## Health and Safety at Work etc. Act 1974 (HSWA)

This is the fundamental piece of legislation for health and safety in Great Britain. It places general duties on everyone involved in work activities.

• Employer's Duties: Employers have a general duty to ensure, so far as is reasonably practicable, the health, safety, and welfare of their employees and others who may be affected by their work. This includes providing a safe working environment, safe plant and equipment, safe systems of work, adequate information, instruction, training, and supervision.
• Employee's Duties: Employees also have duties. They must take reasonable care for their own health and safety and for that of others who may be affected by their acts or omissions. They must also cooperate with their employer on health and safety matters and not intentionally or recklessly interfere with anything provided for health and safety.

## Key Regulations for Forklift Operations

Several specific regulations stem from the HSWA and are crucial for forklift operators:

• The Provision and Use of Work Equipment Regulations 1998 (PUWER):
• Forklifts are 'work equipment' under PUWER. These regulations require that work equipment is suitable for its intended use, maintained in a safe condition, inspected regularly, and used only by people who have received adequate training and instruction. This directly impacts forklift operator training and vehicle maintenance.
• The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER):
• Forklifts are 'lifting equipment' under LOLER when used to lift or lower loads. These regulations require that all lifting operations are properly planned by a competent person, appropriately supervised, and carried out in a safe manner. All lifting equipment must be thoroughly examined by a competent person at specified intervals (e.g., every 12 months for lifting accessories, and every 6 months for equipment used for lifting people, or after substantial modification or damage).
• The Management of Health and Safety at Work Regulations 1999 (MHSWR):
• These regulations require employers to carry out risk assessments to identify and evaluate risks to health and safety. Based on these assessments, employers must implement appropriate control measures. They also require employers to appoint competent persons to assist with health and safety, and to provide health surveillance where appropriate.
• The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 2013 (RIDDOR):
• RIDDOR requires employers to report certain serious workplace accidents, occupational diseases, and specified dangerous occurrences (e.g., a forklift overturning) to the Health and Safety Executive (HSE). This ensures incidents are investigated and lessons learned.

Understanding these regulations is vital for safe forklift operation and compliance.

## Operator's Safety Code

The Operator's Safety Code is a vital set of rules and guidelines designed to ensure the safe operation of forklift trucks and prevent accidents. Adhering to this code is mandatory for all operators and is a core part of the ITSSAR/AITT/RTITB training syllabus.

## Pre-Use Checks (POWARD/P.O.C.A.R.D.)

Before starting any shift, a thorough pre-use check must be carried out. This ensures the truck is safe to operate. Key areas to check include:

• Pressure (tyres), Oil, Water, Attachments, Ropes/chains, Damage/defects.
• Fluid levels (engine oil, hydraulic fluid, brake fluid, battery electrolyte).
• Tyre condition and pressure.
• Forks, mast, and carriage for damage or wear.
• Lights, horn, and warning devices.
• Brakes (foot and parking) and steering.
• Seatbelt and operator controls.

Any defects found must be reported immediately to a supervisor, and the truck should not be used until repaired.

## Safe Operating Practices

• Speed: Drive at a speed appropriate for the conditions, never exceeding site speed limits. Avoid sudden acceleration, braking, or steering.
• Load Handling:
• Always check the load plate to ensure the load is within the truck's capacity and rated load centre.
• Centre the load squarely on the forks, ensuring the forks are fully inserted.
• Tilt the mast back and carry the load as low as possible (typically 100-150mm off the ground) for stability.
• Ensure the load is stable and secure before moving.
• Visibility: Always look in the direction of travel. If the load obstructs your forward view, drive in reverse, unless on a ramp.
• Manoeuvring:
• Sound the horn at blind spots, doorways, and intersections.
• Maintain a safe distance from other vehicles, pedestrians, and edges.
• Pedestrians always have priority. Make eye contact and ensure they acknowledge your presence.
• Ramps and Inclines:
• When travelling loaded, always drive with the forks pointing uphill.
• When travelling unloaded, always drive with the forks pointing downhill.
• Never turn or angle the truck on a ramp.

