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Forklift truck guideSome notes by Stephen Tribbick, Harrow Council Environmental Health Services 17/11/2003partly based on the fact-sheet from www.NuneatonandBedworth/business/healthsafety.

IndexIndex ...................................................................................................................1Introduction .........................................................................................................1The Forklift Truck ................................................................................................1Checking the truck ..............................................................................................2

Lift truck pre-shift check..............................................................................2Routine maintenance..................................................................................4Thorough examination................................................................................4Schedule 1 to the Lifting Operations and Lifting Equipment Regs 1998.....5

Selection of Operators ........................................................................................6Training of Operators ..........................................................................................7Authorisation of Operators ..................................................................................8Basic driving rules ...............................................................................................8Lifting people.......................................................................................................9Layout and Maintenance of Workplace...............................................................9Signalling ..........................................................................................................10Use on the public highway ................................................................................11Employers Checklist - Forklift Trucks................................................................11References / Further Details .............................................................................12Health & Safety Enforcement............................................................................13

IntroductionForklift trucks (FLTs) feature prominently in workplace accidents. Every year there are about8000 lift truck accidents resulting in injury, and about 10 fatalities. Even if people are notinjured in FLT accidents there is often damage to buildings, storage systems or stock. Themain causes of FLT accidents are:

♦ lack of operator training

♦ inadequate premises

♦ poor FLT maintenanceIt is the responsibility of management to assess FLT operations and ensure that safe systemof work are implemented and maintained. Subsequent responsibilities for safe use will alsolie with line managers, supervisors and operators.

The Forklift TruckSafety considerations include:

♦ Operation in the workplace - loading, movement, position of forks, turning etc.

♦ Safe capacity is a function of the rated capacity, lift height and load centre distance,which will be shown on the FLT capacity data plate.

♦ Tyres - inflation pressure; damage; use of safety cage if wheels have split rims, and no‘hot work’ before tyre has been completely removed.

♦ Brakes, horn, safety lock or switch with removable key.

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♦ Seat belt fitted and used when there are significant risks, to avoid being crushed underthe truck should it roll over.

♦ Overhead guard if lift height exceeds 1.8m or if falling objects are foreseeable.

♦ Dangerous moving parts - e.g. traps caused by telescopic mast sections, lifting chainsetc.

♦ Battery charging – eg good ventilation, signage about naked lights, clear procedure foravoiding sparks and shocks, visor, gloves and eyewash.

♦ Potentially explosive/flammable atmospheres - petrol/LPG/diesel FLTs not to beused; electrical FLTs to be suitably protected.

♦ Attachments - may alter the FLTs handling and stability characteristics and rating; needto be securely fastened.

There are over 30 groups of Lift Truck listed by the Association of Industrial Truck Trainers(AITT) eg Rough terrain masted lift truck, Telescopic container handling truck etc. Eachrequires its own training and certification. Some of the comonest types of FLT are shown inthe following table:

TYPE CHARACTERISTICS AITT GROUP

Counterbalanced FLT Counterweight balances load on the forksTiltable mast (5-15o)Operate on fairly smooth surfaces only (warehouse andyard, not pot-holed road or field)Many attachments available

B1 (up to 5tonnes)

Reach Truck Mast ‘reaches’ out to pick up loadLoad is ‘reached’ back and carried within the wheelbase ifpossibleHas greater manoeuvrability in restricted areasOperate on smooth surfaces only (inside warehouse)Always battery-operated and used in warehouses

D1

Side Loader Load is carried on the deck of the FLT, the mast beingtraversed sideways to pick up/set down the loadUsed for long loads e.g. timber or pipesMay be fitted with stabilisersSuitable for rough terrain

C1 (up to 3tonnes)

Pedestrian Controlled FLT Limited lift height (usually no more than 2 metres)Electrically or manually operatedOperator walks with the machine and controls it with ahandleOperate on smooth surfaces only (inside warehouse)

