Lift Trucks in Warehouses

Up Down Up Down Beep

Sounds simple Oh Really

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Safety in the Movement of
People and Materials
Types of Lift Trucks

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 First have you Done your Hazard
Assessment
Next your Equipment Safety Check
Last but not least your walk around
to look for Hazards

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Counterbalance Lift Truck

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Reach Truck

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Rough-terrain Counterbalance

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Telescopic Materials Handler

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Side-loading Lift Truck

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Pedestrian Controlled Lift Truck

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Large Lift Truck

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 Lift Truck Hazards
• Collision with people or vulnerable plant
• Overturning
• Items falling from racking or forks
• Explosion from some batteries
• Hot exhaust
• Dangerous parts e.g. chains, drive shafts etc.
• Driving off edges, into pits etc.
• Placing loads onto peoples feet

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 Lift Truck Hazards
• Fumes
• Noise
• Whole body vibration
• Load slipping from forks

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 Driver Selection
• Reliable and mature attitude
• Physically & mentally fit
• Intelligent
• Over school leaving age
• Not under influence of drink/drugs
• Good vision
• Good hearing

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 Driver Training

• Supervisors should receive an appreciation

• Competent Instructor
• Records should be kept
• Test at end of training
• Employees should be given written
authorisation at end of training
• Refresher training as necessary
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 Work Area

• Separate traffic routes where possible

• Routes should have sufficient width and
clearance for largest trucks used
• Prevent pedestrians entering lift truck
areas
• Eliminate sharp bends or overhead
obstructions wherever possible
• Where hazards cannot be removed, use
clearly marked barriers
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 Work Area
• Signs, warning devices, mirrors etc.
• Instructions to sound horns and restrict speed
• Flexible doors of transparent material where
lift trucks have to pass through

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 Work Area

• Edges of loading bays, excavations & pits

should be clearly marked

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 Work Area

• Where possible, edges should be fitted with

barriers

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 Work Area

• Operating areas should be as

free as possible of
obstructions, but supports,
columns, pipework, racking
or other plant may need to
be protected by special
impact barriers

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 Work Area

• Firm and level surface, ideally concrete or

similar
• Potholes should not be allowed to develop
• Steep gradients should be avoided
• Adequate lighting
• Trucks should be parked in a secure area
• Keys should be kept in a secure place

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 Protecting Pedestrians &
Operators
• Segregate pedestrians and vehicles

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 Protecting Pedestrians &
Operators
• Clearly mark traffic routes
• Use audible and visual warning devices
• High-visibility clothing may be necessary, as
well as safety boots and hard hats
• A Roll Over Protection Structure should be
fitted where there is a risk of overturning and
crushing operator

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 Protecting Pedestrians &
Operators
• Seat belts may be required
• Falling object protection structures should be
fitted where there is significant risk of falling
materials
• Anyone driving a lift truck on a public road
should comply with road traffic legislation

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 The Lift Truck
• Suitable for its intended purpose
• Travel with loads in lowered position
• Do not load beyond SWL (safe working load)
• Dangerous parts should be guarded
• Eliminate ignition sources in battery charging
areas
• Adequate ventilation to disperse fumes

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 Operation of Lift Trucks
• Issue keys only to authorised people
• Lower forks when parked
• Keep to left when operating
• Sound horn at danger spots
• Avoid violent braking or sudden changes in
direction
• Never travel down slopes with load in front

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 Maintenance
• Follow manufacturers recommendations
• Operators should not carry out repairs
• Trucks that are on loan still need to be
checked and maintained

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 Operator Checks

• At beginning of each shift, operator should check

the following and report any defects to his
supervisor:
– Tyre pressure and damage;
– Steering and brakes;
– Fuel, water and oil levels;
– Battery levels;
– Masts and hydraulics;
– All controls;
– Horns and other warning systems; and
– Lights & mirrors
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 Conveyor Hazards
• In-running nips
• Entanglement points at rollers
• Contact with moving parts
• Materials falling from conveyor
• Manual Handling/Ergonomics from incorrectly
set speeds

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 Conveyor Controls

• Guard in-running nips

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 Conveyor Controls
• Emergency trip wires or stop buttons
• Guard power drives and other dangerous
parts
• Nobody allowed to ride on conveyor
• Operatives should be trained and instructed in
safe use

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Conveyor Controls

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 OPM Hazards

• Overturning e.g. overloading, gradients

• Falls of people, goods or materials
• Trapping of people in mechanisms
• Trapping of people against fixed structures
• People struck by moving OPM
• Failure of platform supporting mechanism
• People stranded on platform due to power failure
• Inadvertent movements e.g. misapplication of controls

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 OPM Controls
• Only trained and authorised persons
• Comply with SWL
• Tested and examined every 6 months (LOLER)
• Prevent access to dangerous parts e.g. chains,
mast sections etc.
• Edge protection
• Suitable overhead guards

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 Automated Warehouse Hazards
• Collision between AGVs and people
• Trapping points between AGVs and stationary
objects or fixed structures
• Inadvertent movement of AGVs
• Collapse of palletised loads
• Collapse of AGV
• Slips on oil from machines

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 Automated Warehouse Controls
• Segregate AGVs from pedestrians
• Trip devices on vehicle bumpers
• Sensors on vehicles to slow it to a crawl
• Ensure accurate positioning of AGV at transfer
points
• Easily accessible emergency stops
• Automatic monitoring of safety system

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 Automated Warehouse Controls
• Audible and visual signals
• Guard dangerous moving parts
• Prevent unauthorised human access
• Pressure sensitive mats
• Interlocked access gates
• Permit systems for maintenance
• Clear warning notices

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