## Parking

Always park in a designated safe area. The correct parking procedure is:

• Lower the forks completely to the ground.
• Apply the parking brake.
• Select neutral gear.
• Remove the key to prevent unauthorised use.
• If parking on an incline, chock the wheels where appropriate.

## Reporting and PPE

Report all accidents, incidents, near misses, and equipment defects immediately. Always wear appropriate Personal Protective Equipment (PPE) as required by site rules, such as safety shoes, high-visibility clothing, and hard hats.

## Pre-use Checks and Their Importance

Pre-use checks are a mandatory safety requirement for all forklift operators, carried out at the start of every shift or before the first use of the day. Their purpose is to identify faults that could cause accidents, ensure legal compliance (PUWER, LOLER), and maintain operational efficiency.

If a defect is found: You MUST NOT USE the forklift. Report it immediately to a supervisor, record it in the truck's logbook, and tag the truck "Out of Service".

## Key Areas for Visual Checks (Engine Off, Parked Safely)

Conduct a thorough visual inspection before starting the engine:

• Tyres & Wheels: Check for damage, cuts, embedded objects, and correct condition/pressure.
• Forks & Attachments: Inspect for cracks, distortion, excessive wear (especially at the heel and heel wear marks), and secure locking pins.
• Mast & Chains: Look for damage, correct tension, lubrication of chains, and leaks/damage on hydraulic hoses.
• Overhead Guard & Load Backrest: Ensure they are secure, undamaged, and free from distortion.
• Hydraulics: Check for any visible leaks around hoses, cylinders, and connections.
• Battery (Electric): Inspect charge level, connections, and electrolyte levels (if applicable).
• Engine Bay (IC): Look for leaks, debris, and check general fluid levels (engine oil, coolant, brake fluid, hydraulic fluid).
• Lights, Horn, Warning Devices, Seatbelt: Check condition and apparent functionality.
• Data Plate: Verify it is legible and matches the truck's specifications and rated capacity.

## Operational Checks (Engine On, Safe Area)

After visual checks, start the engine in a safe, clear area and test:

• Brakes: Test both the foot brake (service brake) and parking brake (handbrake) for effectiveness. The parking brake must hold the truck securely.
• Steering: Check for smooth operation and no excessive play.
• Hydraulics: Operate lift, lower, and tilt functions smoothly, listening for unusual noises.
• Gauges & Controls: Verify all gauges are working and controls respond correctly.
• Lights, Horn, Warning Devices: Fully test all functions.

## Maintenance and Legal Requirements

• Operator's Role: Daily checks, keeping the truck clean, and reporting *all* defects.
• Planned Preventative Maintenance (PPM): Regular, scheduled servicing by qualified technicians.
• LOLER (Lifting Operations and Lifting Equipment Regulations 1998): Requires a Thorough Examination by a competent person.
• Every 12 months for standard forklifts.
• Every 6 months if used to lift people.
• PUWER (Provision and Use of Work Equipment Regulations 1998): Requires work equipment to be suitable, safe, and maintained in a safe condition.

## Understanding Stability

A forklift's stability is its ability to resist overturning. This is governed by the Centre of Gravity (CoG), which is the combined CoG of the truck and its load. For a stable operation, this combined CoG must remain within the stability triangle (or pyramid for some trucks), an imaginary area defined by the points of ground contact of the wheels.

Longitudinal stability refers to the truck's resistance to tipping forwards or backwards. It's primarily affected by the load's weight, its position, and mast tilt. Lateral stability is the resistance to tipping sideways, influenced by turning, speed, and uneven ground. Dynamic stability considers how these factors change during operation, such as when moving, lifting, or turning.