A3

Checking the truck

Lift truck pre-shift checkThe following type of check must be completed before the truck is used each day:

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Lift-truckpre-shift check Truck Week

beginning

Item Details

Mon

Tue

Wed

Thur

Fri

Sat

Sun

Fork arms No cracks or distortion. Evenly spaced oncarriage plate and clips engaged

Carriage plate No obvious damage. End stops secure.Back rest Load backrest extension secure and not

damaged or distortedMast No damage distortion or cracks. Inner

channels or runners reasonably clean andsmooth

Lift chain Free from damage or rust. All pins in place

Hydraulics No damage or leakage from any point

Wheels Undamaged. All nuts tight.

Tyres No excessive wear, cuts or foreign bodies.If pneumatic, tyre pressure correct

Lights /indicators

All functioning

Horn / beeperetc

Clearly audible

Mast controls Lift/lower, tilt and side shift operatingproperly.

Hand / parkingbrake

Strong enough to prevent truck being driven

Driving &Service brake

Work properly in both directions whentested slowly

Fuel / power Adequate for shift

Levels Coolant and engine oil levels correct

LPG Cylinder secure, pipes & hoses OK

Steering Works properly in both directions atstandstill and when moving

Chainlubrication

Chain should be sprayed with a suitablelubricant every month or 250 hours

Electric truckbatteries

Battery levels must be topped up withdistilled water where necessary once aweek

Operator’s initialsHour reading when check done

!!!! Tick items that are OK."""" Cross any that have faults, describe problem overleaf and report it to the supervisor beforeattempting to use the truck, if safe to do so.Cross out rows that don’t apply (eg LPG row if it is an electric truck)

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Routine maintenanceRegular preventative maintenance is required. typically every 3 months. Usually theemployer should have a contract for these, with a call-out facility when problems are noted.This will be normal where the truck is on a lease agreement. The operator is oftenresponsible for more regular items eg electrolyte levels, chain lubrication etc.

Thorough examinationLOLER 98 regulation 9 requires the thorough examination of lifting equipment at appropriateintervals to ensure its safe use. This is in addition to any preventative maintenance andthere is often confusion in the trade over this requirement. The Thorough Inspection isusually by an engineer employed by an insurance company, and this is to be preferred tothose by the usual maintenance engineer as it provides an additional level of independence.Where trucks are leased the servicing might be arranged by the supplier, but arranging thethorough examination is often the responsibility of the user. Where trucks are hired, thesupplier might organise both servicing and thorough examinations, albeit with differentengineers.

Most FLTs will require a 6-monthly thorough examination. However, an annual interval couldbe appropriate if the FLT isn’t used for more than 40 hours per week, is never used for liftingpeople and doesn’t have any fitted attachments or a side shift mechanism. The thoroughexamination report must comply with the requirements of Schedule 1 in the LOLER Regs(see below). There is no prescribed form, but as a quick way of checking that a documentisn’t just a servicing check look for statements that:♦ it is a thorough examination,

♦ the FLT is safe to operate OR the defects that make it unsafe, AND any defects that maybecome dangerous in a specified time.

♦ the next thorough examination is required on a certain date.

Amongst other things the examination should ensure that:♦ the forks haven’t worn down by more than 10% of the original thickness at the heel

♦ the chains haven’t stretched by more than 2% of their original length

The British Industrial Truck Association (BITA) recommend that chains are scrapped after 3years or 6000 hours use (whichever is the sooner) OR where used in cold-stores, 2 years /4000 hours. See also LAC 32/1.

Certification of the examinations must be retained for inspection on request.

The actual words of the regulation are as follows. Note that this applies to all types of liftingmachinery, not just FLTs.

