Forklift truck safety: Your back-to-basics guide

Forklift trucks are essential tools in the builders merchant industry, but they also pose a significant risk of accidents and injuries when not operated correctly. According to the Health and Safety Executive (HSE), forklift truck accidents account for 25% of all workplace transport incidents.

Given the significant health and safety risks, we've gone back to basics on forklift truck safety to help you identify and address any gaps in your controls.

Forklift operator training

One of the most critical aspects of forklift truck safety is ensuring that operators are properly trained. All operators must have the correct training and certification to operate a forklift truck. The minimum standard of training required for forklift operators in the UK is a RTITB, AITT or ITSSAR certificate. Training should cover basic operation, load handling, safety procedures, and pre-use inspections.

Once the basic training has been completed, all operators must also undertake workplace-specific or 'familiarisation' training to equip them for the specific conditions of your site. This familiarisation training must be repeated every time the operator changes the type of forklift truck they are operating, or when they move to a new site.

Finally, operators must undertake refresher training at periodic intervals. The recommended frequency for refresher training is every three to five years.

Pre-use inspections

Before each shift, operators must conduct a thorough pre-use inspection of the forklift to identify any defects or issues that may affect its safe operation.

The inspection should cover:

• Tyres: Check for wear, damage, or any foreign objects embedded in the tyres.
• Forks: Check for cracks, bends, or undue wear on the forks.
• Hydraulics: Check the hydraulic system for leaks and proper function.
• Lights and alarms: Verify that all lights and alarms are in good working order.
• Battery: For electric forklifts, ensure the battery is charged and check for any signs of damage.
• General checks: Look for any visible damage to the forklift body, mast, and overhead guard.

Load handling

Incorrect load handling is a major cause of forklift accidents. To prevent accidents, operators should:

• Always ensure loads are properly secured on the forks.
• Never exceed the rated capacity of the forklift.
• Travel with the forks lowered and tilted back for stability.
• Avoid sudden stops, starts, and turns.
• Ensure the driver's view is not obstructed by the load being carried. If the load obstructs the driver's view, they should travel in reverse.

Site management

Effective site management is crucial for preventing forklift accidents. The HSE places a particular emphasis on making sure that vehicles and people are kept apart as effectively as possible. Employers should:

• Designate separate areas for forklift operation and pedestrian access.
• Install barriers, signs, and mirrors to manage traffic flow.
• Implement speed limits and ensure they are clearly marked and enforced.
• Provide adequate lighting in all areas where forklifts operate.
• Manage and control access for visitors and non-essential personnel to forklift operation areas.

Regular maintenance

Regular maintenance of forklift trucks is essential for safety. The Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 requires that all forklift trucks undergo regular thorough examinations by a competent person. LOLER requires a thorough examination of a forklift truck’s lifting equipment at least every 12 months, or every six months if it is used to lift people, unless an examination scheme drawn up by a competent person sets the intervals.

In between thorough examinations, employers must ensure that forklifts are maintained in line with manufacturer recommendations and that any identified defects are repaired promptly.

Key takeaways

Forklift truck safety is a complex area that requires ongoing attention and vigilance. By ensuring that operators are properly trained, conducting regular pre-use inspections, managing loads safely, implementing effective site management measures, and maintaining forklifts in good working order, you can significantly reduce the risk of forklift accidents in your workplace.