## Load Capacity and the Data Plate

The Rated Capacity (or Nominal Capacity) is the maximum weight a forklift can safely lift at a specified Load Centre. The Load Centre is the horizontal distance from the front face of the forks to the centre of gravity of the load (e.g., 500mm or 600mm).

All critical information, including the rated capacity, load centre, mast type, and any fitted attachments, is displayed on the truck's Data Plate (or Capacity Plate). It is illegal and unsafe to operate a forklift without a legible data plate. Deration occurs when the rated capacity is reduced, typically due to non-standard load centres or the fitting of attachments. Attachments always reduce the truck's lifting capacity, and a revised or auxiliary data plate must be fitted.

## Factors Affecting Stability

Many factors can compromise stability:

• Weight of Load: Exceeding the rated capacity is extremely dangerous.
• Load Centre: A load with a longer load centre than specified significantly reduces capacity and stability.
• Height of Load: Lifting a load high reduces both longitudinal and lateral stability.
• Speed & Turning: High speed, especially when turning, drastically reduces lateral stability.
• Ground Conditions: Uneven, sloping, or soft ground can cause instability.
• Mast Tilt: Tilting the mast forwards with a raised load reduces longitudinal stability.

## Safe Operating Practices

Always check the Data Plate before operation. Never exceed the rated capacity. Keep the load as low as possible when travelling, and tilt the mast fully back to increase longitudinal stability. Travel slowly, especially when turning, and avoid sudden braking or acceleration. When ascending or descending ramps, always travel with the load pointing uphill to maintain stability.

## Load Handling, Stacking and De-stacking

Load handling is a critical skill for safe forklift operation, ensuring stability and preventing accidents. Before any lift, always perform a dynamic risk assessment.

Pre-Lift Checks

Before approaching any load:

• Assess the load: Check its weight (never exceed the forklift's rated capacity), centre of gravity, and stability. An unstable or overloaded item must never be lifted.
• Inspect the load and pallet: Ensure the load is secure, stable, and not damaged. Check the pallet for damage – never lift a load on a damaged pallet, as it compromises stability.
• Check the area: Look for obstructions, overhead hazards, and ensure sufficient space for the manoeuvre. Confirm the ground is level and clear.

Lifting and Travelling with a Load

1. Approach: Approach the load slowly and squarely, with forks level and at the correct height to enter the pallet fully without damaging the load or pallet.

2. Engage: Drive fully under the load until it rests squarely against the fork carriage.

3. Lift and Tilt: Lift the load clear of the ground (just enough to clear any obstacles), then tilt the mast back slightly. This increases load stability and prevents it from sliding forward.

4. Travel: Travel with the forks as low as possible (typically 100-150mm from the ground) and tilted back. Maintain clear vision at all times. If vision is obstructed, travel in reverse (if safe to do so and permitted by site rules) or use a competent spotter. Adjust speed to conditions, load stability, and surroundings.

Stacking Loads

Safe stacking prevents collapses and ensures efficient space utilisation.

1. Preparation: Ensure the stacking area is level, clear of obstructions, and the stack below (or racking) is stable and undamaged. Check the racking for capacity and condition.

2. Approach: Approach the stack slowly and squarely. Raise the load to the required height, ensuring the mast is vertical (no forward or backward tilt) before final placement.

3. Placement: Position the load accurately over the stack or racking. Gently lower the load, ensuring it is fully supported by the stack or racking before withdrawing the forks.

4. Withdrawal: Once the load is securely placed, lower the forks clear of the stack and reverse slowly.

5. Stability: Always place heavier loads at the bottom of a stack. Use cross-stacking techniques where possible to interlock layers and enhance stability. Ensure no load overhangs the pallet or stack, as this can cause instability and damage.

De-stacking Loads

De-stacking requires similar precision to stacking.

1. Preparation: Assess the stack for stability and identify the target load. Ensure the area around the stack is clear for the manoeuvre.

