Blog 2020, 2021 & 2022

Worker’s Leg Crushed by Forklift Truck Accident

Keep Pedestrians Away from Your Forklift

In April 2023, The Health and Safety Executive (HSE) fined AkzoNobel Packaging Coatings Limited £600,000 after a worker’s leg was crushed by a forklift truck. The accident occurred at the firm’s Birmingham site on Bordesley Green Road on 8 May 2018.

The man was walking across a pedestrian crossing when a forklift truck collided with him, crushing his leg and ankle. The forklift operator did not slow down while approaching the pedestrian crossing and his vision was restricted by multiple intermediate bulk containers. An intermediate bulk container (IBC) is a pallet mounted, reusable container that is used for storing and transporting bulk liquids and powders. Also known as a tote, the IBC is capable of stacking and can be moved by a forklift. The injured worker needed surgery and skin grafts following the accident. He was unable to return to work after the injury.

The HSE investigation found:

AkzoNobel Packaging Coatings Limited failed to provide adequate risk assessment
Failed to provide a safe system of work
Lack of appropriate supervision which lead to adoption and development of an unsafe custom and practice of work on site

AkzoNobel Packaging Coatings Limited, of Wexham Road, Slough, Berkshire, pleaded guilty to breaching Section 2 (1) of the Health and Safety at Work etc. Act 1974 which states that “It shall be the duty of every employer to ensure, so far as is reasonably practicable, the health, safety and welfare at work of all its employees”. In addition to the £600,000 fine, the company was ordered to pay costs of £3,188 at Birmingham Magistrates’ Court.

HSE inspector Marie Wheeler said: “This incident could so easily have been avoided by the employer adequately assessing the risks and ensuring a suitable workplace transport system was implemented with correct management and supervision in place. Companies should be aware that HSE will not hesitate to take appropriate enforcement action against those that fall below the required standards.”

Ruth Wallace of Wallace Forklift Training London commented that “It is obvious that there were issues with working practices at the firm as operating forklift truck with limited visibility and speed it was travelling at on the route probably known by the driver who should be aware where the pedestrian crossing existed. However, sometimes under work pressure, safety is compromised at heavy cost as in this instance. Maybe supervisors and managers should attend courses for safe working practices for forklift operation”.

Wallace School of Transport including Forklift Training in London is a fully accredited RTITB company with over 60 years' experience. You can be trained either at your own work site or at Wallace Centre in Park Royal. If you have any questions, call Wallace Forklift Training for free on 0800 612 8948, choose option 3 or click here to email us.

What to Look for when Recruiting a Forklift Truck Operator

There is no law which says forklift training has to be provided by an accredited training provider and a qualified trainer. You can be trained by an organisation with no accreditation and be issued with a certificate or you can be trained by a colleague at your workplace. However, if there is an accident, then the employer may find it difficult to prove that the forklift operator has received appropriate training. The Health and Safety Executive's (HSE) Approved Code of Practice (L117) states “operator training should only be carried out by instructors who themselves have undergone appropriate training in instructional techniques and skills assessment”.

It is vitally important for companies looking to recruit forklift operators to ensure that they have appropriate qualifications from an accredited training provider. Both the forklift training organisation and their trainer need appropriate accreditation.

Although commonly referred to as forklift truck licence, it refers to the Certificate of Training. The Approved Code of Practice (L117) states that the forklift operators receive three stages of training, namely:

Basic Training
Specific Job Training
Familiarisation Training

To learn more about these three stages, read Wallace Forklift Training London blog titled “What is Appropriate Forklift Training” or read “The Approved Code of Practice (L117)”.

In this blog we look at what the company recruiting a forklift operator should look for. Incidentally, this also applies to any individuals looking for forklift training organisation as well, as without appropriate training from an accredited organisation, their job prospects may not improve.

What to look for in a Forklift Certificate of Training

A forklift operator job applicant may present a Certificate of Training with their application. A genuine Certificate of training from an accredited organisation should include:

The training organisation’s name. Ensure it has the appropriate accreditation. You can check it on their website or if in doubt or you contact the accreditation body.
The date when the forklift operator training was passed
The type of forklift truck the operator passed the test on
The rated capacity and lift height of the forklift truck
If registered with RTITB and NORS database, it will have the forklift operator Registration number. If in doubt, contact RTITB

Certificate of Training from Wallace Forklift Traing London

Wallace Forklift Training London Certificate of Training

Some forklift operators may not have a Certificate of Training despite having attended training and testing. This is because their training will have been financed by their current or previous employer who has decided to keep the training certificate. However, HSE would prefer that a Certificate of Training be given to all those who have been through training and passed the test, irrespective of who has paid for it.

Ruth Wallace of Forklift Training London says “About a quarter of all workplace accidents requiring a hospital visit are due to forklift truck accidents. For companies using forklift trucks, it is vital that their operators have appropriate training from accredited organisations. In case of a workplace accident involving a forklift truck, without appropriate training, the company would be liable to a hefty HSE fine or even a jail term for those responsible”.

Wallace School of Transport including Forklift Training in London is a fully accredited RTITB company with over 50 years' experience. You can be trained either at your own work site or at Wallace Centre in Park Royal. If you have any questions, call Wallace Forklift Training for free on 0800 612 8948, choose option 3 or click here to email us.

HGV Driver killed in a Forklift Truck Accident

John Fitzpatrick was waiting for his trailer to be loaded at Kingsland Drinks Ltd., a wine and drinks supplier’s depot in Irlam, Salford on 19 August 2020 when he was struck by a forklift truck. He suffered serious head injuries in the fatal accident. The 59 year old driver never regained consciousness after the forklift truck accident.

An investigation by the Health and Safety Executive (HSE), found the company had failed on a number of areas including:

The risk assessment was out of date and not fit for purpose,
There was no pedestrian and vehicle (including forklift truck) segregation in the loading area
Visiting drivers were not given clear information about safety

At a sentencing hearing at Manchester Magistrate’s Court on 25 January 2023, Kingsland Drinks Ltd of the Winery, Fairhills Road, Irlam, pleaded guilty to breaching section 2(1) and 3(1) of Health and Safety at Work Act. The Health and Safety at Work Act Section 2(1) states “It shall be the duty of every employer to ensure, so far as is reasonably practicable, the health, safety and welfare at work of all his employees”.

And section 3(1) covers General duties of employers and self-employed to persons other than their employees. Section 3(1) states “It shall be the duty of every employer to conduct his undertaking in such a way as to ensure, so far as is reasonably practicable, that persons not in his employment who may be affected thereby are not thereby exposed to risks to their health or safety”.

The company was fined a massive £800,000 and ordered to pay costs £5614.

Sharon Butler of HSE said after the hearing, “This death would have been prevented if clear controls had been in place for visiting drivers. Companies who have loading areas need to provide information and instructions to visiting drivers and have clear segregation in place to ensure the site is safe for all who use it. Easy steps can be taken to reduce the risks of visiting drivers becoming injured on site.”

Ruth Wallace of Wallace Forklift Training London, said, “ it was heart-rending to read the personal statement from Paula Fitzpatrick, John’s partner. It seems John was a hard working, full of life character who got on well with everyone. His loss must be devastating for the family. Such accidents shouldn’t happen. If you are reading this, you may be interested in our recent blog entitled, Segregation of Forklift Trucks and Pedestrians”.

Useful Links

Electric Forklift truck - Wallace School of Transport

Electric Forklift Trucks – Battery Types

In Europe, the market for electric forklift trucks has been growing exponentially and is expected to continue growing at 13% per annum until 2030. The electric forklift truck market size is expected to reach £37 billion in Europe by 2030.The markets in UK and Germany are growing fastest. Forklift trucks such as reach, counterbalance, pallet trucks and stackers improve efficiency and this has impacted positively on the market. The innovations in the battery technology, particularly the introduction of lithium ion batteries for forklift trucks has had a huge impact on the sales of electric forklift trucks. The lithium ion battered powered forklift truck sales are expected to grow at 20%.

In this blog, we look at different battery types for electric forklift trucks and their advantages and disadvantages. There are three main types of batteries available for forklift trucks. They are:

Lead Acid batteries
Fast Charge Lead Acid batteries
Lithium Ion batteries

Lead Acid battery powered forklift trucks

The Lead Acid battery was invented in 1859 and with new innovations has improved in performance since. They are used in a variety of applications including cars and forklift trucks. The lead is submerged in sulphuric acid to allow a controlled chemical reaction. The oxygen is the active element as lead oxide reacts with hydrogen ions to form water. The lead then reacts with sulphuric acid to form lead sulphate. The movement of ions through the electrolyte creates the current flow. The reaction is reversed to charge the battery.

There are a number of benefits of using lead acid battery powered forklift trucks. It is one of the cheapest to run. These types of batteries are not only dependable but inexpensive when viewed on a cost-per-watt basis. However lead-acid batteries require regular maintenance. The battery needs to be charged after your shift has finished. Just before you start your next shift, check and top up the water levels if needed after the battery has been fully charged and allowed to cool. If you top-up before it is charged, the water level would be too high and it will bubble over the top of the cells and go into the battery tank leading to further complications and corrosion. This would probably make the forklift truck inoperable for the shift.

The lead acid batteries should only be charged when it has used up 80% of its power. Prematurely charging the battery would damage it. The forklift truck lead acid battery would cost £5k and would normally last between 5 and 10 years. Having to replace the battery prematurely would be expensive. Lead acid batteries are removed from forklift trucks to charge them.

Fast Charge Lead Acid battery powered forklift trucks

The fast charge lead acid batteries are the same technology as lead acid batteries but are built differently. They are coupled with high-efficiency chargers to allow them to be opportunity charged. This allows forklift trucks shorter charging times and hence be able run longer throughout the day to increase productivity including during break times. The battery remains in the forklift truck while it is being charged. The advantages of fast charging are cost savings, higher productivity, safety, and maintenance improvements. Depending on how they are used, the trade-off may be the battery life.

The fast charge lead acid batteries require topping up and maintenance. The forklift trucks with fast charge lead acid batteries also require a full 14 hour charge once a week.

Lithium Ion Battery powered forklift trucks

The lithium ion batteries are extensively used in computers, mobile phones, electrical vehicles including cars and forklift trucks. A lithium ion battery is made up of an anode, cathode, separator, electrolyte and positive and negative current collectors. The anode and cathode store the lithium. The electrolyte carries positively charged lithium ions from the anode to the cathode and vice versa through the separator. The movement of the lithium ions creates free electrons in the anode which creates a charge at the positive current collector. The electrical current then flows from the current collector through a device being powered like a forklift truck to the negative current collector. The separator blocks the flow of electrons inside the battery. Click here to see the animation of how the lithium ion battery works.

Lithium ion batteries are basically maintenance free and require no manual handling. They are a sealed unit and hence no top up is required. However, if you run a lithium ion battery flat, it is likely that it is unrecoverable, unlike lead acid batteries. These batteries are expensive and a counterbalance forklift truck lithium ion battery could cost about £15k to £20k.

Lithium ion batteries can be opportunity charged and the charging times are much faster. However, lithium ion battery powered forklift cannot be operated for long periods without charging.

Each battery type has its advantages and disadvantages. You need to look at your forklift truck requirements to select the ideal battery type for your application.

In this blog we have just look at the battery powered forklift trucks and their advantages and disadvantages based on the type of the battery. However, battery powered forklifts trucks have a number benefits compared to the fossil fuel powered ones and have been gaining market share. One major benefit is that they do not produce dangerous fumes and hence your warehouse does not require special ventilation and they are quiet to run.

