Forklift Truck Safety: Your Legal Duties and Best Practice Guidance for Safer Operations
- Steven Harrison CMgr MCMI
- May 26
- 4 min read
In today’s fast-paced industrial environments—whether warehousing, manufacturing, logistics, or construction—forklift trucks (FLT) play an indispensable role in keeping goods and operations moving. However, with this functionality comes significant responsibility.
At SJH Safety Solutions, we specialise in helping businesses meet their legal obligations and build safer, compliant workplaces. Forklift operations are among the most hazardous workplace activities in the UK. That’s why our expert guidance and audits are designed to reduce your risk and protect your workforce.
🚨 Why Forklift Truck Safety Should Be a Top Priority
The Health and Safety Executive (HSE) reports that around 1,300 UK workers are hospitalised each year following forklift accidents. These range from crushing injuries, falls from trucks, and collisions with pedestrians, to fatalities caused by poor controls and inadequate training.
Beyond the human cost, there are also serious legal and financial repercussions, including:
Fines from the HSE
Loss of productivity and damaged assets
Reputational harm
Increased insurance premiums
⚖️ Your Legal Responsibilities Under UK Law
Under the Health and Safety at Work etc. Act 1974, employers have a general duty of care to ensure the health, safety, and welfare of all employees and anyone who might be affected by their work.
More specifically:
PUWER 1998 (Provision and Use of Work Equipment Regulations) requires that all work equipment (including forklifts) is:
Suitable for use
Maintained in a safe condition
Used only by people who have received adequate training
LOLER 1998 (Lifting Operations and Lifting Equipment Regulations) mandates:
Lifting operations are planned and supervised
Equipment is thoroughly examined at specified intervals
Safe working loads (SWL) are clearly marked and never exceeded
Failure to comply with these regulations can result in criminal prosecution and substantial fines.
🛑 Common Hazards Involving Forklift Trucks
Forklift-related incidents often stem from poor site layout, inadequate training, and a lack of maintenance. Key hazards include:
Pedestrian Collisions
Forklifts and people in shared spaces are a deadly mix. Collisions can occur in warehouses, loading bays, or tight aisles.
Overturning
Excessive speed, uneven surfaces, incorrect loading, or sharp turning can cause forklifts to tip—risking serious injury to operators and bystanders.
Falling Loads
Poorly stacked or unsecured loads can shift or fall, endangering nearby workers.
Operator Visibility
Blind spots, poor lighting, or obstructed views increase the risk of impact, particularly in reversing or tight navigation.
Mechanical Failures
Lack of pre-use checks, poor maintenance, and ignoring warning signs can result in critical failures.
🛠️ Essential Control Measures
A robust forklift safety strategy includes a blend of engineering, administrative, and behavioural controls:
Site and Traffic Management
Create segregated routes for pedestrians and forklifts using barriers or painted lines.
Introduce one-way systems where possible to reduce reversing.
Use speed bumps, mirrors, and warning signs in high-risk zones.
Operator Training and Supervision
Ensure operators hold a valid accredited licence (e.g. RTITB, ITSSAR).
Provide refresher training every 3–5 years or after incidents.
Supervise and monitor compliance with safe driving rules.
Equipment Maintenance
Conduct daily pre-use inspections, covering tyres, forks, hydraulics, and warning devices.
Keep up with scheduled servicing and LOLER thorough examinations.
Maintain records of checks and repairs for compliance.
Load Safety
Stack loads evenly and securely.
Never exceed the truck’s Safe Working Load (SWL).
Use attachments or cages correctly and only when trained.
Environmental Controls
Improve visibility with lighting, convex mirrors, and hi-vis signage.
Use audible alarms and flashing beacons to alert others of moving trucks.
Ensure floor surfaces are well maintained and free from obstructions.
💡 Pro Tips for Safer Forklift Operations
To build a positive safety culture, consider embedding the following best practices:
Involve operators in safety discussions—those at the front line often have the best insight into risks.
Implement a ‘stop and report’ policy—if something looks or feels unsafe, empower staff to act without fear of blame.
Display daily inspection checklists near truck bays and require sign-off before use.
Carry out mock emergency drills involving forklift scenarios to improve response times and awareness.
Use visual data tools—such as traffic heat maps and incident logs—to identify trends and optimise controls.
👷 How SJH Safety Solutions Can Help
At SJH Safety Solutions, we don’t just tick boxes. We deliver practical, tailored support to help you:
Conduct forklift safety audits aligned to HSE standards
Develop site-specific traffic management plans
Deliver bespoke training for managers, operators, and supervisors
Ensure full PUWER & LOLER compliance
Implement effective risk control measures with a measurable impact
We work across manufacturing, warehousing, logistics, and construction sectors, bringing decades of experience and proven systems that drive results.
📞 Ready to Raise Your Forklift Safety Standards?
Protect your people. Protect your business. Stay compliant. If you're unsure where to start, let us guide you.
👉 Contact us today to schedule a free initial consultation.
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🔖 Summary Checklist
✅ Comply with PUWER and LOLER
✅ Train and retrain all FLT operators
✅ Maintain equipment rigorously
✅ Separate people and plant
✅ Promote a proactive safety culture
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