Thorough examination and inspection 9. - (1) Every employer shall ensure that before lifting equipment is put into service forthe first time by him it is thoroughly examined for any defect unless either -

(a) the lifting equipment has not been used before; and

(b) in the case of lifting equipment for which an EC declaration of conformity could or(in the case of a declaration under the Lifts Regulations 1997) should have been drawnup, the employer has received such declaration made not more than 12 months beforethe lifting equipment is put into service;

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or, if obtained from the undertaking of another person, it is accompanied by physicalevidence referred to in paragraph (4).

(2) Every employer shall ensure that, where the safety of lifting equipment depends on theinstallation conditions, it is thoroughly examined -

(a) after installation and before being put into service for the first time; and

(b) after assembly and before being put into service at a new site or in a new location,

to ensure that it has been installed correctly and is safe to operate.

(3) Subject to paragraph (6), every employer shall ensure that lifting equipment which isexposed to conditions causing deterioration which is liable to result in dangerous situationsis-

(a) thoroughly examined -

(i) in the case of lifting equipment for lifting persons or an accessory for lifting, at leastevery 6 months;

(ii) in the case of other lifting equipment, at least every 12 months; or

(iii) in either case, in accordance with an examination scheme; and

(iv) each time that exceptional circumstances which are liable to jeopardise the safetyof the lifting equipment have occurred; and

(b) if appropriate for the purpose, is inspected by a competent person at suitableintervals between thorough examinations,

to ensure that health and safety conditions are maintained and that any deterioration can bedetected and remedied in good time.

Schedule 1 to the Lifting Operations and Lifting EquipmentRegs 1998INFORMATION TO BE CONTAINED IN A REPORT OF A THOROUGH EXAMINATION

1. The name and address of the employer for whom the thorough examination was made.

2. The address of the premises at which the thorough examination was made.

3. Particulars sufficient to identify the lifting equipment including where known its date ofmanufacture.

4. The date of the last thorough examination.

5. The safe working load of the lifting equipment or (where its safe working load dependson the configuration of the lifting equipment) its safe working load for the last configuration inwhich it was thoroughly examined.

6. In relation to the first thorough examination of lifting equipment after installation or afterassembly at a new site or in a new location -

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(a) that it is such thorough examination;

(b) (if such be the case) that it has been installed correctly and would be safe tooperate.

7. In relation to a thorough examination of lifting equipment other than a thoroughexamination to which paragraph 6 relates -

(a) whether it is a thorough examination -

(i) within an interval of 6 months under regulation 9(3)(a)(i);

(ii) within an interval of 12 months under regulation 9(3)(a)(ii);

(iii) in accordance with an examination scheme under regulation 9(3)(a)(iii); or

(iv) after the occurrence of exceptional circumstances under regulation 9(3)(a)(iv);

(b) (if such be the case) that the lifting equipment would be safe to operate.

8. In relation to every thorough examination of lifting equipment -

(a) identification of any part found to have a defect which is or could become a dangerto persons, and a description of the defect;

(b) particulars of any repair, renewal or alteration required to remedy a defect found tobe a danger to persons;

(c) in the case of a defect which is not yet but could become a danger to persons -

(i) the time by which it could become such danger;

(ii) particulars of any repair, renewal or alteration required to remedy it;

(d) the latest date by which the next thorough examination must be carried out;

(e) where the thorough examination included testing, particulars of any test;

(f) the date of the thorough examination.

9. The name, address and qualifications of the person making the report; that he is self-employed or, if employed, the name and address of his employer.

10. The name and address of a person signing or authenticating the report on behalf of itsauthor.

11. The date of the report.

Selection of OperatorsFLT drivers should be reliable, mature and responsible people, with appropriatephysical/mental capabilities. Selection testing may be useful.

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Appendix 2 of HSG6 gives various medical considerations including:♦ pre-employment fitness screening is recommended, as are 5 yearly checks for the over-

40’s.

