Maintaining forklift safety requires adhering to strict regulatory requirements, properly training drivers, and ensuring that all parts and equipment are well-maintained. Additionally, business owners and managers must ensure they have created a safe working  environment and clear guidelines for what to do in emergency situations. 

Keep reading to learn more about forklift health and safety, including:

• Do’s and don’t’s of forklift safety
• Common hazards and how to mitigate them
• Important U.K. regulations
• Types of forklifts and their safety features
• Training and certification for forklift operators
• Necessary daily maintenance procedures
• Creating a safe environment
• Best operational practices 

We have also included a printable daily health and safety checklist for forklift operators to keep on hand in the workplace

As we will explain further, maintaining forklift safety requires detailed knowledge of regulations, comprehensive and ongoing training, and maintenance of safe work environments. Additionally, all organisations and workplaces have their own unique setups and needs. 

However, there are some basic do’s and don’ts that should be followed by any organisation. These include: 

Do's

1. Do Conduct Daily Inspections: Always perform pre-operation checks on the forklift to ensure it is in safe working condition.
2. Do Follow Proper Training Protocols: Ensure all operators are adequately trained and certified to operate forklifts. Continuous training and refresher courses are essential.
3. Do Wear Appropriate Personal Protective Equipment (PPE): Always wear necessary PPE, such as hard hats, safety shoes, and high-visibility clothing, to protect against potential hazards.
4. Do Keep Loads Within Capacity: Ensure that the load does not exceed the forklift’s rated capacity and is securely fastened.
5. Do Maintain Situational Awareness: Stay aware of your surroundings, including other personnel, equipment, and potential hazards in the environment.
6. Do Use Hand Signals: Use clear hand signals and communication with ground personnel when navigating and lifting loads to enhance safety.
7. Do Keep Forks Low: When driving with a load, keep the forks a few inches off the ground to maintain stability and visibility.
8. Do Plan Your Path: When stacking or retrieving loads, plan your route to avoid tight corners and congested areas to enhance safety.
9. Do Use Horns and Warning Lights: Use the forklift's horn and any safety lights to alert others of your presence, especially in tight spaces or at intersections.
10. Do Secure the Forklift When Unattended: When leaving the forklift, set the parking brake and lower the forks to the ground, ensuring the truck is in a stable position.

Don'ts

1. Don't Operate Without a Load: Avoid lifting loads too high or driving with forks raised, as this can lead to a loss of stability and increase the risk of tipping.
2. Don't Allow Unauthorised Operators: Do not permit anyone who is not trained or authorised to operate the forklift.
3. Don't Ignore Warning Signs: Pay attention to warning signs, signals, and the presence of pedestrians, and react accordingly.
4. Don't Use a Forklift for Unintended Purposes: Avoid using forklifts to carry people or transport items that are not designed for forklift use.
5. Don't Operate on Uneven Surfaces: Refrain from using forklifts on slopes or uneven surfaces unless specifically designed for such conditions.
6. Don't Rush or Drive Recklessly: Avoid speeding or making sharp turns that could lead to loss of control or collisions.
7. Don't Operate in Poor Visibility: Never operate the forklift in areas with inadequate lighting or obstructed visibility; use headlights when necessary.
8. Don't Block Aisles or Exits: Avoid parking or leaving the forklift in aisles or near exits, which can obstruct pedestrian traffic or escape routes.

By following these do's and don'ts, operators and employers can help create a safer working environment and reduce the likelihood of accidents involving forklifts.

Forklift operations involve several inherent hazards that can pose significant risks to operators, pedestrians, and the working environment. 

Research underscores the importance of robust safety measures in preventing forklift accidents. According to the Health and Safety Executive (HSE), forklift trucks are involved in a significant number of workplace accidents annually. The HSE reports that there are about 50 deaths and approximately 8,000 injuries related to forklift operations each year in the UK. 

One of the most common hazards is tip-overs, which can occur when a forklift is overloaded or when it's driven too fast around corners. The National Institute for Occupational Safety and Health (NIOSH) has found that forklift tip-overs are the leading cause of fatal injuries in the workplace, often resulting in serious accidents that can lead to death or severe injuries. The changing centre of gravity while lifting loads, especially with high masts or uneven surfaces, increases the risk of tipping and crashing.

Another prevalent hazard involves workers who may be in the vicinity of operating forklifts, leading to struck-by incidents. NIOSH statistics indicate that a high percentage of forklift accidents involve pedestrians, often resulting from visibility issues or operators who may be inattentive. 

