Forklift trucks are used throughout industry across the world because of the numerous benefits they bring. They are most commonly used in construction, logistics, warehousing and manufacturing because they improve the efficiency of moving pallets of goods and heavy materials whilst reducing the need for manual labour. They also free up floor areas by maximising the vertical storage space provided by racking.
When operated correctly, forklifts improve safety in the workplace by minimising the hazards of manual handling and risk of musculo-skeletal disorders such as back injuries and strains. Having a less fatigued workforce and reducing the risk of injury reduces absenteeism and increases productivity.
Forklift trucks come in a wide range of options. They can be battery powered or fuelled by diesel or LPG for indoor or outdoor use. There is counterbalance, reach trucks, pallet trucks and rough terrain models that have built in safety features such as seatbelts, Roll-Over Protective structure, Falling Object Protective structure and load back stops. Attachments can be obtained for awkward loads such as barrels, coils, crane attachments or spreader beams to handle wide loads.
Forklifts have many benefits but they are still involved in about a quarter of all workplace transport accidents. A single fatality or serious injury can ruin the lives of many people, and in some cases, the business involved.
Legal Duties
Employers deploying Forklift trucks must comply with:
Lifting Operations and Lifting Equipment Regulations (LOLER) 1998: specifically on lifting safety (forks, masts, hydraulics, chains, attachments etc.)
Thorough Examination – Must be carried out by a competent person at least every 12 months, or every 6 months if lifting people or using accessories. Note -: Man cages (or Non-integrated work platforms to give their proper term) deployed on Forklifts should not be used for routine work at height. They may only be used for occasional, exceptional, or emergency tasks where it is not reasonably practicable to use safer alternatives, such as a MEWP (Mobile Elevating Work Platform).
Planning of Lifting Operations – Lifting must be properly planned, supervised, and carried out safely.
Safe Working Load (SWL) – FLT must have clear markings of its SWL, and it must not be exceeded.
Record Keeping – All thorough examination reports must be retained and available for inspection.
Defects Reporting – Any defects found during examination that pose a danger must be reported immediately to the duty holder/employer.
Provision and Use of Work Equipment Regulations (PUWER) 1998 – ensures the general safety of the equipment (brakes, steering, tyres, etc.)
Suitability of Equipment – The forklift must be appropriate for the job, load, terrain, and environment (e.g. indoor or outdoor use, narrow aisles).
Maintenance – FLTs must be maintained in a safe condition. This includes routine servicing and keeping records of all work done.
Inspection – Inspections must be conducted when there is a significant risk, and after installation or adverse events (e.g. collisions).
Dangerous Parts Guarded – Moving parts like chains and gears must be guarded where necessary.
Controls – Controls (e.g. steering, lifting) must be safe, clearly marked, and within easy reach. Emergency stops must work.
Warning Devices – Reversing alarms, beacons, and other warning systems must be working if fitted.
Workplace (Health, Safety and Welfare) Regulations 1992
(More specifically for FLTs) – Regulation 17 – Movement of Pedestrians and Vehicles
“Every workplace shall be organised in such a way that pedestrians and vehicles can circulate in a safe manner.”
This includes:
- Designated pedestrian walkways – (E.g. floor markings, loading zones)
- Crossing points
- Barriers and signage
- Visibility and speed controls (Mandatory wearing of Hi-Viz clothing when working near FLT operations, implementing a rule for pedestrians to ensure they are never closer than 3 metres to an operating FLT).
Supervision / Training
Forklift Operator training should always include three stages:
Basic training
Basic training needs to fully cover the skills and knowledge needed to safely operate the type of lift truck and handling attachments (if any) the trainee will be required to use, including being aware of the risks from lift-truck operations. As well as those directly related to the operation of trucks, include associated tasks, such as the hazards associated with refuelling.
Specific job training
Knowledge and understanding of the operating principles and controls of the lift truck to be used, especially relating to handling attachments and loads specific to the job.
Routine inspection and servicing of the truck, in accordance with the operator’s handbook or manufacturer’s instructions, which may reasonably be carried out by the operator.
Using the truck in conditions the operator will meet at work, e.g., gangways; loading bays; racking; lifts; automatic doors; confined areas; cold stores; slopes; rough terrain; loading platforms; other vehicles; and bad weather.
Instruction on site rules, e.g. site layout; one-way systems; speed limits; general emergency procedures; using protective clothing and devices including operator restraints and eye and hearing protection; work near excavations and overhead lines; and other hazards.
Training in the work to be carried out, e.g. loading particular types of vehicles with loads normally found at that workplace.
Safe systems of work, which should include custody arrangements for keys.
Familiarisation training
Applying what has been learnt, under normal working conditions, on the job.
This could include:
- Applying, under normal working conditions, the skills already learned in basic and specific training, starting with simple tasks and moving on to more complex ones.
- Becoming familiar with the lift-truck activities of the employer.
- Familiarisation with the site layout, local emergency procedures and any other feature of the work which it is not practicable to teach off the job.
When it goes wrong
William Stobart & Son Limited were fined £160,000 after an employee lost both legs whilst working at its site near Warrington in June 2022.
Andrew McAuley, 64, an employee was picking orders at the firm’s warehouse in Appleton Thorn. He was working in close proximity to a forklift truck which was being used to load pallets of slate tiles onto a waiting truck. The FLT was carrying two pallets, one on top of the other. The top pallet was not secured to the one below, and when the driver turned the vehicle, both pallets became detached from the forks, with the upper pallet striking Mr McAuley, crushing his legs.
Mr McAuley had to have both legs amputated below the knee. He has been left dependent upon a wheelchair and unable to drive or climb stairs, leading to the need for extensive adaptations to the family home.
An investigation by the Health and Safety Executive (HSE) found that William Stobart & Son Limited failed to ensure this area of the warehouse was organised so that vehicles and pedestrians were segregated and circulated in a safe manner and loads were secured so far as was reasonably practicable.
At a hearing at Warrington Magistrates Court on 30 July 2024, William Stobart & Son Ltd. pleaded guilty to breaching regulation 2(1) of the Health and Safety at Work etc Act 1974. The company was fined £160,000 and ordered to pay £4,478 costs.
After the hearing HSE Inspector Lorna Sherlock said: “The company failed to implement a safe system of work for loading and unloading activities, thereby exposing employees, and others, to the risk of being struck by loads or workplace vehicles. This case illustrates the consequences of failing to segregate vehicles and pedestrians, and to properly secure loads’’.
To discuss your H&S needs with our team – contact us
Useful links to HSE Publications
Use Lift trucks safely – https://www.hse.gov.uk/pubns/indg457.pdf
Lift Truck training – https://www.hse.gov.uk/pubns/indg462.pdf
Rider Operated lift trucks – https://www.hse.gov.uk/pubns/priced/l117.pdf