♦ general health, particularly mobility/agility

♦ vision, which should not normally be less than 6/12 with both eyes (wearing glasses orcontact lenses if needed)

♦ hearing

♦ alcohol & drug abuse

Where trucks are taken onto the public highway then the usual DVLA standards (“ At aGlance”) also apply. These can be seen at www.dvla.gov.uk/at_a_glance/content.htm. Notethey distinguish between Group 1 (car and small FLTs) users and Group 2 (HGV, PSVusers).

Training of OperatorsThe training of workers on any type of work equipment is required by PUWER98, Reg 9:

9. - (1) Every employer shall ensure that all persons who use work equipment havereceived adequate training for purposes of health and safety, including training in themethods which may be adopted when using the work equipment, any risks whichsuch use may entail and precautions to be taken.

(2) Every employer shall ensure that any of his employees who supervises ormanages the use of work equipment has received adequate training for purposes ofhealth and safety, including training in the methods which may be adopted whenusing the work equipment, any risks which such use may entail and precautions to betaken.

There is no nationally prescribed training for pallet trucks or for pedestrian operated lifttrucks. For these the employer should determine what is “adequate training”.

For larger machines, training should be carried out in accordance with the Approved Code ofPractice (ACoP) ‘Rider operated lift trucks: operator training’. 'Rider-operated' means anytruck capable of carrying an operator and includes trucks controlled from both seated andstand-on positions. It relates to stacking rider-operated lift trucks (such as counterbalancedFLTs, reach trucks, rough terrain counterbalanced FLTs and telescopic materials handlers).No person to whom the code applies should be employed to operate a lift truck unless he orshe has satisfactorily completed training and testing as described in the code.

Training should include the following stages:♦ Basic training

♦ Specific job training, relating to the FLT to be used

♦ Familiarisation training at the workplace, under supervision.

♦ Conversion training would be needed for operators going onto a different group of FLTseg a reach truck after originally being trained on a counterbalance truck.

Records should be kept of training completed by individuals and their associated test results.Certificates of basic training are a useful, practical means of providing documentaryevidence that relevant training has taken place and an appropriate level of operating ability

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has been attained. In addition to the paper certificate, the operator will be given a smalllaminated card showing their qualification. Note that these will give the date and thegroup(s) of truck on which the training has been completed.

Refresher training and assessment is not specified in the HSE guidance but is recognised bythe training organisations as useful every 5 years or so. Sooner if there is cause forconcern. Employers should continuously monitor the performance of operators to ascertainwhether they might need refresher training. Indicators might be near misses, accidents orconsistently unsafe working practices. This is especially the case if operators are occasionalusers, have not operated trucks for some time, or there has been a change in their workingpractices or environment.

The HSE has recognised five bodies as competent to operate voluntary schemes ofaccreditation for training providers(See LAC 32/7). These are:♦ The Association of Industrial Truck Trainers (AITT) whose accreditation scheme is known

as the Independent Training Standards Scheme and Register (ITSSAR);

♦ The Construction Industry Training Board (CITB) whose scheme is part of the Certificateof Training Achievement Scheme (CTA) which covers many types of construction plant.HSC’s recognition is only for lift truck training;

♦ Lantra National Training Organisation (previously ATB Landbase);

♦ The National Plant Operators Registration Scheme

♦ RTITB Ltd.

Authorisation of OperatorsNot everyone who has been trained in the past should automatically be allowed to operateFLTs within a business. There should be a formal authorisation process.

Authorisation should be:♦ in writing

♦ confined to the type of FLT and work for which the employer has found the operatorcompetent

♦ for a specified period.

Authorisation should be withdrawn by the employer pending a review or retraining if there isan accident, if the operator displays poor standards or is unwell or otherwise incapacitated.

Basic driving rulesManagers or inspectors should check that operators are following the following principles:

♦ Driving at a speed appropriate to the circumstances

♦ Only moving with a raised load at a creep speed. And only whilst stacking.

♦ Normal travel is with the forks 100 - 150mm above the ground.