Forklift Safety Message

Segregation of Forklift Trucks and Pedestrians

Forklift truck is a big heavy piece of equipment, weighing as much as four average family cars or even more, and therefore any incident with a pedestrian may cause serious injury or can be fatal. In UK, about 25% of all workplace accidents involving a visit to a hospital are due to forklift truck accidents.

Everybody working within the vicinity of a forklift truck needs to understand the hazards and must receive appropriate training. Forklifts can tip over easily and cannot stop quickly after braking. Also forks, mast and heavy loads can reduce visibility of the forklift driver. When turning, the back of the forklift truck swings over and may hit a pedestrian, if they are too close. Forklift trucks often operate in a noisy environment and there is danger that the pedestrian or the forklift driver may not hear each other. Forklift trucks are most commonly used in warehouses and storage facilities where there are often many pedestrians and hence it is vital that the forklift trucks and pedestrians are kept separate.

By creating driving paths for forklift trucks and walkways for pedestrians you can keep them apart, although there are areas where this may not be possible. Keeping forklift trucks and pedestrians separate can be achieved by using symbols and different coloured lines on the floor. For example, use yellow for forklift truck path and green for footpaths, white lines for storage locations and red for fire extinguishers or emergency doors that must always be accessible. For high use areas, use of physical barriers may be advisable.

It is never possible to avoid pedestrians crossing the forklift path entirely. To make it safer, create pedestrian crossings with the symbols on the floor and appropriate signs advising forklift drivers to slow down. Also think of gates that prevent pedestrians to cross without thinking. Another danger area is the doorway from one hall to another which can be a bottleneck and the views on the other side can be limited. It is advisable to have a separate door for the pedestrians, if possible with a fence to guide them to the door. It should be further away from the door access for the forklift truck to prevent pedestrians taking the easiest route.

There are number of other devices available to warn of approaching forklift trucks like sirens and LED lights that projects red lines on the floor to be avoided by pedestrians. Click here to read our blog on Safety Lighting for Forklift Trucks. Warning signs and mirrors to see around the corner need to be placed at hazardous area such as blind corners.

The safety rules implemented must be followed by everyone including the supervisors, management and visitors. The senior staff should lead by example.

It is very important to segregate the pedestrians and forklift trucks wherever possible for the safety of all personnel. An accident would cause severe disruption to productivity, injury to staff and could be costly for the company.

Bravery and Courage of a Teenager following a Forklift Truck Accident

Although this incident happened in Montana, USA it is such a compelling story that we thought our readers would find it interesting and informative for forklift operators.

Loren Schauers was working on a bridge rehabilitation project in 2019, aged 19, when he was involved in an incident while driving a forklift truck which had serious consequences for the rest of his life.

On the day of the incident, the bridge was reduced to a single lane, controlled by traffic lights while work was in progress. There were orange water barriers and one of the drivers knocked the water barrier off. Loren was tasked to put the water barrier back in position using a forklift truck. However, cars ignored the traffic lights and started illegally passing him. As one car passed him, Loren veered the forklift truck too close to the edge where the ground was not compacted. The weight of the forklift truck made indentation in the ground, which made the forklift truck tilt upwards and was slowly about to roll over.

As the forklift truck started to topple, Loren unbuckled his seatbelt and tried to jump out. However, the seatbelt ended up wrapping around his legs. He swung out and broke two of his ribs by hitting the floorboard of the forklift truck. Loren had never received any forklift truck training and did not know that the protocol was to stay in the cab with the seatbelt on. Loren said “I now know that to unbuckle the seatbelt and try to jump was wrong idea, but it was just a fight or flight reaction”

The forklift truck fell 50 feet (15.24m) below and landed on Loren’s hips and right forearm. Loren was conscious the whole time. An air ambulance arrived, pulled Loren up the hill on a stretcher and flew him to the local hospital, which did not have the expertise to deal with his injuries and he was flown to Seattle. Loren had lost his right forearm and hand, broken his right collarbone and shoulder, and his lower body had been crushed. He also suffered a blockage in his lung artery (pulmonary embolism) and needed a breathing tube. Loren’s lower body was so badly crushed that he made a brave decision to have everything below his waist amputated, called hemicorperectomy surgery.

After numerous operations and a number of times when he was not expected to make it, Loren was well enough to go home in 4 month instead of 18 months the doctors had predicted he would be in hospital. In September 2022, Loren celebrated the third anniversary since the accident. His girlfriend Sabia Reiche stood by him and they got married in February 2021. He now has a prosthetic arm and is able get around in a wheelchair. They also bought their own home.

Loren Schauers’ courage, bravery and fighting spirit after a serious forklift truck accident has to be applauded when most people would have given up. His story is well documented on social media and YouTube channel.

The key lesson for forklift truck drivers is that the equipment is huge and heavy and training is vital for safe operation.

Wallace Forklift Training London blog photo HSE Inspector’s visit to a Forklift Operator – A Case Study

In our last blog, we talked about what a forklift operator should expect from the Health and Safety Executive’s (HSE) visit. In this blog we look at a case study of the HSE inspector’s visit to a forklift operator.

In 2019, the HSE inspector made a routine visit to a stone handling company. It found issues with the lifting arm of the forklift truck and it was deemed not fit for purpose. A prohibition notice is issued if there is a risk of serious personal injury now or in the future. The prohibition notice stopped the use of the forklift truck until the lifting arm was replaced. The firm complied with the prohibition notice.

However, 2 years later in 2021, there was a serious accident at the firm involving the same forklift truck and HSE investigated and prosecuted the company despite it going into liquidation. The accident occurred when 2 employees were trying to off-load two tonne set of ten stone slabs from a trailer. They had removed the packaging and each stone slab was to be removed individually by a forklift truck. The stone slabs began to topple while one of the employees altered a clamp attached at the end of the lifting arm of the forklift truck. Both men jumped from the trailer to avoid the toppling stone slabs. However, the falling slabs hit one of the employees’. He sustained a broken leg and severe bruising and was off work for ten months.

The HSE investigated and found:

The same lifting arm which had the probation notice was back in use
The forklift truck had not been serviced or maintained
No forklift truck operator training had taken place
The company and the director failed to implement a safe method of work
The employees’ had not been provided with any instructions or supervision on the day.

The company, in care of the liquidator, admitted to two breaches of the Health and Safety at Work etc 1974. The company and its former director were fine £2000 each and had to pay £5000 in costs.

Ruth Wallace of Wallace Forklift Training in London said that “considering the weight of the stone slabs, quick reaction of the employees probably saved them from more serious injury or fatality. It is unclear whether the lack of forklift truck’s service, maintenance and operator training contributed to the accident. However, failure to implement a safe method of work and lack of instructions and supervision surely contributed and the use of the forklift truck’s lifting arm which had been under the prohibition notice was negligent”.

HSE Inspector’s Visit – Info for Forklift Truck Operator

In our last blog, Ruth Wallace of Wallace School of Transport alluded to the need to keep a full training record of forklift truck drivers, especially in case of Health and Safety Executive (HSE) investigation. An HSE inspector can visit at any time and may arrive without warning. The highest incidence of workplace accidents involve forklift trucks, hence keep forklift training records up to date as an HSE inspector may want to look at them.

The HSE inspector’s job is to ensure that you keep workers and anyone who may be affected by your work, healthy and safe. They may also give you advice on health and safety. While the inspector is visiting, he may:

Ask you about your workers and what they do,
Look at any possible health risks,
Look at any machinery or other equipment you may have including forklift trucks,
Ask to see records or other documents including forklift training records,
Take photographs

The inspector may also ask about health and safety issues at your workplace and your knowledge and experience of health and safety. The inspector may talk to your employees including forklift truck drivers.

The inspector will take action if you are breaking the law and may stop a dangerous activity immediately. The laws affecting the forklift truck operators are:

What happens after HSE inspector’s visit?

Advice

The inspector may offer advice, either verbally or in writing, about improvements you could make to health and safety in your workplace. This advice is free.

Notification of Contravention (NoC)

NoC tells you about health and safety laws you’ve broken and explains how you’ve broken them. NoC will tell you what you need to do to stop breaking the law. The inspector will give you NoC only if you have broken the law seriously enough for them to write to you about it. If the inspector gives you NoC, you’ll have to pay for the cost of the visit.

Improvement Notice

An improvement notice will tell you what’s wrong and any changes you need to make to put things right. You will have at least 21 days to make any changes. You commit a criminal offence if you don’t make the changes in the given time.

Prohibition Notice

You may get a prohibition notice if there is a risk of serious personal injury now or in the future. A prohibition notice orders you to stop doing something until you have made it safe to continue. You commit a criminal offence if you don’t comply with a prohibition notice.

Prosecution

You can be prosecuted for breaking health and safety laws or for failing to comply with an improvement notice or a prohibition notice. The courts can fine you or in some cases send you to prison.

Links that may be useful for forklift truck operators:

1 Lift-truck training Advice for employers

2 Thorough examination of lifting equipment - A simple guide for employers

3. Wallace Forklift Training Blog on Thorough Examination

In the next blog we will look at a case study and the outcome of HSE inspector’s visit to a forklift operator.

Wallace School of Transport is a fully accredited RTITB company with over 50 years' experience. You can be trained either at your own work site or at Wallace Centre in Park Royal. If you have any questions, call Wallace Forklift Training for free on 0800 612 8948, choose option 3 or click here to email us.

Refresher Training for Forklift Truck Drivers

Forklift Training at Wallace site in Park Royal, London

In the current climate with inflation at about 10%, fuel prices going through the roof and pressure to increase wages to combat cost of living crisis, most companies are going through difficult times and are tightening their belts by cutting out non-essential spending. However, forklift driver refresher training should not be part of your cost cutting drive. Forklift trucks are large heavy piece of equipment and accidents could be fatal. Therefore, even those who are trained and experienced need to be routinely retested or refresher trained to ensure that they continue to operate forklift trucks safely.

The Provision and Use of Work Equipment Regulations 1998 (PUWER) place certain requirements on employers. You must make sure that all people who use, supervise or manage the use of work equipment including forklift trucks have received adequate training, which includes:

the correct use of the equipment;
any risks from its use;
the precautions to take

There is no fixed mandate to how often the refresher training should take place. It is generally accepted that forklift drivers should have refresher training every three to five years. Most reputable forklift training providers should advice you on this issue. However, if you have concerns or a driver has an accident or a near miss, then the refresher training should be taken earlier than recommended. Other instances where the refresher could be taken earlier include, if you have not used the forklift truck for a while or are an occasional user or your work environment has changed. Under the National Operator Registration Scheme (NORS) the forklift truck drivers are subjected to a refresher course every three years and an expiry date is included on their NORS qualifications.

Regular refresher training will ensure that the drivers maintain good driving habits, learn new skills and reassess their abilities. If you have any area you need more help with or have concerns, talk to a reputable forklift training provider who may be able to help you. Generally, refresher training should only take one day. In exceptional circumstances, it may take two days of training.

Do not confuse conversion training and refresher training. Conversion training is different from Refresher training. Conversion training enables trained and experienced operators to extend the range of forklift trucks they are qualified to drive. It involves learning to operate a truck of a different category, such as a counterbalanced operator converting to operate, for example, a reach truck, articulated lift truck, or very narrow aisle man-up stacking truck. Conversion training should follow a similar pattern to initial forklift truck training, including basic, specific job, and familiarisation training and testing.

Ruth Wallace of Wallace Forklift Training says “in an event of accident, having a full training record of the forklift driver will help you, especially in case of an HSE investigation, and therefore do not skimp on the refresher training”.

