Take the Next Step in Fall Prevention 

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For tailored product advice or compliance consultation, contact Spacepac:
sales@spacepac.com.au | 1300 763 444

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