♦ Looking in the direction they are travelling

♦ Travelling in a direction in which they have a clear view, or using a trained banksman orguide. So counterbalanced trucks go backwards if the load obstructs vision (but whengoing uphill on a slope with a bulky load, travelling forwards but with help from a guide)

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♦ Never going across sloping ground, only up or down.

♦ When travelling on a slope when loaded, with the load uphill.

♦ When travelling on a slope when unloaded, with the forks downhill.

♦ Leaving the truck parked with forks on the ground, handbrake on and key removed.

♦ Never parking on a slope.

♦ Never lifting anyone on the forks or on a pallet.

♦ Never carrying passengers.

Lifting peopleThe lifting of anybody standing on the forks, or on a pallet, is dangerous and illegal.However, there is a safe way of using a FLT for this task – by means of a special cagesecurely fitted to the forks called a mobile elevating work platform (MEWP). This gives aworking platform with a handrail so if the worker is jerked or looses their balance they cannotfall to the ground. They are also protected from entanglement in the lifting chains. SeePM28 for details. However, this arrangement should only be for occasional jobs, not forregular order picking or similar operations, as FLTs lack the controls and safety devices inpurpose designed vehicles.

Layout and Maintenance of Workplace♦ Roadways and aisles etc. should have sufficient width and overhead clearance (for

loaded FLTs and for FLTs passing each other if necessary); road humps should beavoided; consideration could be given to a 1-way system if warranted; adequate lightingis essential.

♦ Pedestrians should be prohibited where possible, or risks assessed and controlled bythe use of signs or barriers that are clearly marked (black and yellow diagonal stripes).

♦ Edges of loading bays etc. should be clearly marked or, where possible, fitted withbarriers.

♦ Avoidance of sharp bends, obstructions, etc.

♦ Warning devices, mirrors etc. may be needed where barriers cannot be used.

♦ Structural features should be identified, marked and protected (e.g. with impactbarriers).

♦ Parking areas for FLTs should be provided in a secure or supervised area to preventunauthorised access.

♦ Ceilings, lighting fittings, ductwork etc overhead can be struck by a raised load if theoperator is careless. It may be worth getting an engineer to adjust the maximumoperating height to avoid this risk.

Protection of personnel should be achieved by consideration of the following measures:♦ Segregation of pedestrians from vehicles (barriers, marking of routes, warning

devices).

♦ Audible warning devices on FLTs, e.g. horn, reversing bleeper.

♦ Flashing beacons on FLTs.

♦ High visibility clothing.

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♦ Head protection, where there is a risk of head injury from falling objects.

SignallingIt is generally best for the FLT operator to only drive in directions they can see clearly. Witha large load this can mean going in reverse. But they will be times when a guide can assist.This signalman or banksman must use clear signals – as laid down in the Health & Safety(Safety Signs and Signals) Regulations 1996 (Schedule ix). They must also stand in aposition that avoids them being in danger should a load fall or the truck move unexpectedly.Suitable personal protective equipment should be worn – hi-vis vest, safety shoes etc.

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Use on the public highwayEven if the operator’s possesses a forklift training certificate, they must also have an ordinarydriving licence if they are to take their truck onto the highway to unload a lorry or movegoods to an adjacent building. Their licence must include category B for trucks under3500kg, C1 for trucks between 3500 and 7500kg or C for trucks over 7500kg.

Road tax may also be payable. DVLA (tel 01792 783 661) gave the following advice inSeptember 2003.

Registration and licensing is governed by the Vehicle Excise and Registration Act1994 (VERA). All trucks used on the highway to unload lorries etc must obtain anddisplay a tax disk. The certificate of insurance and appropriate test certificate must beshown when applying.

There is no charge for this for electric trucks, but they must still apply annually.

FLTs of 3500kg or less are licensed as Private Light Goods class and the annual feeis £165 for engines over 1549cc or £110 if smaller than that.