Useful Links:

Forklift Driver Fatigue

Forklift Driver Fatigue blog

In the last blog, we highlighted forklift truck accidents that could have been prevented if the right procedures were in place. You can minimise the chances of accidents but it is difficult to completely eliminate them due to human factors. One of these is the forklift driver fatigue. Fatigue is defined as the state of feeling tired, weary or sleepy. It should be considered a workplace hazard, as it can be a form of impairment. Operating a forklift truck requires attention, precision and reaction. All of these can easily be hampered when a lack of sufficient sleep builds up over a period of time.

The causes of forklift driver fatigue include:

Lack of sleep
Long working hours
Work pressures like stress and anxiety
Work environment like noise, uneven surfaces the forklift traverses over and busy warehouses
Ergonomics like sitting position and lighting
Issues at home

Some of the common signs of forklift drive fatigue include:

Poor decision making
Lack of or poor communications
Lack of concentration
Irritability
Memory Loss
Difficulty staying awake

Some causes of forklift fatigues are easier to deal with. Ergonomic issues such as sitting position and lighting can be remedied. If noise is causing you fatigue, headphones that cut out some of the noise will help. However, this may have other issues such as inability to hear emergency sirens putting the forklift driver in danger. It is up to the discretion of the employer whether to allow headphones but generally it is not encouraged.

Some warehouses operate 24 hours a day and workers are often on shifts. Other workplaces require forklift drivers to work after most of the other workers have left resulting in evening or night work. You may find it difficult to sleep during the day as our bodies are hardwired to sleep at night.

Causes of fatigue may not necessarily be linked to work. In this hot summer, it is difficult for most of us to sleep soundly. However, if you are doing shift work and trying to sleep during the day, it is almost impossible in this hot weather. There may be other factors causing lack of sleep such as family pressures or money worries. If you are a forklift driver and are having issues sleeping, talk to your supervisor or manager.

The best way to deal with forklift driver fatigue is communications and awareness. Talk to the forklift driver of the dangers and risks of fatigue. The behaviour of most people change when they are fatigued. Be aware of this and try to find out the reason for the change in behaviour. If it is due to lack of sleep, try to alter the sleep patterns. You may need to seek professional help if the forklift driver fatigue persists.

Keep Pedestrians away from your Forklift

Preventable Forklift Truck Accidents

This year the National Forklift Safety Day was held on 14 June 2022. It is a global event and this year’s focus was on Operator Training. As mentioned in a number of blogs recently, about a quarter of all workplace accidents involve a forklift truck and hence it is vitally important that the forklift truck operator is appropriately trained.

Wallace has dedicated training forklift training facilities at its site in Park Royal. Wallace also provides operator forklift training at your own site. To emphasise the need for training and following Health and Safety Regulations, we highlight three recent accidents involving a forklift truck.

Peterlee Magistrates’ Court heard a case where the driver was assisting in loading of pallets of cardboard tubes on his vehicle. The forklift truck, reversed and struck the driver causing injuries to his right leg. An investigation by Health and Safety Executive (HSE) found that there was lack of suitable segregation between pedestrians and vehicles. Corespec of County Durham pleaded guilty to breaching Regulation 17(1) of the Workplace (Health, Safety and Welfare) Regulations 1992. It was fined £117,585 and ordered to pay £5404 in costs.

HSE inspector Ashfaq Ali said, “This injury was easily preventable. Planning for transport safety and implementing safe working practices should avoid such incidents. Workplace transport is a significant hazard, and the risks must be recognised and managed. There are simple and effective measures employers can take to help keep everyone safe. Companies should be aware that HSE will not hesitate to take appropriate enforcement action against those that fall below the required safety standards.”

In another incident, Leeds Magistrates’ Court heard a case of a HGV delivery driver, employed by Brighthouse Pallet Services Ltd, being struck by falling pallets whilst they were being unloaded using a forklift truck from a HGV trailer by Seal It Services Ltd at its site at Elland. The HGV driver suffered a fracture to one of his neck vertebrae.

An investigation by HSE found both companies failed to provide a safe system of work. All delivery drivers who visited Seal It Services should have been moved to a safe location for waiting while their vehicle was being unloaded using a forklift truck.

Brighouse Pallet Services Ltd pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc Act 1974. The company was fined £4,000 and ordered to pay £4806.60 in costs.

Seal It Services Ltd pleaded guilty to breaching Section 3(1) of the Health and Safety at Work etc Act 1974. The company was fined £50,000 and ordered to pay £4,654 in costs.

David Welsh of HSE, said: “Loading and unloading of HGVs by forklift trucks is among the most dangerous transport activities in the workplace. People can be hit by falling objects, struck by forklifts, or fall from vehicles. All such incidents can result in serious personal injury and the risks involved must be managed by all those who have legal duties for the safety of delivery drivers, both their employer and the sites they deliver to. This incident could so easily have been avoided by implementing the simple control measure of keeping the delivery driver out of the area where the forklift truck was operating to maintain a safe system of work.”

In the third accident, Lerwick Sheriff Court heard a case of Karen Allen, an employee of QA Fish Ltd, who suffered significant fatal leg injuries as a pedestrian, following an accident with a forklift truck in Scalloway, Shetland.

A joint investigation by Police Scotland and the HSE found that no site-specific workplace transport risk assessment had been carried out. The forklift truck operation was vital to the business but the company failed to provide control measures to segregate pedestrians and vehicles in a safe manner.

QA Fish Ltd pleaded guilty to breaching Section 2(1) and Section 33(1)(a) of the Health and Safety at Work Act 1974 and have been fined £80,000.

HSE Inspector Connor Gibson said “The tragic outcome of this incident clearly highlights why dutyholders must ensure that vehicle and pedestrian movements at their work site are properly assessed and adequately controlled. This fatal incident could and should have been prevented via suitable and sufficient control measures segregating pedestrians from vehicle movements.”

All three above accidents could have been prevented had the correct Health and Safety at Work procedures been implemented. It is vital to separate forklift routes and pedestrians wherever possible. Forklift trucks are large heavy pieces of equipment and contact with a pedestrians could be fatal. All the companies would have suffered significant disruption to their business operations and incurred heavy fines. Also ensure that the forklift truck operator training is fully up to date including refresher courses.

Safety Lighting for Forklift Trucks

Wallace Forklift Training has previously highlighted the risks involved in forklift truck operations. About a quarter of all workplace accidents involve a forklift truck. Other than training and ensuring that the forklift truck route and pedestrians are kept separate wherever possible, there are a number of safety features available that reduces the risks of accidents. Your forklift is probably equipped with headlights and tail or brake lights. However, in this blog we will highlight the use of other safety lighting on a forklift truck to enhance safety by increasing pedestrian awareness of moving hazards. There is a wide range of forklift safety lighting styles available from spots, arrows, arcs and strobes to suit most applications. The benefits of forklift safety lighting include:

Increased safety for pedestrians and operators
Available in different colours (generally red and blue), styles and designs to suit your needs
Can be retrofitted to the forklift truck
Uses long life LED bulbs
Robust and durable to withstand forklift truck operations in all environments
Provides an alternative to audio warning or you can combine audio and lighting

The different types of safety warning lights available include:

Danger Zone Lights - This projects a bright light on the floor to warn the pedestrians to keep away from this danger zone, i.e. creates a no go zone around the forklift truck. The zone area can be adjusted to meet your specific requirements. This prevents foot injuries and collisions from rear end swing.

Forklift Arc Light – This an alternative to danger zone light. Instead of a zone, it projects a bright arc light in front of the direction of travel and basically provides the same benefits as Danger Zone Light.

Front and Rear LED Strip Lights – this offers extra visibility to the driver as well as warns pedestrians of the vicinity of the forklift truck. It also allows the pedestrians to identify the direction of travel as the light changes colour from white to red when the forklift changes direction.

Safety Spot Light – An LED light that projects a large spot in front of the forklift warning pedestrians and other vehicles. Particularly useful when approaching a blind corner or crossing aisles as the light spot is detected before the forklift truck giving ample warning to on-coming traffic.

Safety Arrow Light – Similar to the safety spot light with the same benefits but projects a large arrow light on the floor in front a few meters ahead of the direction of travel, either forwards or backwards.

Beacon Strobe Light – attached to a forklift truck, the LED beacon strobe light rotates and flashes during operation giving all round visibility and warning pedestrians and other vehicles. Beacon strobe light provides a cheap safety feature.

Safety lighting for forklifts is a relatively cheap form of increasing safety in the work environment. There are number options available and hence review them to select the one that best suits your requirements.

Increase Warehouse Capacity using Reach Forklift Truck

With near double-digit inflation with prices of everything rising, businesses have to juggle costs to survive. If you need to increase warehouse capacity, moving to larger premises is one option but the costs will go up including rent, business rates and heating and lighting bills. However, another option is to stack goods even higher. You may even be able to double your warehouse capacity. Using a reach forklift truck you can stack pallets as high as 12.5m. There are other options line VNA (very narrow aisle) forklift trucks which can lift loads even higher up to 13.5m. However, these can only be used in the aisles as they need guidance systems like guide rail or wire. The VNA forklift truck cannot be turned, only the load can be turned. Hence these are ideal for specialist warehouses and are very expensive.

Using a counterbalance forklift truck, you can reach racking of up to 4m. Using a taller mast you can go even higher. But if you want to stack goods up to 12.5m, then for most warehouses, the only option is to use a reach forklift truck.

In this blog we look at some of the features you should be looking for stacking goods at a great height. These include:

Good visibility. Ensure the reach forklift truck you are buying is designed for maximum visibility for stacking high loads. Overhead guards should give maximum visibility as well as protection against falling objects.
Ensure the design of the mast is slender to give maximum visibility of the load.
Use a reach forklift that helps put a pallet in the high racks safely using camera/monitor combination.
A pre-set height selector will provide further assistance. The height selector could be pre-set to align with the rack height.
Automatic centring of fork tilt and side shifting in advance will improve safety and productivity as it will reduce cycle times.
Stopping loads at height might result in in mast swaying back and forth. The forklift operator has to wait for the mast to stop swaying before the load can be put away. However, the reach forklift truck can be equipped with passive sway control which dampens the mast movement. Alternatively, you can have active sway control which pro-actively controls sway movement through a software.

Using a reach forklift truck is a great way to increase warehouse capacity by stacking loads higher and save costs associated with moving to larger premises.

Which Option to Choose – Hiring, Buying or Leasing a Forklift Truck

Deciding on whether to buy, hire or lease a forklift truck depends on the individual needs and circumstances of the company. In this blog we look at the pros and cons of hiring, buying, or leasing a forklift truck.

Hiring a Forklift Truck

Hiring a forklift truck or a fleet does not need large upfront cash or easy access to borrowing. In the current uncertain times with Covid-19 pandemic, this is a major benefit. By not incurring a large upfront cost, you could spend more on other areas like increasing your workforce or spending more on marketing or production.
Certain costs such as maintenance and repairs to the forklift truck are not your responsibility
Hiring a forklift truck over the busy periods like Christmas to supplement your existing fleet could be prudent as no-one wants the equipment to be idle over long periods of time.
If you need a specialist forklift for certain tasks or projects, then it would be cheaper to hire one over the specific period of time.
Overall, hiring a forklift truck which is used continuously is more expensive than buying or leasing one.
If you hire a forklift and change them regularly, the staff will need a period of adjustment.
Forklifts are hired out to a number of clients and you may not get the equipment in prime condition compared to buying new or leasing.
If you are not sure of your future requirements, either for specification or usage, it may be better to hire a forklift initially.