Additionally, there are risks associated with collisions between forklifts and other equipment or structures, particularly in crowded or poorly organised workspaces. 

Other hazards include falling loads resulting from improper securing or unbalanced loads, as well as incidents related to mechanical failures and maintenance neglect, which can compromise the forklift's safe operation.

Click here to learn more about preventing common forklift accidents

To effectively mitigate the risks associated with fork-lift operations, businesses must implement comprehensive hazard identification and risk assessment strategies. 

One effective strategy is conducting regular safety audits and inspections to make sure that all equipment is functioning correctly and that safety protocols are being followed. 

Risk assessments should involve evaluating all areas of operation, including forklift routes, storage layouts, and pedestrian crossings to identify potential hazards. Employees should be encouraged to actively participate in safety inspections through reporting near misses or unsafe conditions, which can help to identify risks before they lead to accidents.

Another strategy is to employ the hierarchy of controls, a systematic approach to addressing hazards starting with the most effective measures. This could involve eliminating the hazard altogether, such as redesigning the workspace to avoid tight areas where collisions might occur, to implementing engineering controls such as installing guard rails or barriers to protect pedestrian walkways. 

Administrative controls, such as establishing safe operating procedures and providing refresher training, also play a crucial role in preventing accidents. PPE should complement these strategies, ensuring that all personnel in forklift operations are equipped with necessary gear such as helmets and high-visibility clothing.

Learn about the true cost of forklift accidents.

The first step to creating the right environment for health and safety while operating a forklift is to have a deep understanding of current regulations. These are in place to guide operations and help mitigate risk while operating heavy equipment.

Some of the most important U.K. regulations include: 

Health and Safety at Work Act 1974 (HSWA): 

This foundational legislation emphasises the responsibility of employers to ensure the health and safety of employees and others affected by their work activities. This includes the safe use of forklifts.

Provision and Use of Work Equipment Regulations 1998 (PUWER): 

These regulations require that any work equipment, including forklifts, is suitable for its intended use, maintained in a safe condition, and inspected regularly. Employers must also provide training for operators.

Lifting Operations and Lifting Equipment Regulations 1998 (LOLER): 

LOLER requires that all lifting equipment, including forklifts, is properly maintained, thoroughly inspected, and used correctly to ensure the safety of lifting operations.

Building your policies around these regulations is key to maintaining health and safety. They create an important framework for daily operations and should be referenced whenever possible. Keeping up to date with any changes to these policies, or new regulations, is also necessary.

After utilising UK regulations to set a framework for your operations, the next step is to gain a deeper understanding of the types of forklifts available and their safety features. 

Choosing the right truck for the job is critical for safety as it ensures proper load capacity, stability, and suitability for the operational environment. Using equipment suited to specific tasks helps prevent overloads and accidents while promoting efficiency in material handling. Proper fit for operator comfort and training requirements, along with adequate safety features, further reduces risks and enhances compliance with safety regulations.

Below are common types of forklifts, and the safety features they usually include:

Counterbalance Trucks

Counterbalance trucks are primarily designed to lift and transport heavy loads on pallets or containers. 

The name "counterbalance" comes from the design that uses weights (located at the rear) to offset the weight of the load being lifted at the front, maintaining stability while lifting. This safety feature is important for preventing tipping while moving heavy loads. 

Key safety features:

• Counterbalance to prevent tipping
• Low centre of gravity for better stability 
• Emergency breaking system for stopping power against heavy loads
• Inbuilt security functions to prevent unauthorised operation
• Engineered for 360 degree visibility

Reach Trucks

Reach trucks are specialised forklifts designed for handling materials in narrow aisle warehouses. They are particularly efficient for stacking and retrieving loads at height, making them ideal for maximising storage in limited spaces. The right reach truck will also ensure operator comfort and safety.

Key safety features: 

• Stability systems to help maintain balance when lifting loads at height or extending the forks 
• Load weight indicators to prevent overloading
• Height restriction sensors prevent the mast from lifting beyond a predefined height limit in certain areas, ensuring safe operations in warehouses with low ceilings.

Pallet Trucks 

Pallet trucks are used to lift and transport pallets within warehouses, distribution centres, and retail environments. They are typically operated manually or can be powered as electric pallet trucks. As with reach trucks, pallet trucks should also be comfortable and safe to operate. 

Key safety features:

• Many pallet trucks include a controlled release function that allows operators to lower the load slowly and safely, reducing the risk of sudden drops.
• Fork stops or protective features to ensure that pallets cannot slide off during transportation. Some designs have forks shaped to better secure pallets.