FLTs over 3500kg are Works Truck, Special Vehicles Taxation Class. The annual feeis £165.

Employers Checklist - Forklift Trucks1 Can you produce training certificates for all of your operators? YES / NO2 Do they refer to the classes of trucks that are being driven? YES / NO3 Do you have a system for refresher training every 5 years? YES / NO4 Do you have a system of written authorisation for operators of FLTs? YES / NO5 Do you know the basic safety rules your operators should follow, and check

they are doing so from time to timeYES / NO

6 Do you maintain your premises in such a condition as to secure safety inthe use of FLTs (signage, barriers, lighting, layout, mirrors, trafficmanagement systems etc.)?

YES / NO

7 Do you maintain your FLTs by regular servicing, and are records kept? YES / NO8 Can you produce a current certificate that clearly states it is a “Thorough

Examination”YES / NO

9 Has the pre-shift check sheet been completed by the operators this week YES / NO10 Can you produce an adequate risk assessment covering the use of fork

trucks and the associated hazards and your controlsYES / NO

11 If the truck ever goes onto the public highway, is it separately insured androad taxed annually.

YES / NO

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References / Further DetailsThe following documents are available through HSE Books by phoning #### 01787 881165 orvia their website www.hsebooks.co.ukCode Year Pages Title ISBN and price

or sourceHSG6 2000 56 Safety in working with lift trucks ISBN 07176 17815

£6.50L117 1999 20 Approved Code of Practice and

Supplementary Guidance "Rider OperatedLift Trucks- operator training"

ISBN 07176 24552£5.00

PM28 2000 8 Working platforms on forklift trucks ISBN 07176 12333£6

PM15 1998 12 Safety in the use of pallets ISBN 07176 15227£6

HSG187 1999 42 Control of Diesel Engine Exhaust Emissionsin the Workplace.

ISBN 07176 16622£6.95

MISC175 1999 2 Retrofitting of roll-over protective structures,restraining systems and their attachmentpoints to mobile work equipment.

www.hse.gov.uk/pubns/misc175.pdf

SIR60 2003 47 Safety of Industrial Lift Trucks – a survey ofaccidents and incidents

ISBN 07176 27543£10 orwww.hse.gov.uk/pubns/sir60.pdf

HSG113 1996 26 Lift trucks in potentially flammableatmospheres

ISBN 07176 07062£7.75

WIS2 2000 4 Safe stacking of sawn timber and boardmaterials

free

LAC32/1 2000 3 Examination procedure and discard criteriafor FLT lift chains

www.hse.gov.uk/lau/lacs/32-1.htm

LAC32/6 2000 2 Repairs to fork arms for FLT www.hse.gov.uk/lau/lacs/32-6.htm

LAC32/7 2003 5 Rider-operated lift trucks: operator trainingapproved code of practice

www.hse.gov.uk/lau/lacs/32-7.htm

Video 1993 8 mins Dangerous maneuvers 07176 19656 £40MISC241 2000 3 Fitting and use of restraining systems on lift

truckswww.hse.gov.uk/pubns/misc241.pdf

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Health & Safety EnforcementHealth & Safety Inspectors from the Council or the HSE will visit from time to time and canrequire operators to show them relevant documentation such as training certificates,servicing records, thorough examination certificates and pre-shift check sheets. If they findproblems then, depending on the seriousness, they can:

♦ informally ask for changes to be made,

♦ serve an Improvement Notice demanding specified works are done in a set time

♦ serve a Prohibition Notice demanding that specified activities cease until certain thingsare done.

♦ Seize equipment they consider dangerous

♦ OR prosecute for the offences seen.If a prohibition notice is being served then the officer may note the truck hour meter toensure the truck isn’t used later. However this will only record the time the key is turned, notwhether the truck actually moves or is used for lifting or is being repaired by an engineer.Alternatively they may fit security tags onto the wheel.