Forklift truck guide Some notes by Stephen Tribbick, Harrow Council Environmental Health Services 17/11/2003 partly based on the fact-sheet from www.nuneatonandbedworth/business/healthsafety. Index Index...1 Introduction...1 The Forklift Truck...1 Checking the truck...2 Lift truck pre-shift check...2 Routine maintenance...4 Thorough examination...4 Schedule 1 to the Lifting Operations and Lifting Equipment Regs 1998...5 Selection of Operators...6 Training of Operators...7 Authorisation of Operators...8 Basic driving rules...8 Lifting people...9 Layout and Maintenance of Workplace...9 Signalling...10 Use on the public highway...11 Employers Checklist - Forklift Trucks...11 References / Further Details...12 Health & Safety Enforcement...13 Introduction Forklift trucks (FLTs) feature prominently in workplace accidents. Every year there are about 8000 lift truck accidents resulting in injury, and about 10 fatalities. Even if people are not injured in FLT accidents there is often damage to buildings, storage systems or stock. The main causes of FLT accidents are: lack of operator training inadequate premises poor FLT maintenance It is the responsibility of management to assess FLT operations and ensure that safe system of work are implemented and maintained. Subsequent responsibilities for safe use will also lie with line managers, supervisors and operators. The Forklift Truck Safety 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. 1
Seat belt fitted and used when there are significant risks, to avoid being crushed under the 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 chains etc. Battery charging eg good ventilation, signage about naked lights, clear procedure for avoiding sparks and shocks, visor, gloves and eyewash. Potentially explosive/flammable atmospheres - petrol/lpg/diesel FLTs not to be used; electrical FLTs to be suitably protected. Attachments - may alter the FLTs handling and stability characteristics and rating; need to 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. Each requires its own training and certification. Some of the comonest types of FLT are shown in the following table: TYPE CHARACTERISTICS AITT GROUP Counterbalanced FLT Counterweight balances load on the forks Tiltable mast (5-15 o ) Operate on fairly smooth surfaces only (warehouse and yard, not pot-holed road or field) Many attachments available B1 (up to 5 tonnes) Reach Truck Mast reaches out to pick up load Load is reached back and carried within the wheelbase if possible Has greater manoeuvrability in restricted areas Operate 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 being traversed sideways to pick up/set down the load Used for long loads e.g. timber or pipes May be fitted with stabilisers Suitable for rough terrain C1 (up to 3 tonnes) Pedestrian Controlled FLT Limited lift height (usually no more than 2 metres) Electrically or manually operated Operator walks with the machine and controls it with a handle Operate on smooth surfaces only (inside warehouse) A3 Checking the truck Lift truck pre-shift check The following type of check must be completed before the truck is used each day: 2
Lift-truck pre-shift check Truck Week beginning Item Details Mon Tue Wed Thur Fri Sat Sun Fork arms Carriage plate Back rest Mast Lift chain No cracks or distortion. Evenly spaced on carriage plate and clips engaged No obvious damage. End stops secure. Load backrest extension secure and not damaged or distorted No damage distortion or cracks. Inner channels or runners reasonably clean and smooth Free from damage or rust. All pins in place Hydraulics No damage or leakage from any point Wheels Undamaged. All nuts tight. Tyres Lights / indicators Horn / beeper etc Mast controls Hand / parking brake Driving & Service brake Fuel / power No excessive wear, cuts or foreign bodies. If pneumatic, tyre pressure correct All functioning Clearly audible Lift/lower, tilt and side shift operating properly. Strong enough to prevent truck being driven Work properly in both directions when tested slowly Adequate for shift Levels Coolant and engine oil levels correct LPG Cylinder secure, pipes & hoses OK Steering Chain lubrication Electric truck batteries Works properly in both directions at standstill and when moving Chain should be sprayed with a suitable lubricant every month or 250 hours Battery levels must be topped up with distilled water where necessary once a week Operator s initials Hour reading when check done! Tick items that are OK. " Cross any that have faults, describe problem overleaf and report it to the supervisor before attempting 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) 3
Routine maintenance Regular preventative maintenance is required. typically every 3 months. Usually the employer 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 often responsible for more regular items eg electrolyte levels, chain lubrication etc. Thorough examination LOLER 98 regulation 9 requires the thorough examination of lifting equipment at appropriate intervals to ensure its safe use. This is in addition to any preventative maintenance and there is often confusion in the trade over this requirement. The Thorough Inspection is usually by an engineer employed by an insurance company, and this is to be preferred to those 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 the thorough examination is often the responsibility of the user. Where trucks are hired, the supplier might organise both servicing and thorough examinations, albeit with different engineers. Most FLTs will require a 6-monthly thorough examination. However, an annual interval could be appropriate if the FLT isn t used for more than 40 hours per week, is never used for lifting people and doesn t have any fitted attachments or a side shift mechanism. The thorough examination 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 document isn 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 may become 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 3 years 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 lifting machinery, not just FLTs. Thorough examination and inspection 9. - (1) Every employer shall ensure that before lifting equipment is put into service for the 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 drawn up, the employer has received such declaration made not more than 12 months before the lifting equipment is put into service; 4