Buying a Forklift Truck

Overall buying a forklift truck is the most cost effective long term option, especially if you operate multiple shifts, handle specialist products or have a steady predictable workflow.
You can customise the forklift truck for your specialist needs
By buying a forklift truck, you will be able to depreciate it, resulting in tax write-offs
It will be an asset on your books
When you want to change or upgrade your forklift, you can use it as collateral to finance the new purchase or you can sell it.
Buying lets the employees familiarise themselves with the equipment and if you have the same fleet with the same brands and models, this will also help.
To reduce costs, you can buy a second hand forklift truck
Buying a forklift reduces flexibility as you are stuck with what you have bought
Hire or leased forklift has to be returned in a certain condition as stipulated in the contract. However, if you own it minor nicks are not a major concern.
Owning a forklift or fleet of them requires additional paperwork like the Thorough Examination .

Leasing a Forklift Truck

Leasing is basically hiring for a longer term. It is usually cheaper than hiring but more expensive than buying
Like hiring, the upfront cost of leasing is a lot lower
You may also have an option to include maintenance package into your monthly payments. This will enable you to accurately track the total costs without having to account for any unforeseen circumstances.
Generally, you will get a new forklift truck at the start of the lease and every time you renew and hence you will get an upgrade with the latest models
You have the flexibility of upgrading to a different specification at the end of your lease, based on your current requirements
At the end of the lease you also have the flexibility to purchase it.
Like hiring, you do not own the forklift and hence it is not an asset on your books.
Most lease agreements have a usage limit. If your usage is higher, you will have to pay extra.
You are also relying on the lessor to provide timely service and repairs when necessary. Any delays will result in downtime.

In conclusion, whether to hire, buy or lease will depend on your individual circumstances. As mentioned above each has its pros and cons.

Forklift Truck Incidents Involving a Third Person

In the last blog we highlighted the fatal forklift truck accident at Boss Scaffolding Limited and the costs it incurred following the Health and Safety Executive investigation which included a suspended prison sentence for the director. In this blog we look further into the safety of workers involved in the forklift truck incidents as reported by UK Material Handling Association. The figures give vital information for all companies using forklift trucks and their priorities in formulating their health and safety policies.

Forklift trucks are dangerous. About a quarter of all workplace accidents involve a forklift truck resulting in around 1300 UK workers being hospitalised each year. Here are the key statistics regarding accidents from the reportable forklift truck incidents between 2016 and 2019 involving a third person:

43% of all forklift truck reportable incidents involved impact with a third person
65% of those involved pedestrians are engaged in activities unrelated to the immediate forklift truck operation
20% of the victims were co-workers or supervisors
15% were delivery drivers working or assisting with loading and unloading their vehicles

There are a number of Health and Safety lessons to be learned from the above statistics. Simple measures such as traffic route demarcation and physical barriers would stop most of the incidents involving impact with a third person. Companies using forklift trucks need to assess the risks and manage the worksite traffic. The key aspect is to keep pedestrians and vehicles apart and the best way to do it is by installing physical barriers. Using safety assistance systems like warning zone light, optimised braking paths and automatic speed adjustments further reduces the risks of forklift truck incidents involving a third party.

Personal protective equipment like hi viz jackets will also help reduce forklift truck accidents with the third party, especially if there are warning signs in areas where hi viz jackets are compulsory.

Another aspect of accident prevention is training. Not only does the forklift operator need to have appropriate training but all the employees need to receive health and safety training specific to their workplace and need to be aware of risks and dangers. Particular attention need to be paid to visiting drivers as they might be not be aware of the company’s health and safety requirements and may not have received appropriate training.

Ruth Wallace of Wallace School of Transport says that “the costs of a forklift truck incident could be substantial. Injury to the personal, damage to the equipment including the forklift truck and to the buildings and the loss of goods and productivity could all add up to thousands of pounds. Prevention is by far a cheaper option”.

HSE Reports on a Fatal Forklift Truck Accident

A recent press release from Health and Safety Executive (HSE) highlights the case of Shaun Flynn who died of his injuries following a forklift truck accident. Mr Flynn had just finished loading a lorry in the yard of Boss Scaffolding Limited when he was struck from behind by the raised forks of a moving counterbalance forklift truck.

An investigation by HSE found that the Boss Scaffolding director and an employee failed to take reasonable care for the health and safety of others who might be affected by poor management of risks arising from the use of counterbalance forklift truck in a state of disrepair.

Boss Scaffolding director pleaded guilty of breaching Section 7 of the Health and Safety at Work Act 1974. He was sentenced to 10 weeks imprisonment, suspended for eighteen months and ordered to pay £7,000 fine and £45,000 costs.

Speaking after the hearing, HSE inspector Jenna McDade said: “This case highlights the importance of regular pro-active maintenance and inspection of work equipment, to ensure equipment does not deteriorate to the extent that it puts people at risk. Sadly the tragic death of Mr Flynn could have been prevented”.

A Thorough Examination (TE) is a mandatory inspection required by law to ensure that the mechanical parts of a forklift truck are in safe working order and is roughly equivalent to the MOT for cars. Work equipment must be examined at least once a year. Read our blog on “Thorough Examination of a Forklift Truck“, for more information.

As reported in previous blogs, around 1,300 UK employees are hospitalised each year with serious injuries following forklift accidents. The debilitating and life-changing injuries suffered include, complex fractures, dislocations, deglovings and amputations. Forklift truck accidents cause most serious accidents in a workplace in UK, even more than heavy goods vehicles.

There are a number of reasons why forklifts are so dangerous in a workplace, including:

Forklifts can weigh up to 4 tonnes (more than twice the weight of an average family car)
Their speeds can reach up to 18mph (over 28kmh)
Forklifts often raise hefty loads to considerable heights, a dangerous combination
Loads are usually carried in the front of a forklift, which can obstruct the view of the driver
Forklifts are often operated in busy areas with lot of people around
Forklifts only have brakes on the front tyres, making them difficult to stop
Forklifts have counterweights or batteries at the rear to compensate for lifting heavy weights. This uneven weight distribution makes it difficult to handle
The rear wheels control the turning circle which cause the rear end to swing outward and this increases the chances of tipping over during tight turns

To avoid forklift accidents at the workplace, ensure that the equipment is well maintained, operated by a trained driver and appropriate safety procedures are in place.

Safety of Warehouse Employees

Wallace Forklift Training blog - Safety of Warehouse Employees

In the last blog we looked at the safety of the visiting engineer carrying out Thorough Examination of a forklift truck. In this blog we look at the safety of all employees in a warehouse. The relevant legislation is The Workplace (Health, Safety and Welfare) Regulations 1992 which covers a wide range of issues including safety of employees in most workplaces including warehouses. It includes the regulatory requirements on issues such as cleanliness, lighting, floor conditions, falls and falling objects and traffic routes amongst many others.

A warehouse is a busy workplace with fast moving hive of activity. Accidents happen even in a best run warehouse but following safety rules would minimise these. Accidents are a major financial risk for employers as it can lead to inspection by Health and Safety Executive (HSE), litigation, and fines. Accidents cause injuries resulting in employee’s absence from work impacting on production. It can also cause damage to the property and machinery and require a great deal of paperwork and certain area of the warehouse may be closed, further impacting production.

Slips, trips and falls are the most common cause of non-fatal accidents in a workplace. Hazards such as split substances, discarded boxes and cables are cause of many accidents. Any spills should be cleaned up immediately, clear any obstructions and tidy up cables. Use heavy duty cable covers if they run over the floor. Use warning signage where appropriate. Where possible, the cleaning should be done outside work hours or busy periods to reduce risks. Floors should be even to reduce risk of falling when carrying a load. Anti-slip paint and appropriate shoes will further reduce risks. Failure to identify, remove or make safe a hazard is dangerous and breaches health and safety regulations.

HSE reports that 20% of non-fatal accidents are due to manual handling such as lifting or carrying loads. Providing adequate training can reduce strain and sprain injuries. Where possible, lift heavy loads using machinery such as forklift trucks.

Crush injuries and machinery accidents in a warehouse are common resulting from operating forklift and pallet trucks and packaging machinery. Accidents caused by being trapped by machinery can be fatal. In 2018, according to HSE statistics, 10% 0f fatal accidents were caused by collapsing or overturning machinery. Injuries caused by forklift trucks were some of the most common in a warehouse. About 1300 employees are hospitalised each year with serious injuries following a forklift accident. These accidents can be avoided by appropriate training, adequate supervision, maintenance of the equipment and clearly marked route for the for the forklift truck.

Another major cause of injury in a warehouse is from falling objects, mainly due to carelessness or poorly constructed shelves. Pay particular attention to loading and unloading the shelves and the weight distribution.

Employers are required by law to provide employees with Personal Protection Equipment (PPE) and appropriate training on how to use it and care for it. There are numerous types of PPE like hard hats, high visibility jackets, steel-toe cap and anti- slip shoes. The management must access the most appropriate PPE for the task. Employees must report to the management if the PPE is damaged and need replacing.

Training, appropriate safety procedures and good house-keeping are most important to mitigate the risk of accidents and injuries.

Useful Links

Safety of Visiting Engineer Carrying out Thorough Examination of a Forklift Truck

In the last blog we talked about the Thorough Examination (TE) of the forklift trucks at your site by a Consolidated Fork Truck Services (CFTS) accredited engineer. In this blog we talk about your legal duty of care to the visiting engineer. The site has the legal duty of care to all employees and visitors.

The site manager is responsibility for looking after the visiting engineer. However as a forklift operator, the site manager may delegate the responsibility of looking after the CFTS accredited engineer to you.

The legislation applicable is Health and Safety at Work etc Act 1974. The main duties placed on employers are sections 2 and 3 of the Act and are qualified by the phrase ‘so far as is reasonably practicable’. This means balancing the level of risk against the measures needed to control the risk in terms of time, money or trouble. Control measures should be adopted unless they are grossly disproportionate to the risk. This judgment is an essential part of the risk assessment process and will be informed by approved codes of practice, published standards and Health and Safety Executice or industry guidance where available. The size of the business and its financial strength do not determine the health and safety standards to be achieved.

At your workplace as a forklift truck operator you should have received induction training which includes health and safety at work. It should have covered provision of lifting and access equipment, working at height, supervision of lone workers and disposal of waste. Use the skills learned at the induction training to help you look after the visiting engineer.

The visiting engineer should be provided with a safe environment to work in. This means an area with controlled access, with no through traffic, vehicle movements or operating machinery. It should be well lit and sufficiently ventilated, ideally under cover or indoors, clean, without oil spills, slip or trip hazards. The visiting engineer should have sufficient space to carry out the Thorough Examination of the forklift truck and should be free from overhead obstructions. The TE should take place on a firm, smooth, level floor of sufficient load carrying capacity.

The visiting engineer should have access to welfare facilities such as washroom and canteen and access to his own van.

In a recent incident a visiting employee of a farming company died when he was crushed against a mobile seed dressing vehicle by a forklift truck. He had finished processing wheat seeds when his colleague got into a forklift truck to move the last bag. When the forklift truck was started, it suddenly moved forward, trapping the visiting employee against the mobile seed dressing vehicle which was fatal.

The farming company was prosecuted under s 2(1) of the Health and Safety at Work etc. Act 1974 for not taking reasonably practicable steps to prevent the employee walking into the dangerous gap between the forklift truck and the mobile seed-dressing vehicle. They also failed to establish suitable authorisation for driving the farmer's forklift truck and other farm machinery. The company pleaded guilty and were fined £35,000 plus £17,076 costs.