Related: What Forklift Size Should You Be Using?

Ensuring your forklift operators are properly trained and certified is not only key to improving safety in the workplace but is also required under the regulations mentioned above. 

Many companies develop their own training programmes in accordance with the Health and Safety Executive guidelines and may issue internal certification. These programmes often include practical assessments and ongoing training to ensure compliance with safety regulations.

However, there are also several nationally recognised certifications, including:

• The Road Transport Industry Training Board Certification offers accredited forklift operator training courses covering various types of forklifts, including counterbalance, reach trucks, and pallet trucks.
• The Independent Training Standards Scheme and Register Certification is another recognised body that provides forklift operator training and certification. Their training programmes cover a range of lift trucks and emphasise health and safety standards.
• The National Plant Operators Registration Scheme Certification offers training and certification for various types of material handling equipment, including forklifts. 
• The Construction Industry Training Board Certification provides training courses for forklift operators, especially in the construction industry. Their certification is recognised across the industry and ensures compliance with safety standards.
• The Institution of Occupational Safety and Health Certification is not specifically for forklift operators, but it offers valuable training courses on health and safety management that cover the safe operation of machinery, including forklifts. 

These certifications are recognised to help ensure workplace health and safety. They are essential for operators as they significantly enhance safety by reducing the risk of accidents and injuries through proper training on safe operating procedures and hazard recognition. 

Additionally, qualifications ensure compliance with legal regulations, improve operational efficiency and reduce costs associated with damages and downtime. 

Certified operators possess a comprehensive understanding of the specific equipment they use, leading to increased competence and productivity. 

Furthermore, obtaining these qualifications fosters a culture of safety within the workplace, builds trust with employers and clients, and opens up opportunities for career advancement. Overall, investing in proper training is beneficial for both operators and organisations.

Read more about creating a culture of health and safety in the workplace.

Conducting daily safety checks for forklifts is crucial to ensure they operate safely and efficiently. Here are some essential daily safety checks that operators should perform before using a forklift:

1. Visual Inspection

• General Condition: Look for any visible damage, leaks, or wear on the forklift’s exterior, including the body, forks, and tyres.
• Forks: Check for cracks, bends, or excessive wear on the forks, ensuring they are in good condition and properly aligned.

2. Fluid Levels

• Hydraulic Fluid: Verify the hydraulic fluid levels are within the recommended range to ensure properly functioning lifting and steering systems.
• Fuel Level: Check the fuel or battery charge level, ensuring it is sufficient for the day’s operations.

3. Braking System

• Foot Brake: Test the foot brake to ensure it engages and releases properly without any unusual noise or resistance.
• Parking Brake: Verify that the parking brake holds securely when applied.

4. Controls and Instrumentation

• Operational Controls: Test all operational controls (tilt, lift, lower, horn, etc.) to ensure they respond correctly and are functioning properly.
• Warning Lights and Alarms: Check that all indicator lights, gauges, and alarms are operational and displaying correct readings.

5. Tyres and Wheels

• Tyre Condition: Inspect tyres for proper inflation, punctures, and significant wear or damage that could affect stability or performance.
• Wheel Assembly: Check wheel bolts and ensure they are secure and in good condition.

6. Mast and Chains

• Mast Condition: Inspect the mast for any signs of damage or excessive wear and ensure it operates smoothly.
• Chain and Sheave: Check the chains (on units with chain lifts) for proper tension, wear, and lubrication.

7. Seat and Safety Features

• Operator Seat: Ensure the operator's seat is secure and comfortable, with no damage or obstructions.
• Seat Belt: Verify that the seat belt is functioning and in good condition.

8. Safety Equipment

• Overhead Guard: Ensure the overhead guard is intact and free from damage to protect against falling objects.
• Lighting: Check that all lights (headlights, brake lights, and indicators) are operational to ensure visibility and communication with others.

9. Emergency Equipment

• Fire Extinguisher: Ensure the fire extinguisher, if equipped, is accessible, fully charged, and in good working condition.
• First Aid Kit: Verify that the first aid kit is stocked and available for use.

10. General Cleanliness

• Clear Debris: Make sure the forklift is free of any debris or obstruction that might interfere with safe operation.

Performing these daily safety checks helps identify potential issues before they lead to accidents, ensuring that forklifts operate safely and efficiently throughout the day. 

Operators should document these checks, and any discrepancies should be reported immediately to maintenance personnel for corrective actions.

Optimising warehouse layout for safety involves strategically planning the arrangement of aisles, storage areas, and workstations to minimise hazards and enhance the flow of operations. 