or, if obtained from the undertaking of another person, it is accompanied by physical evidence referred to in paragraph (4). (2) Every employer shall ensure that, where the safety of lifting equipment depends on the installation 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 is exposed to conditions causing deterioration which is liable to result in dangerous situations is- (a) thoroughly examined - (i) in the case of lifting equipment for lifting persons or an accessory for lifting, at least every 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 safety of the lifting equipment have occurred; and (b) if appropriate for the purpose, is inspected by a competent person at suitable intervals between thorough examinations, to ensure that health and safety conditions are maintained and that any deterioration can be detected and remedied in good time. Schedule 1 to the Lifting Operations and Lifting Equipment Regs 1998 INFORMATION 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 of manufacture. 4. The date of the last thorough examination. 5. The safe working load of the lifting equipment or (where its safe working load depends on the configuration of the lifting equipment) its safe working load for the last configuration in which it was thoroughly examined. 6. In relation to the first thorough examination of lifting equipment after installation or after assembly at a new site or in a new location - 5
(a) that it is such thorough examination; (b) (if such be the case) that it has been installed correctly and would be safe to operate. 7. In relation to a thorough examination of lifting equipment other than a thorough examination 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 danger to persons, and a description of the defect; (b) particulars of any repair, renewal or alteration required to remedy a defect found to be 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 selfemployed 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 its author. 11. The date of the report. Selection of Operators FLT drivers should be reliable, mature and responsible people, with appropriate physical/mental capabilities. Selection testing may be useful. 6
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 or contact lenses if needed) hearing alcohol & drug abuse Where trucks are taken onto the public highway then the usual DVLA standards ( At a Glance ) also apply. These can be seen at www.dvla.gov.uk/at_a_glance/content.htm. Note they distinguish between Group 1 (car and small FLTs) users and Group 2 (HGV, PSV users). Training of Operators The 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 have received adequate training for purposes of health and safety, including training in the methods which may be adopted when using the work equipment, any risks which such use may entail and precautions to be taken. (2) Every employer shall ensure that any of his employees who supervises or manages the use of work equipment has received adequate training for purposes of health and safety, including training in the methods which may be adopted when using the work equipment, any risks which such use may entail and precautions to be taken. There is no nationally prescribed training for pallet trucks or for pedestrian operated lift trucks. For these the employer should determine what is adequate training. For larger machines, training should be carried out in accordance with the Approved Code of Practice (ACoP) Rider operated lift trucks: operator training. 'Rider-operated' means any truck capable of carrying an operator and includes trucks controlled from both seated and stand-on positions. It relates to stacking rider-operated lift trucks (such as counterbalanced FLTs, 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 or she 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 FLTs eg 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 documentary evidence that relevant training has taken place and an appropriate level of operating ability 7
has been attained. In addition to the paper certificate, the operator will be given a small laminated card showing their qualification. Note that these will give the date and the group(s) of truck on which the training has been completed. Refresher training and assessment is not specified in the HSE guidance but is recognised by the training organisations as useful every 5 years or so. Sooner if there is cause for concern. Employers should continuously monitor the performance of operators to ascertain whether they might need refresher training. Indicators might be near misses, accidents or consistently unsafe working practices. This is especially the case if operators are occasional users, have not operated trucks for some time, or there has been a change in their working practices or environment. The HSE has recognised five bodies as competent to operate voluntary schemes of accreditation 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 Certificate of 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 Operators Not everyone who has been trained in the past should automatically be allowed to operate FLTs 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 operator competent for a specified period. Authorisation should be withdrawn by the employer pending a review or retraining if there is an accident, if the operator displays poor standards or is unwell or otherwise incapacitated. Basic driving rules Managers 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 or guide. So counterbalanced trucks go backwards if the load obstructs vision (but when going uphill on a slope with a bulky load, travelling forwards but with help from a guide) 8
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 people The 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 cage securely fitted to the forks called a mobile elevating work platform (MEWP). This gives a working platform with a handrail so if the worker is jerked or looses their balance they cannot fall to the ground. They are also protected from entanglement in the lifting chains. See PM28 for details. However, this arrangement should only be for occasional jobs, not for regular order picking or similar operations, as FLTs lack the controls and safety devices in purpose 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 be avoided; consideration could be given to a 1-way system if warranted; adequate lighting is essential. Pedestrians should be prohibited where possible, or risks assessed and controlled by the 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 with barriers. 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 impact barriers). Parking areas for FLTs should be provided in a secure or supervised area to prevent unauthorised access. Ceilings, lighting fittings, ductwork etc overhead can be struck by a raised load if the operator is careless. It may be worth getting an engineer to adjust the maximum operating 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. 9
Head protection, where there is a risk of head injury from falling objects. Signalling It is generally best for the FLT operator to only drive in directions they can see clearly. With a 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 a position 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. 10
Use on the public highway Even if the operator s possesses a forklift training certificate, they must also have an ordinary driving licence if they are to take their truck onto the highway to unload a lorry or move goods to an adjacent building. Their licence must include category B for trucks under 3500kg, 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 in September 2003. Registration and licensing is governed by the Vehicle Excise and Registration Act 1994 (VERA). All trucks used on the highway to unload lorries etc must obtain and display a tax disk. The certificate of insurance and appropriate test certificate must be shown 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 fee is 165 for engines over 1549cc or 110 if smaller than that. FLTs over 3500kg are Works Truck, Special Vehicles Taxation Class. The annual fee is 165. Employers Checklist - Forklift Trucks 1 Can you produce training certificates for all of your operators? YES / NO 2 Do they refer to the classes of trucks that are being driven? YES / NO 3 Do you have a system for refresher training every 5 years? YES / NO 4 Do you have a system of written authorisation for operators of FLTs? YES / NO 5 Do you know the basic safety rules your operators should follow, and check YES / NO they are doing so from time to time 6 Do you maintain your premises in such a condition as to secure safety in YES / NO the use of FLTs (signage, barriers, lighting, layout, mirrors, traffic management systems etc.)? 7 Do you maintain your FLTs by regular servicing, and are records kept? YES / NO 8 Can you produce a current certificate that clearly states it is a Thorough YES / NO Examination 9 Has the pre-shift check sheet been completed by the operators this week YES / NO 10 Can you produce an adequate risk assessment covering the use of fork YES / NO trucks and the associated hazards and your controls 11 If the truck ever goes onto the public highway, is it separately insured and road taxed annually. YES / NO 11
References / Further Details The following documents are available through HSE Books by phoning # 01787 881165 or via their website www.hsebooks.co.uk Code Year Pages Title ISBN and price or source HSG6 2000 56 Safety in working with lift trucks ISBN 07176 17815 L117 1999 20 Approved Code of Practice and Supplementary Guidance "Rider Operated Lift Trucks- operator training" 6.50 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 HSG187 1999 42 Control of Diesel Engine Exhaust Emissions in the Workplace. MISC175 1999 2 Retrofitting of roll-over protective structures, restraining systems and their attachment points to mobile work equipment. SIR60 2003 47 Safety of Industrial Lift Trucks a survey of accidents and incidents 6 ISBN 07176 16622 6.95 www.hse.gov.uk/pu bns/misc175.pdf ISBN 07176 27543 10 or www.hse.gov.uk/pu bns/sir60.pdf ISBN 07176 07062 7.75 free HSG113 1996 26 Lift trucks in potentially flammable atmospheres WIS2 2000 4 Safe stacking of sawn timber and board materials LAC32/1 2000 3 Examination procedure and discard criteria www.hse.gov.uk/la for FLT lift chains u/lacs/32-1.htm LAC32/6 2000 2 Repairs to fork arms for FLT www.hse.gov.uk/la u/lacs/32-6.htm www.hse.gov.uk/la u/lacs/32-7.htm LAC32/7 2003 5 Rider-operated lift trucks: operator training approved code of practice Video 1993 8 mins Dangerous maneuvers 07176 19656 40 MISC241 2000 3 Fitting and use of restraining systems on lift trucks www.hse.gov.uk/pu bns/misc241.pdf 12
Health & Safety Enforcement Health & Safety Inspectors from the Council or the HSE will visit from time to time and can require operators to show them relevant documentation such as training certificates, servicing records, thorough examination certificates and pre-shift check sheets. If they find problems 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 things are 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 to ensure the truck isn t used later. However this will only record the time the key is turned, not whether 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. 13