It is your legal duty to look after the Health and Safety of the visiting engineer or any visitor, as any mishaps could be very costly and cause injury.

Useful Links

Thorough Examination of a Forklift Truck

Forklift Truck

TE must cover both, the lifting mechanism under LOLER 98 and the safe use of a forklift truck under PUWER 98. Use Consolidated Fork Truck Services (CFTS) accredited companies to ensure that TE is carried out by an accredited examiner with stringent standards and procedures that meets the LOLER and PUWER regulations. CFTS is part of UK Material Handling Association (UKMHA). Only CFTS accredited companies can use the distinctive kitemark on their literature, certification and reports, and can place the CFTS stickers on the forklift trucks they inspect.

TE should include the following to meet the LOLER and PUWER requirements:

Mast – must be inspected throughout its full range of movement

Chains – chain failure is potentially damaging and therefore must be tested for wear, elongation and corrosion which are often tricky to spot. Measurements in at least three places are essential. A change of 3% means that the chains have to be replaced. Chain anchor points and pulleys also need checking.

Load Backrest – essential to keep forklift loads from falling backwards. The load backrest must be inspected to make sure it is structurally sound and securely mounted.

Carriage – the forklift arm carrier must be checked for distortion and cracking

Forks – the fork arms must be of correct capacity. Inspect for signs of wear, cracks, deformation and splaying

Tilt Mechanism – must move in a controlled and even manner with no signs of damage or scoring

Hydraulic Systems – forklift hydraulic systems, cylinders, reservoir, hoses and pipes must be checked thoroughly

Rating Plate – must be securely attached, legible and have a capacity rating for the forklift truck

Controls – all control cables and linkages must be checked for correct operation, corrosion, damage and signs of potential failure.

Overhead Guard or Cab - provides protection from falling loads. Damaged overhead guard or cab could be sign of structural problems. It should be checked to ensure it is sound and securely mounted

Seat Restraint and seat mounting – seat belts and other devices are designed to keep the forklift operator safely seated in an event of tipping. They should be securely mounted and free from damage. Seat mountings must be secured as well as the panel to which it is mounted.

Traction System – on internal combustion engine (ICE) forklift trucks the prime mover and transmission should be checked as well as the exhaust system. For electric forlift trucks, check the battery connections.

Brakes – all service and parking brake systems must work as expected. Brake failure could be catastrophic and could cause a lot of damage and hence must be thoroughly checked.

Chassis – check for damage and cracking in the welds

Wheels and Tyres – are vital for the sound running of the forklift truck. Wheels must be in sound condition and securely fixed. Tyres must be checked for wear, damage and bonding failure.

Counterweight – in ICE forklifts as the batteries provide the counterweight in electric ones. Counterweights could weigh as much as 2 tonnes or more and therefore ensure that it is securely fixed and undamaged.

Safety Systems – all safety systems should be checked to ensure that they function properly including visible and audible warning devices.

Recently, there have been a number of clarifications to GN28, the industry guidance. These include the requirement to carry out the TE every six months for lorry mounted trucks where the operator can be lifted with the truck and also for attachments not permanently mounted to the forklift truck. Click here to read more on the clarifications to GN28.

Safety must be of paramount importance to any organisation using a forklift truck. This includes training of the operator as well as ensuring that the forklift truck is safe to use.

What is Appropriate Forklift Training?

What is Adequate Forklift training

The UK Material Handling Association (UKMHA) is currently running a Safety Drive 2021 campaign and is committed to sharing the latest innovations and good practice in the industry. This week’s focus is on TRAINING. UKMHA was formed recently with the merger between British Industrial Trucks Association (BITA) and the Forklift Truck Association (FLTA). To learn more, read our blog entitled “Launch of UK Material Handling Association”. Following the training theme, we look at what is adequate training for forklift truck operator.

Forklift Truck Operator Training

The employers have a legal obligation to adequately train all the operators using material handling equipment such as forklift trucks. Trained operators have fewer accidents, are less likely to damage the equipment and improve performance and increase productivity. However the key question is what is adequate forklift training?

Adequate Forklift Training

If you want to drive a car or a lorry, you get an appropriate licence. However, for a forklift truck, officially there is no licence. The certificate you get from the forklift training provider is often referred to as a licence but you must ensure that the training provider is accredited by an appropriate organisation like RTITB.

The Health and Safety Executive’s (HSE) Forklift Truck Code of practice for operators (L117), advices that all forklift truck operators must go through:

Basic Training
Specific Job Training
Familiarisation Training

Basic Training

Basic training should cover all the skills and knowledge needed to safely operate the type of forklift truck and handling attachments (if any) the trainee will use. The Basic Training should include awareness of the risks from lift-truck operation. It should take place ‘off the job’, without the pressures of production.

Specific Job Training

After completing basic training, the forklift operator should be trained on an actual truck, loads and site from where he will be operating. Specific Job Training should include knowledge and understanding of the operating principles and controls of the forklift truck to be used, especially relating to handling attachments and loads specific to the job and routine inspection and servicing of that truck, in accordance with the operator’s handbook or manufacturer’s instruction. The forklift truck operator should be trained in conditions he will meet at work such as gangways, loading bays, racking, lifts, automatic doors, confined areas, cold stores, slopes, rough terrain, loading platforms, other vehicles, and bad weather. Instruction on site rules like site layout, one-way systems, speed limits, general emergency procedures, eye and hearing protection, work near excavations and overhead lines, and other hazards. Training should include all work to be carried out like loading particular types of vehicle with loads normally found at that workplace, using the forklift truck fitted with working platforms where appropriate, safe systems of work, which should include custody arrangements for the keys.

Familiarisation Training

Familiarisation training is the third stage of forklift training, which should be carried out on the job, under close supervision, by someone with appropriate knowledge. This could include applying under normal working conditions, the skills already learned in basic and specific training, starting with simple tasks and moving on to more complex ones and becoming familiar with the forklift-truck activities of the employer. It should also include familiarisation with the site layout, local emergency procedures and any other feature of the work which it is not practicable to teach off the job.

Refresher training

Regular refresher forklift training will ensure operators maintain good driving habits, learn new skills where appropriate and reassess their abilities. Refresher training or retesting might also be appropriate where operators have not used forklift trucks for some time, are occasional users, appear to have developed unsafe working practices, have had an accident or near miss, have changed their working practices or environment. There is no specific time period after which you need to provide refresher training or formal assessment. However, you may decide that automatic refresher training or re-certification after a set period of time is the best way to make sure employees stay competent. RTITB recommend re-certification every 3 years. Often the forklift training provider specifies how often you should take refresher training. Whatever approach you adopt for refresher training, you will still need to monitor performance in case operators need extra training before the set period ends.

Only after the employees have successfully completed all three elements of training, the employer should give a written authorisation to operate the forklift truck that you have been trained to use.

Follow Forklift Truck Maintenance Routine for Optimal Performance

Follow Forklift Truck Maintenance for Optimal Performance In a recent Health and Safety Executive (HSE) investigation, a company in Nottingham who pleaded guilty were fined £80,000 and ordered to pay costs of £6478 following an incident involving a side loader forklift truck. It was found that the company did not maintain the side loader forklift as per the manufacturer’s specifications. This leads us to the topic of the this blog – Forklift Truck Maintenance

Forklift trucks are large and heavy piece of equipment which if not maintained regularly, could cause accidents and injury to staff and as in above case, lead to a hefty fine by HSE. Additionally, a well maintained forklift truck would avoid costly downtime, ensure peak performance and maximise the lifespan of the equipment.

LOLER (Lifting Operations and Lifting Equipment Regulations 1998) are a set of regulations designed to make lifting operations, and the use of lifting equipment such as forklift trucks, as safe as can be. The regulations make sure that you impose a system of regular checks, thorough inspections, and routine maintenance. The other relevant regulation is Provision and Use of Work Equipment Regulations 1998 (PUWER).

There are three main maintenance schedules all forklift users should employ. These are:

daily check-up
monthly / quarterly maintenance
annual maintenance

Daily Check-up

It is generally recommended that a daily check-up of the forklift truck is carried out before every shift. This should include:

Tyres check – ensure they are inflated, free of damage or excessive wear and the wheel nuts are tight
Forks and mast are not bent, cracked or showing excessive rust. Mast lift chain and rollers are in good condition
Hydraulic lines are free of damage or cracks and are not leaking. Check fluid levels
Check for damage on all hoses and cables and lift cylinders
Check the seat belts.
Start the forklift truck and check the lights and horn
Check the fuel level or battery charge level for electric forklift trucks
Check engine oil and engine coolant
Move the forklift truck a short distance and check for and leaks or spillages left behind from its parking position
Test the accelerator, steering, brakes, hand brake and signals
Raise the forks up and down and test the tilt mechanism

A daily check-up should take only a few minutes.

Monthly / Quarterly Maintenance

You must follow the maintenance schedule provided by the manufacturer and it will also depend on your daily usage. For example you may be required to change oil every three months or every 250 hours of use. The monthly or quarterly maintenance should be done by a competent qualified person. The inspection should include:

Accelerator and brake pedal free play check
Check hand brake
Check tyre wear and tyre pressure
Check lift chain tension, mast operation, carriage rollers, lift and tilt cylinders
Check hydraulic oil pump
Check differential and transmission oil
Check and where necessary change all filters, hoses and valves
Clean the radiator
Replace the fuel and hydraulic filters
Lubricate chassis-mast attachment

Annual Maintenance

Annual maintenance is often carried out by external specialist. You need to follow the manufacturer’s specifications to ensure the warrantee is valid. Check forklift truck thoroughly for any potential repairs that may be needed to ensure optimal performance, safety and durability.

This is a brief summary of forklift truck maintenance. The actual maintenance will vary for each forklift depending on the fuel, usage and the age of the forklift. It is important that any fault found is remedied as soon as possible. A record of all the maintenance should be kept including the daily check-up.

Forklift Truck Accident Results in a Hefty Fine

A recent Health and Safety Executive (HSE) report highlighted a facilities services company that was fined £30,000 and had to pay costs of £7636 after pleading guilty. The incident involved an employee who was carrying out inspections of drain covers adjacent to a workshop. The forklift truck operator was unloading boxes for delivery to the canteen. The forklift operator’s view was obscured by the load on the forks. This resulted in the accident with the employee inspecting the drain covers. He suffered a broken leg.

The company had transgressed under the following sections of the Health and Safety at Work etc. Act 1974:

Section 2(1) – Duty of employer to ensure health, safety and welfare at work of all employees
Section 3(1) – Duty of every employer to ensure that persons not in his employment who may be affected are not exposed to risks to their health or safety

The HSE's investigation found the company had failed to carry out the appropriate risk assessment. It failed to ensure vehicles and pedestrians were not working at the same time in the same place.

In another recent accident, a forklift truck crashed into a refuse skip, seriously injuring two employees. In UK, about 1300 workers are injured and hospitalised every year due to forklift truck accidents with 42% of fatalities caused by vehicles tipping over (read our blog on Loading Capacity of a Forklift Truck for advice on how to prevent forklift truck from tipping over)

The training of the forklift operators and all the safety processes are the responsibility of the employer. The HSE’s Code of Practice for Forklift Trucks - L117, states that adequate operator training consists of three stages – Basic, Specific and Familiarisation. It is best to get the forklift training from an accredited organisation. Wallace Forklift Training is RTITB accredited. We have a dedicated facility for forklift training in Park Royal in London and we can also carry out training at your site. Our customers mainly come from individuals who want to improve their job prospects or from companies who sent their employees for training and refresher courses.