2. Approach: Approach the load squarely with forks at the correct height. Ensure the mast is vertical.

3. Engage: Drive fully under the load until it rests against the fork carriage.

4. Lift and Tilt: Lift the load clear of the stack. Once clear, tilt the mast back to secure the load and prevent it from sliding.

5. Withdrawal: Reverse slowly and carefully, ensuring the load remains stable. Lower the load to the travelling position once clear of the stack.

Always report any damaged loads, pallets, or racking immediately. Never attempt to lift an unstable or obviously overloaded item.

## Refuelling and Recharging Procedures

Proper refuelling and recharging procedures are crucial for forklift safety and operational efficiency. Always follow manufacturer guidelines and site-specific rules. Only trained and authorised personnel should carry out these tasks.

General Safety Precautions

Regardless of the power source, several general safety rules apply:

• Always carry out procedures in designated, well-ventilated areas.
• NO SMOKING or naked flames are permitted in these areas due to the risk of igniting flammable vapours or gases.
• Always switch off the forklift's engine/ignition, remove the key, and apply the parking brake.
• Wear appropriate Personal Protective Equipment (PPE), which typically includes gloves and eye protection.
• Know the location and correct use of spill kits and appropriate fire extinguishers.
• Report any damaged equipment (e.g., fuel lines, battery cables) immediately and do not use it.

Electric Forklifts (Battery Recharging & Changing)

Electric forklifts are powered by large, heavy batteries. Recharging produces hydrogen gas, which is highly explosive.

• PPE: Acid-resistant gloves, eye protection (face shield), and an apron are essential.
• Ventilation: Ensure the charging area is extremely well-ventilated to disperse hydrogen gas.
• Charging: Connect the charger correctly (positive to positive, negative to negative). Do not overcharge.
• Electrolyte Levels: Check electrolyte levels after charging. Top up with distilled water if needed, but never overfill before charging, as the liquid expands.
• Battery Changing: Use correct lifting equipment (e.g., a battery hoist or pallet truck) and ensure the battery is securely fastened in the truck.

LPG Forklifts (Cylinder Changing)

LPG (Liquefied Petroleum Gas) cylinders contain highly flammable gas under pressure.

• Procedure: Park the forklift, switch off the engine, and apply the parking brake. Close the valve on the old cylinder, then run the engine until the fuel in the line is used up and the engine stops.
• Disconnecting: Disconnect the coupling (LPG couplings typically have a left-hand thread).
• Connecting: Carefully remove the old cylinder and replace it with a full one, ensuring it's correctly seated and the locating pin engages. Connect the coupling securely.
• Leak Check: Slowly open the valve on the new cylinder. ALWAYS check for leaks using a soap solution, never a naked flame.

Diesel/Petrol Forklifts (Refuelling)

Refuelling internal combustion forklifts requires care to prevent spills and fire hazards.

• Fuel Type: Always use the correct type of fuel for the forklift.
• Procedure: Turn off the engine and apply the parking brake. Remove the fuel cap slowly to release any pressure.
• Filling: Do not overfill the tank; allow space for fuel expansion. Avoid splashing.
• Spills: Immediately clean up any fuel spills using a spill kit. Ensure the fuel cap is securely replaced after refuelling. Dispose of contaminated materials safely.

## Safe Manoeuvring and Hazard Awareness

Safe manoeuvring of a forklift is crucial to prevent accidents, injuries, and damage. It requires constant awareness of your surroundings and adherence to established safety procedures.

Driving Techniques

Always start by checking the truck's condition and ensuring you are wearing your seatbelt. When travelling, the load must be carried as low as possible (typically 100-150mm off the ground) and tilted fully back to maintain stability. This keeps the combined centre of gravity low and within the stability triangle.

Speed must be appropriate for the conditions – never exceed site speed limits and generally operate at a brisk walking pace indoors. Avoid sudden acceleration, braking, or steering, as these can cause the load to shift or the truck to become unstable. When approaching blind spots, intersections, doorways, or areas with pedestrians, sound your horn and slow down. Always give way to pedestrians and maintain a safe distance from other vehicles and structures.

When your forward view is obstructed by the load, you must drive in reverse, looking over your shoulder in the direction of travel. Always look in the direction of travel. When driving on ramps or gradients, always drive with the load facing uphill to maintain stability, whether ascending or descending. Never turn on a ramp or gradient.

Hazard Identification

Constant hazard awareness is paramount. Be vigilant for:

• Pedestrians and other vehicles: Always assume they might not see you. Use your horn and make eye contact.
• Floor conditions: Look out for spills, uneven surfaces, potholes, debris, or loose materials that could affect traction or stability.
• Overhead obstructions: Pipes, lighting, doorways, low ceilings, and sprinkler systems can be struck by the mast or raised load. Always check your overhead clearance.
• Blind spots and corners: Slow down, sound the horn, and proceed with caution.
• Loading docks and trailers: Ensure trailers are properly chocked and secured before entering. Be aware of the gap between the dock and trailer.
• Restricted areas: Pay attention to designated pedestrian zones, no-entry areas, and areas with limited headroom or width.
• Stability: Understand how the load centre and weight affect the truck's stability. Never exceed the Safe Working Load (SWL).

Parking Safely

When parking, always choose a designated, safe, and level area away from main traffic routes and emergency exits. The forks must be fully lowered to the ground, the handbrake applied, the gear selector placed in neutral, and the key removed to prevent unauthorised use. This ensures the truck is secure and does not pose a hazard.

## Forklift Anatomy and Controls

Understanding the anatomy and controls of a forklift is fundamental for safe and efficient operation. Familiarity with these components ensures you can perform pre-use checks, operate the machine correctly, and identify potential faults.

## Key Anatomical Components

• Chassis/Frame: The main structural body of the forklift, providing the foundation for all other components.
• Mast: The vertical assembly at the front of the forklift that performs the lifting and lowering of loads. It typically consists of inner and outer channels, lift chains, and hydraulic cylinders.
• Carriage: A component that travels up and down the mast, to which the forks and any attachments are mounted.
• Forks: The L-shaped steel arms that engage with the pallet or load. They must be correctly spaced and fully engaged under the load.
• Overhead Guard: A protective cage above the operator's compartment designed to protect the operator from falling objects. It is NOT designed to withstand a full load falling.
• Load Backrest: An extension of the carriage, preventing the load from shifting backwards towards the mast and operator.
• Counterweight: A heavy mass, usually cast iron, located at the rear of the forklift to counterbalance the weight of the load being carried at the front.
• Tyres: Can be solid (for indoor, smooth surfaces) or pneumatic/cushion (for outdoor, uneven surfaces), affecting stability and ride.
• Power Source: Either an Internal Combustion Engine (ICE) (diesel, LPG, petrol) or an electric battery, providing power for movement and hydraulics.
• Data Plate (or Load Chart): A crucial plate found on the forklift, detailing essential information such as the truck's unladen weight, maximum lifting capacity, load centre, and mast type. This must *never* be obscured or removed.

## Essential Controls

• Steering Wheel: Controls the direction of the forklift, typically operating the rear wheels for greater manoeuvrability.
• Accelerator Pedal: Controls the speed of travel.
• Brake Pedal: Used to slow down and stop the forklift.
• Direction Lever: Selects forward or reverse travel.
• Hydraulic Levers: Control the mast functions:
• Lift/Lower: Raises and lowers the forks.
• Tilt: Tilts the mast forwards (to pick up/deposit) or backwards (to stabilise the load during travel).
• Side-shift (if fitted): Moves the carriage and forks horizontally left or right, aiding precise load positioning.
• Parking Brake: A vital safety control to secure the forklift when stopped, preventing unintended movement.
• Ignition/Key Switch: Starts and stops the engine/power.
• Horn: Used to warn pedestrians and other operators.
• Lights and Indicators: For visibility and signalling, especially in low light or busy areas.