Forklift Safety Rules for the Workplace: A Guide for UK Businesses
Forklift trucks are involved in around 8,000 accidents in UK workplaces every year, according to the HSE. Many of these are preventable with the right procedures, training, and management. This guide outlines the core forklift safety rules every UK business should have in place.
Legal framework
Forklift safety in the UK is governed by several pieces of legislation, including the Health and Safety at Work Act 1974, the Provision and Use of Work Equipment Regulations 1998 (PUWER), and the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER). Together, these require employers to:
- Ensure forklift operators are adequately trained and competent
- Maintain equipment in safe working order
- Carry out and document risk assessments for forklift operations
- Put in place traffic management to protect pedestrians
Pedestrian segregation
The single most effective measure to prevent forklift accidents is the physical separation of pedestrians and forklift operating areas. Best practice includes:
- Clearly marked pedestrian routes that do not cross forklift routes
- Physical barriers such as Armco, bollards, or safety rails at key points
- Designated crossing points with clear give-way markings
- Pedestrian-only zones in areas with high foot traffic
Site speed limits
Most indoor operations enforce a maximum speed of 5 mph (8 km/h). Outdoor yard speeds are typically capped at 10 mph on clear routes and lower in congested areas. Speed limits must be clearly signed and enforced by management.
Safe load handling
- Never exceed the rated capacity of the truck — check the data plate before each unfamiliar lift
- Ensure loads are stable and secure before moving
- Travel with the forks as low as possible — typically 150–300mm from the ground
- Tilt the mast back when travelling with a load to improve stability
- Never raise a load with anyone in the vicinity who could be struck if the load shifts
- Never carry passengers on a forklift unless it is fitted with an approved second seat
Operator rules
- Only trained and authorised operators may use a forklift
- Operators must complete a pre-use check at the start of each shift
- Seatbelts must be worn at all times where fitted
- Do not use a mobile phone while operating a forklift
- Report any defect or safety concern immediately — do not continue operating a defective truck
Refuelling and charging safety
- Refuel or change LPG cylinders only in designated, ventilated areas
- Do not smoke near refuelling areas
- Charge electric forklift batteries only in designated charging areas with adequate ventilation to disperse hydrogen gas
- Do not charge a damaged battery
Management responsibilities
Safety does not happen by itself. Management must enforce rules consistently, investigate all near-misses and incidents, carry out regular site audits, and ensure equipment is inspected and serviced on schedule. A culture where operators feel comfortable reporting faults — without fear of blame — is essential.
Safe, compliant equipment from Davison Forklift
All equipment supplied and hired by Davison Forklift is prepared and inspected to ensure it meets safety standards before delivery. We carry out LOLER thorough examinations and can support your compliance programme. Contact us on 01952 915 060.