Load Rating Capacity of a Forklift Truck

One of the major causes of forklift truck accidents is the lack of knowledge or misuse of forklift truck’s weight limit or rating capacity. Forklift trucks basically operate as a seesaw. On one end is the counterweight and on the other end is the load. The front axle is the fulcrum. The rule is that the force of the counterweight is always greater than the force of the load. This stops the forklift from tipping over.

Forklift trucks have a safe lifting capacity and height specified by the manufacturer on the rating or data plate. However, this does not mean that the forklift truck can lift any weight to the maximum height safely. The dimensions of the load, the position on the forks and the weight distribution affects the maximum load that can be lifted.

The maximum load that can be lifted is stated on the rating/data plate at a specified load centre. If load centre is not at the optimum level, the forklift cannot lift the maximum load.

Load Centre

Load centre is the balance point of a load or centre of gravity of the load, of an evenly balanced load whilst sitting on the forklift truck forks. If the load is evenly balanced on a pallet and butted up to the carriage, then the horizontal centre of gravity is half the distance from one end of the pallet. On a typical 48 inch x 48 inch (1.22m x1.22m) pallet, the horizontal centre of gravity or load point is 24 inches (0.61m).

However, how high you stack a load is also very important to achieve maximum load and height. For maximum load, the vertical centre of gravity for a balanced load should not be more than the horizontal centre of gravity, that is, for a 48 inch x 48 inch pallet, the vertical centre of gravity should not be more than 24 inches high.

Load Capabilities of a Forklift Truck from Wallace Forklift Training London

In the diagram above, for maximum load capability for a balanced load, centre of gravity in the vertical direction (C) should be no greater than the horizontal centre of gravity dimension (B).

If you divert from the optimum load centre, the weight and height capability of a forklift truck reduces considerably. Often the loads are not perfectly balanced and may not be in a symmetrical shape. Therefore, the operator needs to factor in all the different parameters when lifting a load.

Rating Plate of a Forklift Truck

Rating Plate of a Forklift Truck

Forklift Truck Attachments

Sometimes forklift truck attachments such as fork extensions, booms and rotating heads are necessary to lift certain loads. However, adding attachments alters the load centre and the lifting capability of a forklift truck due to the additional weight of the attachment itself and because an attachment generally extends the truck’s load centre. It is important to seek expert advice and recalculate the loading capacity of a forklift truck after adding attachments. Fitting an attachment to a forklift truck will reduce the truck’s rated capacity, this is known as de-rating. To indicate this reduction in capacity, a new rating plate specifically relating to the attachment for the forklift truck, must be secured to the truck before it is used with the attachment.

Forklift trucks are large heavy pieces of equipment and hence paying attention to load capacity of the vehicle is important to avoid accidents, injury and damage to the goods being lifted. If you receive training from a reputable organisation, the training will include the load capacity of the forklift truck. Training is available to anyone aged 17 or older who is physically and mentally fit and you do not need a car driving licence.

Some Useful Links:

Key Components of a Forklift Truck

Forklift trucks keep the world functioning efficiently. This is a bold statement but when you look around, almost everything or part of it has been moved by a forklift truck. Most factories, warehouses and retail outlets including supermarkets use forklifts in their everyday operations. To move materials and goods efficiently saves money and hence you need dependable forklift trucks. To get the best out your forklift truck you need to understand how it works. In this blog we explain the key components of a forklift truck.

Key Components of a Forklift Truck

Power Source – The power of the forklift comes from either an internal combustion engine (ICE) or an electric motor. The fuel for ICE is either diesel or liquid propane gas. The electric forklift is powered by lithium ion or lead-acid battery. The power source or engine is generally located under the driver’s seat. The power source requires most attention in a forklift truck with maintenance and refuelling or charging for the electric ones. Read our blog on "Benefits of Electric Forklift Trucks”.

Forklift Truck Frame – This is like a chassis of a car. All key components like wheels, counterweight and mast are attached to the frame.

Counterweight – This is a cast iron weight fixed usually to the rear of the forklift. It counters the weight of the load being lifted giving stability and preventing the forklift from being toppled over. The counterweight dictates the carrying capacity of the forklift. The carrying capacity is listed on the rating plate. In electric forklifts, the battery often provides the counterweight.

Forklift Mast – This enables the main function of the forklift which is to raise and lower the load. It also allows the load to tilt. It is the vertical section in front and consists of interlocking rails powered by hydraulic cylinders. The hydraulic vertical cylinder lifts the forks and carriage while the tilt cylinder caters for the tilt of the carriage and the forks. The mast may have different stages such as duplex, triplex and quad (2, 3 or 4 stages). More stages allow loads to be lifted to greater heights and hence quad achieves the greatest height the forklift load can be lifted.

Carriage – The carriage is located in front of the mast and includes the forks and the load backrest. The function of the forks is to lift the load from the bottom. The load backrest allows the load to rest on and prevents the load from slipping backwards towards the operator. It also protects the mast from being damaged by the load.

Forklift Tyres – Obviously you need tyres to move and there are several options available. You may have a three or four tyre/wheel options. Four tyres allow higher loads to be carried while three tyres allow smaller turning circle, ideal where space is limited. Cushion tyres are suited to indoor use while pneumatic tyres are ideal for outdoor use as they have better traction and can handle uneven and rough surfaces.

Operator Cabin – This is where the driver operates the forklift from and generally consists of operator seat, steering wheel, brake pedals, parking brake or hand brake, mast control, acceleration pedal, inching pedal and gauges. It also has lift lever, tilt lever and side shift lever.

Overhead Guard – The overhead guard protects the forklift driver from any falling object. This could be from the load which is not secured properly or if the driver bumps into a rack while moving.

Rating Plate - Also known as capacity plate, nameplate or data plate, it contains important information such as carrying capacity, lift height, weight, fuel type, forward and back tilt degrees, tyre and other safety information. All forklift drivers must be familiar with the information on the rating plate.

All forklift drivers must be familiar with their vehicle for safe and efficient operation. Forklift driver training must include a section on key components of a forklift truck.

How to stay grounded and get the best from Forklift Truck Training

Grounding techniques to get the best from your forklift training

Training involves learning new skills and you have to listen and assimilate information and apply it. At Wallace we have been training forklift, lorry and bus drivers for over 50 years. There are certain instances where a trainee/learner is not focused due to a variety of reasons which could include stresses at work, issues at home or getting stuck in the traffic on the way to training site. We are going through a challenging time due to the COvid-19 pandemic and people are often worried about their jobs, finances and health of their family members. Wallace Forklift Training has been open throughout the lockdown as forklift training is deemed an essential service to keep the country moving. If you are not focused, handling a large piece of equipment like a forklift truck or an HGV lorry could cause considerable damage and injury to yourself and others.

You need to be focused to get the best out of your training. Sometimes, you are not feeling the best on the day and at these instances using “grounding” techniques may help.

What is Grounding

Grounding is a practice that can help you pull away from your worries and negative or challenging emotions. These techniques may help you refocus on what’s happening at the moment. There are three techniques of grounding: Mental, Physical and Soothing.

Mental Grounding Techniques

These are all about focusing your mind and getting back to the present. There are a number of techniques you can use which include:

Imagine – Think of a pleasant or comforting mental image. Make it as real as possible. You could say this is about going to your ‘happy place’.
Use humour – Take a few minutes to think of something funny or a joke somebody recently told you. This can quickly jolt you out of a negative mood.
Memory Game - where you look at a detailed picture for 10 seconds and the look away and try to recreate the picture in your mind or list all the things from the picture.
Categories - Choose one or two broad categories, such as football teams, countries or car models. Take a minute or two to mentally list as many things from each category as you can.
Use maths/numbers – Even if you are not good at maths, numbers can help centre you – Count backwards from 100 or think of a number and ways you can arrive at, e.g. number 20 (10+10, 10x2, 5+5+5+5, 30-10, 4+16)
Recite something in your head like a song or poem. Visualise each word on a page.
Anchoring phrase – this might be like “I am John Smith, 25 years old, live in Wembley. Today is 14^th May, I am at Wallace Forklift Training Site, You can describe the weather or your surroundings, etc

Physical Grounding Techniques

This method is about using your five senses to bring you back into the moment and help you focus. Examples of Physical Grounding possible at a training site include:

Run cool or cold water over your hands or wrists
Clench and release your fists, stretch or even jump up and down if it is possible
Focus on your breathing, noticing each inhale and exhale
Take a short walk if you are early for training. Concentrate on your steps — you can even count them. Notice the rhythm of your footsteps and how it feels to put your foot on the ground and then lift it again.
Listen to your surroundings or noises around you. Do you hear machinery or traffic? If you hear people talking, what are they saying? Let the sounds wash over you and remind you where you are.
Feel your body, either sitting or standing. Focus on how your body feels from head to toe, noticing each part. Curl your fingers and wiggle your toes.
Try the 5-4-3-2-1 method. Working backward from 5, use your senses to list things you notice around you. For example, you might start by listing five things you can see, then four things you hear, three things you can touch, etc.

Soothing Grounding Technique

This is all about using techniques to comfort yourself at times of distress by giving you a positive experience to counter any negative ones. This enables you to concentrate. Techniques include:

Thinking of your favourites like colour, food, sports, movies
Picture the voice or face of your loved ones - the people you care about and how they make you feel
Plan a treat for yourself like a holiday, meeting friends going to your favourite restaurant
Practice self-kindness - Repeat kind, compassionate phrases to yourself like “You’re having a rough time, but you’ll make it through”, “You’re trying hard, and you’re doing your best”, etc.
Visualize your favourite place. It could be anywhere. Create a mental image with colours and sounds. Remember the last time you were there.

Grounding, also known as anchoring is an effective way to focus, remove negativity and be in the present and generally does not cost you anything. Forklift, lorry or bus training could be quite expensive and your future career prospects may dependent on you doing well. Therefore, use the grounding technique to get the best out of you. There are lot more techniques and with practice you will get better at it.

Health and Safety App for SMEs

Health and Safety App The Health and Safety Executive (HSE) has recently released a Public Beta test mobile app to help organisations understand the law regarding Health and Safety including their rights and responsibilities. It is specially designed for small and medium sized enterprises (SME). HSE's mission is to prevent death, injury and ill-health in workplaces. The app was created in partnership with The Stationary Office (TSO) and allows its users to easily navigate through the content and find the guidance using the built-in search function. Automatic live updates are available so that the users are up to date with the latest advice, guidance and legislation.

What is a Beta Test

Beta Testing is the final round of testing before a product is released. A public beta test allows the public to try the product with the aim of uncovering any bugs or issues so that they can be addressed before general release.

The app contains three main sections, which are:

1. The Health and Safety Toolbox (HSG268)

This section explains the Health and Safety law and your responsibilities as an employer. It provides an overview of all potential risks, applicable to organisations. Topics covered are:

How to manage health and safety
Your organisation
Your workers
Your workplace
Electrical safety
Fire safety
Gas safety
Harmful substances
Machinery, plant and equipment
Manual handling
Noise
Personal Protective Equipment (PPE)
Pressure equipment
Radiations
Risk assessments
Slips and trips
Vibration
Working at height
Working in confined spaces
Work-related stress
Workplace transport

2. A Guide to Managing Risk

This section provides a simple step-by-step guide and practical advice on how to manage risk. It includes:

Steps needed to manage risk
Identify hazards
Assess the risks
Control the risks
Record findings
Review the controls
Risk assessment template and examples

3. Work-Related Stress

This section includes a condensed version of HSE's stress management standards approach. Designed for smaller organisations, it comprises a step by step guide to manage work-related stress for:

Small organisations (up to 50 employees)
Medium-size organisations (51-250 employees)
Medium-size organisations, with multiple sites

Ruth Wallace of Wallace School of Transport says “getting expert advice on Health and Safety is expensive and hence an easy to use App would be very helpful. I hope as many SMEs as possible participate in the Public Beta testing as it is in all our interest to have a robust app which works well”.

The HSE health and safety app is now available to downloaded as a one-off introductory rate of only £2.99 from the Apple iOS store and the Google Play Store.

Launch of UK Material Handling Association

Wallace Forklift Training London The merger between British Industrial Truck Association (BITA) and the Forklift Truck Association (FLTA) has created the UK Material Handling Association (UKMHA) to represent interest of all the diverse materials handling industry and to ensure it has a single, authoritative voice. Also included in the merger is the subsidiary co-owned by BITA and FLTA, Consolidated Fork Truck Services (CFTS), the accrediting body introduced to deliver the first national procedure for Thorough Examination.

Until now, BITA represented the interests of industrial truck manufacturers, while FLTA promoted the interests of dealers, owners and operators. Both associations will continue in their respective roles until the merger process is fully completed, but under the UKMHA brand. The chief executive of FLTA, Tim Waples, has been appointed chief executive of UKMHA.

The UKMHA is a not-for-profit organisation with aim of improving standards in the industry. Their existing campaigns include National Forklift Safety Day, the Forklift Safety Convention and the Safety Drive. The merger will strengthen the offering of the combined organisations, enhancing the services delivered to members and all those who own and operate forklift trucks. The UKMHA’s mission statement is “Providing the entire material handling industry with a single voice and ensuring the highest standards of safety and service are maintained at all times”.

The UKMHA will initially act as an umbrella organisation with plans to merge BITA and FLTA in the near future. To ensure the material handling industry remains operationally effective during the coronavirus emergency, the UKMHA is making freely available a series of guidelines produced by BITA to help protect everyone working in the industry. It states that “It is important for the safety of everyone in the material handling industry that these recommendations are adhered to”.

The agenda for UKMHA will be the continued focus on improving standards of safety and service across the entire industry. Manufacturers will benefit from UKMHA’s increased scope, offering them far better access to and the opportunity to develop stronger relationships with their end-users and supporting dealers, according to an association statement.

The UKMHA said a quick recovery in the UK material handling industry from the economic upheaval suffered in 2020 due to COVID-19 was unlikely but was optimistic that vaccine programme and free trade agreements offer hope of recovery later in the year. However, any return to pre-pandemic levels of business is unlikely until 2023. In its latest UK Forklift Truck Market outlook, prepared for BITA by the Oxford Economics Consultancy projects 19% growth in 2021 and 6% growth in 2022.

Benefits of Electric Forklift Trucks

Benefits of an Electric Forklift Truck If you are in the market to buy a forklift truck, you have a large number of options to consider. First you have to consider the type of forklift which is ideal for you, depending on the maximum load, maximum height, the turning circle and the environment it will operate in. The types of forklift trucks available are:

Counterbalance
Reach
Pivot Steer / Articulated also known as Bendi or Flexi (Click here to read the blog on Pivot Steer Forklifts)
Truck Mounted also known as MOFFETT (Click here to read the blog on Truck Mounted Forklifts)

Then you to have to decide on the type of fuel from diesel, liquid propane gas (LPG) or Electric.

In recent years we have seen a huge increase in the sale of electric cars (about 148% up from last year), although from a low base, and about 30% decrease in the sale of diesel cars. Similarly, there has been a huge increase in the sale of electric forklift trucks compared to diesel and LPG. In this blog we will look at the benefits of electric forklift trucks which include:

1. Ease of Use

Electric forklifts offer a smooth and comfortable drive. It has no clutch and hence is much easier to drive like an automatic car. The electric forklift is operated with steering wheel and an accelerator. The overall experience of driving electric forklift truck has been said to reduce stress on the operator, allowing the driver to concentrate on his job thus reducing the risk of accidents.

2. Reduced Noise

Like electric cars, electric forklift are a lot quieter than diesel and LPG as it does not have an internal combustion engine. Hence the only noise is from the tyres. However, quieter forklifts may be deemed a disadvantage as it does not warn others employees that it is approaching. With the correct safety procedures in place, the quietness of electric forklift trucks should not be a disadvantage and it also enables the driver to hear other employees and vehicles better thus reducing the risks of accidents.

3. Reduced Operating Costs

Although the initial investment may be higher for electric forklift trucks, the lifetime cost is lower as the operating cost is lower. Electric forklift trucks have fewer mechanical components hence the servicing and maintenance cost is lower. It does not need regular oil or coolant changes. The battery does need to be regularly maintained through cleaning and servicing to ensure your forklift operates at an optimum level of efficiency. Also the cost of electricity is less than diesel and LPG, which needs ordering and storage.

4. No Pollution – Zero Carbon Dioxide Emissions

Electric forklift trucks emit no carbon dioxide and therefore it is environmentally friendlier. It is better for the driver and other workplace employees. When it comes to warehouse ventilation, there is no need for expensive ventilation solutions or you do not need to keep the warehouse doors open for ventilation and thus reduce heating bills. This makes it ideal for use in food processing industry.

5.0 Extended Operating Times

The introduction of lithium batteries have revolutionised the electric forklift sector. They are great for increasing operating times between battery charges. Consequently, they are becoming more commonplace. Lithium cells also have the added benefit in that they can be opportunity charged in-between shifts or during breaks without any damage to the cells. More companies are making the switch to electric power as a result.

There are numerous other advantages of using an electric forklift truck. They can be used indoors and outdoors, the three wheelers offer small turning circle and better rear visibility. Electric power is available on all types of forklift trucks. Electric forklift trucks can be used on most jobs except for the highest of the loads and tallest heights to be reached.

Updated COVID-19 HSE Guidelines for Forklift Truck Training

We wrote a blog, “Wallace Forklift Training is Open for Business” in March 2020 during the first lockdown following advice from Health and Safety Executive (HSE), Road Transport Industry Training Board (RTITB) and Association of Industrial Truck Drivers (AITT). The HSE has revised and updated its advice which is summarised in this blog. HSE has confirmed that urgent and essential forklift operator training can continue during the current lockdown and hence Wallace Forklift Training is open for business.

HSE advises that employers should ensure that all staff who operate a forklift truck are adequately trained. These include initial or refresher training for new starters, refreshers for existing staff or when existing staff use new types of equipment. A forklift lift truck operator should be routinely monitored and go on a refresher or retest, usually every 3-5 years. This is a best way to make sure that the forklift operator remains competent.

To manage the risks of COVID-19 transmission, HSE has advised employers and forklift training providers to consider;

if the training needs to be done urgently, based on their own assessment of forklift drivers’ competence and experience;
If there are other qualified forklift drivers with the appropriate training who could carry out the tasks on a short-term basis;
Checking prior to training commencing that no one is exhibiting Covid-19 symptoms;
Providing a system for separate entry and exit points from sites so that social distancing can be maintained
Minimising touch points and shared contact surfaces, such as pens, pointers, or touch screens;
To have easy and safe access to toilets and handwashing facilities with hot and cold running water, and that handwashing is carried out at regular intervals;
How social distancing can be maintained. This may mean reducing class size if suitable distancing cannot be maintained;
Sanitising shared surfaces such as equipment controls between users;
Providing fresh air ventilation wherever possible by opening windows or doors. Mechanical ventilation should not be set to air recirculation mode;
Use of alternative learning methods such as e-learning or webinars where practicable;
Minimising face to face work wherever possible.

Wallace School of Transport has over 50 years’ experience and has dedicated facilities for training on all types of forklifts including Counterbalance, Reach. Pivot Steer and Truck Mounted (also called MOFFETT). Ruth Wallace of Wallace School of Transport said, "we do not use brokers/agents and contractors and hence have complete control of all the processes. This enables us to follow HSE guidelines for safety of our staff and customers".

Click here to follow Government Guidance on COVID-19.

Truck Mounted Forklift Truck Operating Skills Enhances Job Prospects

Truck Mounted Forklifts have been around for over 40 years. It was invented by Cecil Moffett of Clontibret, Ireland and have revolutionised the logistics industry. Truck Mounted Forklift is commonly known as Moffett after its inventor and is located on a back of a lorry or trailer without taking up load space. The Truck Mounted Forklift is based on counterbalance principal but the wheels are moved forward under the load, resulting in the fulcrum being further forward, thus reducing the need for heavy counterweight.

Truck Mounted Forklift - Moffett - Wallace Forklift Training

The benefits of Truck Mounted Forklift include:

Costs and Labour Saving – Without Truck Mounted Forklift, some of your customer will have to hire a forklift or borrow one. Either way you will still need a certified driver. With Truck Mounted Forklift, the lorry driver also operates the forklift. This saves time and money. Even if your customer has a forklift, having a Truck Mounted Forklift means that the company’s forklift can keep working on its usual job. It is estimated that for some jobs, Truck Mounted Forklift delivery compared to HIAB could be up to 70% cheaper.
Health and Safety – With no forklift on site, the only option is to offload the lorry by hand. This could cause injury even with moderately light loads, resulting in staff taking time off work.
Speed and Ease of Operation – Truck Mounted Forklift can be dismounted and ready to use in as little as a minute. They are easy to use and eliminate manual handling as the load can be precisely and safely positioned by the operator in almost any location. Time is money and manually handling is clearly slow. HIAB (acronym for Hydrauliska Industri AB) or Crane Loader is also slow as it takes time to unload every pallet using lifting chains. Each time lifting chains have to be attached and removed when using a HIAB, while on Truck Mounted Forklift offloading is quick and easy.
Access and Manoeuvrability – Truck Mounted Forklift is lighter, more agile/manoeuvrable, and can be used in places where accessibility is difficult such as construction and off-road sites. For example, if you are delivering a load of bricks at a construction site which is difficult for a lorry to reach, then a HIAB can only offload the bricks by the side of the road but a Truck Mounted Forklift can take the bricks all the way to the construction site. A Truck Mounted Forklift has all wheel drive with diff locks and large diameter pneumatic tyres and hence can tackle rough terrain.

Truck Mounted Forklifts are popular in a number of sectors including:

beverage logistics,
recycling material transportation,
delivery of technical and medical gases,
agriculture
delivery to live events,
builder and timber merchants - delivering building materials, plasterboard, insulation & wood.
pet food, bird seed & agricultural feed distribution,
palletised distribution
landscape and gardening

Drivers with Truck Mounted Forklift certification often earn more because their qualifications and skills increase productivity for their employer who can reward them accordingly.

If you planning to get HGV/LGV/lorry licence, then why not get a Truck Mounted Forklift / Moffett certification as well for a small additional cost. Contact Wallace School of Transport on 020 8453 3440 or 0800 612 8948

If you need a driver with Truck Mounted Forklift / Moffett operating skills or would like to get a Truck-Mounted Forklift qualification, or if you’ve got the qualification and are looking for work we can help. Call Wallace School of Transport – 0208 453 3440 ask for Russell

If you are a lorry driver and would like to enhance your skills and job prospects by getting Truck Mounted Forklift / Moffett certification, then Wallace Forklift Training can help you. Call Wallace Forklift Training for free on 0800 612 8948, choose option 3 or click here to email us

Risks Involved in Loading LGV using Forklift Trucks

Forklift Truck loading LGV/HGV Loading and unloading Large Goods Vehicle (LGV) or Heavy Goods Vehicle (HGV) is an everyday task for most logistic companies and warehouses, but it is fraught with dangers if not executed properly. Loading and unloading a LGV/HGV is usually done by forklift trucks and takes place where there are other moving vehicles and pedestrians, although these should be kept to a minimum or eliminated completely if possible to reduce the risk of accidents. A forklift operator should be aware of the risks involved with the type of vehicle they are loading or unloading, such as the characteristics of trailer suspension movement and ensure that the LGV/HGV is securely parked. Also moving heavy loads at height adds to the risks.