One effective strategy is to create clear, defined pathways for both pedestrian and forklift traffic. Marked walkways can help separate foot traffic from equipment movement zones, reducing the risk of collisions. 

Adequate space should be allocated between shelving units and workstations to allow safe manoeuvrability for forklifts and other machinery. 

Using safety signage to indicate pedestrian zones, caution areas, and traffic rules can further enhance awareness and communication among workers about safe practices within the warehouse.

Another key strategy is to implement visual management tools such as colour-coded systems for storage and aisles, which can aid in quick identification of specific areas. 

Utilising vertical space effectively by employing pallet racking systems can help reduce the footprint of storage areas whilst maintaining safety when stacking products. Ensuring that emergency exits, fire extinguishers, and first aid kits are easily accessible and clearly marked also contributes to a safer layout. 

Finally, regularly conducting safety audits and involving employees in discussions about layout optimisation can foster a culture of safety, encouraging ongoing improvements to the warehouse environment.

Load Handling and Stability Principles

Proper load handling and stability are critical to safe forklift operation and preventing accidents. Operators should always check the load's weight and ensure it is within the forklift's rated capacity. Overloading can cause stability issues, leading to tipping over during lifting or transport. Additionally, loads should be evenly distributed on the forks to maintain balance. 

When lifting, operators must position the forks as close to the centre of the load as possible, which helps stabilise it and reduce the risk of shifting while moving. It is also important to secure loads with straps or wrapping materials if necessary, especially when handling items that might slide or fall off the forks during transport.

When moving loads, operators should take care to keep the forks low—typically just a few inches from the ground—to enhance stability and visibility. Lifting loads too high can alter the centre of gravity and increase the likelihood of tipping, particularly when turning. 

Cornering should be done cautiously, with ample time to slow down and adjust the mast's angle whilst keeping an eye on the environment. After placing the load, operators should ensure it is positioned securely in the storage area before leaving the forklift unattended, a key principle for maintaining workplace safety.

Maintaining Situational Awareness Whilst Operating a Forklift

Situational awareness is vital for forklift operators as it involves understanding and reacting to the dynamic environment within the workplace. Operators should consistently monitor their surroundings for potential hazards, including pedestrians, other equipment, and structural elements such as shelves and beams. 

This awareness allows operators to anticipate movements, make informed decisions, and react timely to evolving situations. Regularly scanning the area and using peripheral vision can help operators stay alert to any unexpected changes in the environment, ensuring a proactive rather than reactive approach to safety.

Moreover, effective communication with team members is a crucial part of situational awareness. Operators should use hand signals or verbal communication to inform colleagues of their actions when navigating crowded areas. 

Maintaining a clear line of sight whilst travelling with a load is also essential; operators may need to travel in reverse to ensure visibility. 

Related: 5 Recommended Safety Features to Reduce Forklift Truck Accidents.

Having an emergency response plan (ERP) in place is crucial for minimising the impact of accidents and emergencies in any workplace, particularly in environments like warehouses where the use of forklifts and other heavy machinery is prevalent. 

An ERP provides a structured approach to managing various emergency situations, such as accidents, fires, hazmat spills, and severe weather events. It outlines the necessary procedures for immediate action, ensuring that employees understand their roles and responsibilities during an emergency. This clarity can significantly reduce panic and confusion during a crisis, enabling a more effective and timely response that can save lives and limit property damage.

In addition to enhancing safety, an effective ERP can also facilitate compliance with health and safety regulations. Organisations in the UK, such as those governed by the Health and Safety at Work Act and other workplace safety regulations, are required to have plans in place for emergency response. A well-documented and practised ERP not only helps companies meet legal obligations, but it also demonstrates a commitment to employee safety and welfare, which can improve overall morale and foster a culture of safety within the organisation.

Training for Dealing with Accidents or Injuries

Training employees to deal with accidents or injuries is an essential component of workplace safety and emergency preparedness. Such training should encompass a range of topics, including first aid protocols, emergency evacuation procedures, and specific actions to take in the event of a forklift-related accident. 

Organisations should implement regular training sessions to ensure that all employees are familiar with the emergency response plan and their specific roles within it. Hands-on training can be particularly beneficial, allowing employees to practice critical skills in a controlled environment, which increases confidence and competence in real-life situations.

Additionally, involving employees in emergency drills can be an effective way to reinforce training and prepare the workforce for actual emergencies. These drills allow staff to practice responding to various scenarios, such as medical emergencies, fires, or chemical spills, enabling them to develop a better understanding of the response protocols. 

