Forklift trucks are a vital part of many workplaces, particularly in warehousing, construction, manufacturing, and logistics. However, they also present significant risks if not properly managed.
A suitable and sufficient forklift truck risk assessment is essential to identify hazards, protect employees and others, and ensure compliance with health and safety law.
Why risk assessments matter
Carrying out a forklift truck risk assessment isn’t just a box-ticking exercise—it underpins safe operations and helps organisations take a proactive approach to risk management.
Employers are legally required to assess risks associated with forklift operations, ensure equipment is suitable, and implement safe systems of work. This includes ensuring only trained and competent drivers operate the vehicles and that equipment is properly maintained.
Beyond legal duty, risk assessments help prevent , reduce disruption, and create safer working environments.
Main forklift truck hazards
While risks will vary depending on the workplace, common hazards associated with forklift trucks include:
Vehicle overturning (roll-over)
Forklifts can become unstable, particularly when overloaded, travelling on uneven ground, or turning at speed. Without proper controls, this can lead to serious or fatal crushing injuries.
Collisions with pedestrians or vehicles
Forklift trucks often operate in busy environments. Poor segregation or visibility can result in collisions with pedestrians or other vehicles.
Falling loads
Incorrect stacking, overloading, or unsafe lifting practices can cause loads to fall, posing a risk to anyone nearby.
Unsafe use of equipment
Using forklifts for unintended purposes—such as lifting people or acting as a work platform introduces significant risk.
Poor maintenance or defects
Faulty brakes, tyres, lights, or steering systems can increase the likelihood of accidents if not identified during inspections.
Unauthorised or incompetent use
Untrained or unauthorised operators significantly increase the risk of accidents and unsafe practices.
Moral, legal, and financial reasons to manage forklift risks
Moral responsibility
At its core, managing forklift safety is about protecting people. Employers have a duty of care to ensure employees, contractors, and visitors are not exposed to avoidable harm.
Serious forklift incidents can result in life-changing injuries or fatalities—outcomes that are always preventable with the right controls.
Legal compliance
Under UK Health & Safety law, employers must assess workplace risks and implement suitable control measures. This includes ensuring:
- Equipment is safe, suitable, and maintained
- Operators are , competent, and authorised
- Safe systems of work are in place
- Risks between vehicles and pedestrians are controlled
Failure to comply can result in enforcement action, fines, or prosecution.
Financial protection
Poor forklift safety management can lead to:
- Workplace accidents and associated compensation claims
- Equipment damage and operational downtime
- Increased insurance premiums
- Loss of reputation and business disruption
Key control measures for forklift safety
A robust forklift truck risk assessment should identify and implement practical control measures such as:
Safe systems of work
- Segregate pedestrians and vehicles using barriers or designated walkways
- Clearly mark routes and restricted areas
- Implement speed limits and traffic management systems
Training and competence
- Ensure all operators are trained, tested, and authorised
- Regularly review competence and refresher training needs
- Supervise new or inexperienced operators
Pre-use checks and maintenance
- Carry out daily inspections of brakes, tyres, steering, lights, and warning systems
- Ensure regular servicing and statutory examinations are completed
- Record and act on defects immediately
Vehicle safety features
- Fit and use seatbelts to protect operators in the event of overturning
- Ensure roll-over protection is in place where required
- Install reversing alarms and warning devices where appropriate
Load handling controls
- Never exceed the safe working load
- Ensure loads are stable and secure before movement
- Prohibit lifting people on forks or pallets
Workplace environment
- Maintain safe surfaces and clear routes
- Ensure adequate lighting and visibility
- Manage blind spots and junctions with mirrors or signals
Creating a safer workplace
Forklift truck risk assessments are not static documents—they should be reviewed regularly and updated when:
- Work processes change
- New equipment is introduced
- Incidents or near misses occur
- New hazards are identified
By taking a proactive, structured approach to forklift safety, employers can reduce risks, protect their workforce, and ensure compliance with legal requirements.
Conclusion
Forklift trucks are powerful tools—but with that power comes responsibility.
A well-developed risk assessment allows businesses to identify hazards, implement effective controls, and create safer working environments for everyone.
Getting it right not only protects people but also strengthens your organisation’s compliance, reputation, and operational resilience.
Get expert support with Peninsula
If you’re unsure whether your forklift truck risk assessment is suitable and sufficient, you’re not alone. Many employers struggle to identify all relevant hazards and implement robust, practical control measures.
Peninsula’s expert Health & Safety advisors can support you with:
- Developing or reviewing forklift truck risk assessments
- Identifying hazards and applying the most effective control measures
- Creating safe systems of work tailored to your business
- Ensuring compliance with current UK health and safety legislation
- Delivering training and guidance to support competent forklift operation
Get in touch with Peninsula today for expert advice and support to help you manage workplace risks with confidence.