RTITB has recently published a blog highlighting the five top tips for safe loading of LGV/HGV with forklift trucks. Here is a summary of the top tips.

1) Training

All forklift operators involved in loading and unloading must have received appropriate training by an RTITB accredited instructor and should train across all three stages – Basic, Job Specific and Familiarisation. The company must ensure that the forklift operator certificate is valid. If expired, a re-fresh and re-certification is required. The forklift operator must be aware of the risks involved. A fully trained forklift operator will not only improve load handling safety and reduce damage but also maximise productivity and ensure compliance with relevant regulations.

2) Be Prepared

The essential part of forklift operator training is to understand what is required before loading or unloading begins. The operator must take personal responsibility for their own safety and should not rely on others to make necessary checks and take appropriate safety steps. Site specific guidelines on policies and procedures regarding loading and unloading must be in place.

Before loading or unloading begins, the vehicle or trailer must be properly secured. The safety procedures should include:

ensuring that the LGV/HGV parking brakes are on,
neutral is engaged,
engine is switched off
keys removed
wheels chocked and any stabilisers or ‘semi-trailer trestles’ such as fifth wheel supports are applied

3) Establish what a ‘Good’ load looks like

Operators need to be trained as to what a ‘good’ load looks like. All loads or pallets should be in a good condition prior to loading. Forklift truck operators must be taught how loads should be securely attached to a pallet and to a vehicle once loaded to prevent it from moving or falling off. Overhanging loads should be avoided if possible.

Uneven loads can make a vehicle unstable and hence loads should be spread as evenly as possible. Consideration should be given to multi drop deliveries so that the LGV/HGV can be loaded in the correct sequence.

During loading, consideration must be given to the unloading process so that the load arrives in a safe and suitable condition. Checks should be made before unloading to make sure no movement has occurred during transit. It is also important that the load will not move or fall when the restrains are removed.

4) Specific Risks

Forklift truck operators loading and unloading LGV/HGV should be aware of the risks involved, which includes knowledge of vehicles they are loading. For example, extra care needs to be taken when loading and unloading unsupported semi-trailers as excessive weight placed over the kingpin may result in the trailer tipping forwards. Also they need to be aware that there is no edge protection if they are loading or unloading curtain-side trailers. Failure to load correctly may lead to upending or damaging the trailer, collapsing the landing gear, lateral instability, trailer suspension movement, load bed damage or working at height incidents all of which pose a serious risk to safety. Forklift operators should be trained with an understanding of how to assess and reduce these risks.

5) Understanding of Other Equipment a Forklift Truck operator may come across

Forklift operators must be aware of the other equipment that they will come across and the risks involved, such as ramps, dock bridging platforms and goods lifts. Safety checks should be made before using these equipment. They must be able to check if the equipment is compatible with the vehicle or trailer, how to secure it properly so that is doesn’t move and how to securely fit any edge protection. They should check the maximum load permissible on ramps, platforms and lifts and ensure that the combined weight of their truck and the load does not exceed the maximum load.

There are numerous other risks involved in loading and unloading a LGV/HGV vehicle. Appropriate forklift training should mitigate these risks.

Click here to read the full RTITB blog.

Wallace Forklift Training offers Pivot Steer Truck training

Pivot Steer Forklift Truck training also known as Bendi or Flexi trucks

To keep up to date with the latest trends, Wallace Forklift Training has invested in a Pivot Steer Forklift Truck, also known as Bendi (manufacturer’s name) or Flexi truck. Wallace Forklift Training are pleased to offer training on all three types of forklifts, namely Pivot Steer, Reach and Counterbalance at its dedicated forklift training facility at Park Royal in London. Alternately, we can also train you at your own site.

What’s special about the Pivot Forklift trucks is that they bend in the middle. In other words, they are articulated. The forks are on a pivot which can be moved to the left or the right and can be at a complete right angle to the body where the operator sits (on top of the batteries). The versatile Pivot Forklift truck has the speed of a Counterbalance truck with the high lifting capacity of a Reach truck and can operate in very narrow aisles (VNA) which allows warehouse and distribution companies to increase capacity on their existing site without paying extra rent or rates and without the expense of moving to bigger premises. Another advantage of Pivot Steer forklift truck is that they are legally allowed to lift their load as they move – something not allowed in Reach trucks. This cuts the time they need to position a load on a shelf. It’s estimated that this increases productivity by up to 15%.

The graphics below clearly shows the advantages of the Pivot Steer forklift truck’s ability to operate in a VNA. In a typical warehouse you could have upto 77 bays of racking if you use Pivot Steer forklift, compared with 60 for Reach trucks and 46 for Counterbalance trucks.

Advantages of Pivot Steer Forklift Truck also known as Bendi or Flexi Trucks

Due to the benefits of Pivot Steer forklift trucks, they are currently outselling Counterbalance and Reach machines. Of course, it’s going to take many years for the traditional and trusty Counterbalance and Reach forklifts to be completely phased out as there are still many machines in use every day. However, more and more people who want forklift qualifications are deciding to get training and certificates to operate all three machines.

Having all three Counterbalance, Reach and Pivot Steer (or even two Counterbalance and Pivot or Reach and Pivot) opens up more job opportunities. For example, looking at job vacancies on Reed.co.uk, over a quarter of the jobs advertise want Pivot Operators (or a combination of Pivot and Counterbalance and/or Reach).

If you are planning to get forklift training, make sure it also includes Pivot Steer forklifts as it will improve your future job prospects.

Forklft and Pedestrians – Safe Working Distances

Forklift accidents Welcome back to Wallace Forklift Training blogs. Although our forklift training has been operational throughout the COVID-19 lockdown as forklift drivers were deemed key workers, some of our admin staff had a break.

In this blog, we look at the safety of pedestrians working in the vicinity of forklift operations. In UK, about 1300 workers are injured each year by forklift truck accidents. According to RIDDOR, 75% of these are impact with pedestrians that were completing tasks unrelated to the forklift truck operation. In our July 2019 blog titled Fatal Forklift Truck Accident reported by Health and Safety Executive (HSE), we highlighted the case of Christine Workman who was struck by a forklift truck while walking on a designated pedestrian area. Therefore, a question arises that what is a safe distance to work while in vicinity of a forklift operation?

Ideally, there should be no pedestrians in the vicinity of a forklift operation. However this is not is not always possible. To minimise the risks, some companies opt for generic safe distance rule across the entire site. However, not all tasks are the same and each task has its own risks associated with it. Therefore, each task must have a risk assessment carried out followed by appropriate safe systems of work procedures to minimise the risk of accidents.

A lot of third party injuries occur to colleagues working alongside forklifts. These could be due to falling loads or unstable loads which a colleague is trying to help stabilise. This should never happen as it is likely to lead to severe injuries or even fatalities. A falling load may damage goods but if no one else is in the vicinity, it will not cause injury to the third party. In the January 2020 blog title Work Related Fatal Injuries Data from HSE, we highlighted a case of Michael Douglas Autosalvage where a forklift was being loaded on to a recovery vehicle. The metal ring on the forklift truck that the winch wire was attached to failed, causing fatal injuries to a third party.

Another key issue to avoid accidents is to ensure that the forklift driver as well as all workers are well trained and are aware of the risks associated with forklift operation.

March 2020 - Coronavirus (Covid-19) – Wallace Forklift Training is Open for Business

Following guidance from Health and Safety Executive (HSE), RTITB and Association of Industrial Truck Trainers (AITT), Wallace Forklift Training is open for business and will continue training new operators and those who need requalification. Forklift operators are deemed key workers to keep the country functioning.

Adam Smith, the Managing Director of AITT says:

“Forklift operator training is required by law and employers have a legal obligation to ensure the safety of their staff. During this time, those who supply essential items such as food and medical resources are classed as critical workers, so it is extremely important that they receive appropriate training on the equipment they are required to use.

Conversion training may also be necessary where workers are having to change roles or work with different equipment, as businesses adapt ways of working to new circumstances. Employers must be vigilant and ensure that operators are not complacent on site. Goods are crucial right now and companies cannot risk damage and downtime caused by reckless operation.”

All new forklift truck operators must be fully trained to avoid accidents at this critical time. Those who need requalification training may extend the validity of current certificates by up to 3 months, provided they can demonstrate that training could not take place for reasons associated directly with coronavirus such as closure of training facilities, unavailability of trainers or complying with advice on isolation and social distancing.

Ruth Wallace of Wallace School of Transport says “It is our duty to take care of welfare and safety of all our staff and customers and will follow government guidance on coronavirus (COVID-19) including social distancing, washing hands and frequently cleaning and disinfecting objects and surfaces that are touched regularly. We are proud to do our part to keep the country functioning”

Click here to view the HSE statement regarding forklift Training

Click here to view the Government Guidance on coronavirus

Wallace has a dedicated facilities for training forklift drivers at Park Royal or can carry out training at your own site.

January 2020 - Work Related Fatal Injuries Data from HSE

The Health and Safety Executive (HSE) recently released annual figures for work-related fatal injuries for 2018/19. The data revealed that 147 workers were fatally injured, which is at a rate of approximately 1 worker per 200,000. There was an increase of 6 fatalities over the previous year, although the number has remained broadly level in recent years.

The fatal workplace injuries are spread across different sectors, with agriculture, forestry, fishing and waste and recycling seeing the largest fatalities with 32 deaths. This sector accounts for a small fraction of the workforce but has 20% of worker fatalities. The three most common causes of fatal injuries which account for 60% of the injuries are:

Workers falling from height (40)
Being struck by a moving vehicle (30)
Being struck by a moving object (16)

The HSE data also highlights risks to older workers. Workers aged 60 or over account for 10% of the workforce but 25% of the fatal injuries were to this age group.

In addition to the above figures, 92 members of the public were fatally injured in incidents connected to work.

One fatal accident that may be of interest to our customers took place at Michael Douglas Autosalvage Ltd in Carlisle. A customer had purchased a lift truck from the salvage company which was being loaded onto a recovery vehicle. The metal ring on the lift truck that the winch wire was attached to failed, causing the lift truck to fall and trap the customer against the skip lorry. The HSE found that the company had failed to ensure that the lifting process was properly planned by a competent person and failed in its duty not to expose customers to risk. Michael Douglas Autosalvage Ltd was fined £23,000 and ordered to pay costs of £8000.

For more information, click here for link to HSE site.

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Blog 2020, 2021 & 2022

What to look for in a Forklift Certificate of Training

Lead Acid battery powered forklift trucks

Fast Charge Lead Acid battery powered forklift trucks

Lithium Ion Battery powered forklift trucks

Hiring a Forklift Truck

Buying a Forklift Truck

Leasing a Forklift Truck

Forklift Truck Operator Training

Adequate Forklift Training

Basic Training

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Load Centre

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What is Grounding

Mental Grounding Techniques

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Soothing Grounding Technique

What is a Beta Test

1. The Health and Safety Toolbox (HSG268)

2. A Guide to Managing Risk

3. Work-Related Stress

1) Training

2) Be Prepared

3) Establish what a ‘Good’ load looks like

4) Specific Risks

5) Understanding of Other Equipment a Forklift Truck operator may come across

Wallace Forklift Training offers Pivot Steer Truck training

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