After drills, conducting debriefings to discuss what went well and what can be improved helps to continuously enhance emergency preparedness and ensure that the response plan evolves based on practical experiences.

All workplaces should have first aid kits that are stocked with essential supplies such as bandages, antiseptics, tape, and other medical items. The kits should be regularly checked and replenished to ensure the availability of necessary materials. 

Clear signage should be used to display the location of first aid kits and emergency equipment, such as fire extinguishers and eyewash stations, ensuring they can be quickly accessed during an emergency. 

Additionally, maintaining a list of emergency contacts, including local emergency services, poison control centres, and company-specific first-aid responders, should be easily accessible in every area of the warehouse. This information could be displayed prominently near phones or in common areas, enabling swift communication with appropriate resources in a crisis.

Ongoing Review and Improvement of the Emergency Response Plan

It is crucial to recognise that an emergency response plan is not static; it requires ongoing review and refinement. Regular audits of the ERP should be conducted to assess its effectiveness and adapt to any changes in the workplace environment or operations. 

For instance, changes in warehouse layout, introduction of new equipment, or an increase in workforce size may necessitate updates to the response plan to ensure continued effectiveness. 

Engaging employees in the review process can provide valuable insights into potential issues that may not have been previously identified, allowing organisations to proactively refine their plans.

Organisations should stay informed about industry best practices and legal requirements pertaining to emergency preparedness. Networking with other companies and participating in industry safety seminars can provide additional resources and knowledge for enhancing the effectiveness of an emergency response plan. 

The commitment to continuous improvement not only helps organisations create a safer workplace but also reinforces the importance of safety as a core value within the organisational culture, ultimately protecting employees and the organisation’s reputation.

1. What safety devices must be installed on the forklift?

Forklifts must be equipped with essential safety devices such as seat belts, horns, lights, backup alarms, and overhead guards to protect the operator and enhance visibility. Additionally, some models may have stability systems and cameras to assist operators in monitoring their surroundings.

2. How do operators ensure they are driving forklifts safely?

To drive a forklift safely, always adjust your speed according to the environment, keep the forks low while moving, and be aware of your surroundings. Use hand signals for communication, avoid sharp turns, and never exceed the load capacity to maintain stability and prevent accidents.

3. Which forklift safety precautions should be considered?

Safety precautions for forklifts include performing daily inspections, ensuring proper training and certification for operators, and using appropriate PPE. It's also critical to maintain clear pathways, obey signage, and avoid lifting loads above the maximum height to minimise risks.

4. What should operators do before using a forklift?

Operators should conduct a thorough pre-operation inspection to ensure the forklift is in safe working condition, checking fluid levels, brakes, lights, and forks. Additionally, they should verify the load capacity and ensure that their area of operation is clear of obstacles and hazards.

5. How often should forklift training be updated?

Forklift training should be updated regularly, typically every three years, or sooner if there is a change in equipment, job tasks, or significant accidents. Continuous training helps to reinforce safety practices and keep operators informed about any new regulations or technologies.

6. What should you do if an accident occurs while operating a forklift?

In the event of an accident, ensure the safety of all individuals involved and call for medical assistance if necessary. Report the incident to a supervisor and complete any required documentation to assess the cause and prevent future occurrences.

7. Why is visibility important when operating a forklift?

Visibility is crucial for safe forklift operation, as it allows operators to see potential hazards, pedestrians, and obstacles in their path. Maintaining clear sightlines and using mirrors or cameras can help improve awareness and reduce the risk of collisions.

8. How can traffic in a warehouse be safely managed?

Traffic in a warehouse can be managed by implementing designated pedestrian walkways, using signage to alert individuals of forklift operations, and providing thorough training on traffic rules. Clear communication and maintaining a slow speed in crowded areas further enhance safety for both operators and pedestrians.

Forklift safety is essential not only for protecting employees but also for promoting workplace efficiency. With forklift operations being integral to material handling in various industries, the potential for accidents can lead to significant downtime, increased costs, and even severe injuries. 

By prioritising safety through effective training, upholding operational best practices, and adhering to safety regulations, businesses can create a more secure working environment and enhance overall productivity. A culture that values safety not only reduces the likelihood of incidents but also fosters employee morale and commitment to their roles.

We encourage all employers and employees to adopt robust safety practices and engage in continuous training to stay updated on safety protocols. Regularly reviewing emergency response plans and conducting safety drills can prepare your team for unforeseen situations. 

To learn more about maintaining safety for forklift operators, including useful guidelines on material handling, download our free guide: