HSA - Forklift Truck

Forklift Truck

What is a ‘rider-operated lift truck’?
A ‘rider-operated lift truck’ means any truck capable of carrying an operator, including trucks controlled from both seated and stand-on positions, which may be fixed or foldaway.

How often should a forklift truck be checked/tested?
Forklift trucks are subject to statutory examination by a competent person once in every period of 14 months if engaged in construction or located in an industrial premises. This inspection must be carried out once in every 12 months if subject to Docks Regulations. Otherwise, they are subject to periodic inspection in accordance with S.I. 299 of 2007 (Safety, Health and Welfare at Work (General Application) Regulations 2007).

A system should be established for reporting defects and ensuring that remedial work is carried out. A planned routine maintenance system should include:

Daily checks of tyres, brakes, reversing alarm, flashing beacon, etc. by the driver at the beginning of each shift
In-depth weekly checks by the supervisor/manager; these reports should be written and kept on record
Maintenance as per the manufacturer’s instructions
Checks by a competent engineer following any major repair, modification or accident

What is the difference between an integrated working platform and a non-integrated workingplatform for forklifts?
An integrated working platform is an attachment on a forklift with controls that are linked to and isolate the truck controls, so that only the person in the platform can control the lift height of the platform and truck movements.

A non-integrated working platform, on the other hand, is an attachment for use in conjunction with forklift trucks that elevates people, but they have no controls in the platform that allow them to control the lift height or the truck movements, i.e. all truck and working platform movements are controlled by the truck operator. With reference to the Safety, Health and Welfare at Work (General Application) Regulations, 2007, the use of a non-integrated working platform is only permissible in exceptional circumstances.

Should a non-integrated working platform be CE marked?
NO. As the occasional use of non-integrated working platforms is only allowed in some EU member states, there is no free movement of these platforms allowed throughout the EU, and, as such, they must not be CE marked.

If a working platform is used for lifting people, do they have to wear any additional PPE?
PPE requirements should be determined in the risk assessment. Additionally, when working from such a platform, and if it is required that people must lean out of the platform in order to carry out work, they should wear a harness and lanyards that, when linked to the platform’s anchorage points, prevent them from overbalancing and falling over the rails. If practicable, the platform should be positioned so as to prevent the need for people to lean out when carrying out work.

Training

What training courses for forklifts are approved by the HSA?
The Authority does not approve any forklift training courses nor do they recognise any specific certificates. The HSA encourages that operators be trained in accordance with the HSA Code of Practice for Rider-Operated Lift Trucks.

The bodies listed below do, however, operate accreditation schemes for training providers and instructors. These are voluntary accreditation schemes, which are not mandatory, but are intended to help set and maintain professional training standards. However, inclusion in these guidelines does not imply approval by the Authority. Additionally, these bodies may themselves be involved in the delivery of training to instructors and lift truck operators:

FAS operate a scheme for the approval and registration of Training Organisations and Trainers. Individuals or organisations providing forklift truck training may apply to FAS for inclusion on its register of Approved Trainers/Training Organisations. FAS also provide training and certification for operators and maintain a register of trained operators. See www.fas.ie or contact 01 6070500.
RTITB Ltd. (formerly the Road Transport Industry Training Board) offers accreditation of lift-truck operator and instructor training to:

(a) Commercial training organisations providing operator training at permanent centres or on customers’ premises with suitable facilities

(b) Employers’ own in-house lift-truck training schemes

(c) Commercial training organisations providing lift-truck instructor courses

Access to accreditation is open to any individual or organisation able to demonstrate the meeting of RTITB’s published criteria. Annual renewal is subject to the results of regular independent and impartial monitoring, of training provision by RTITB assessors. RTITB accreditation is applicable to the full range of truck/types and attachments and to Material Handling Equipment used in a variety of industry settings.

RTITB Instructor Training is available through a National and International Network of Approved Instructor Centres. Following continuous assessment during the training course, all candidate instructors are independently examined by RTITB. Those successful in meeting the required examination standard become eligible for inclusion on the RTITB National Register of Qualified Instructors and are issued with a personal identification badge and certificate.

Registration lasts for a period of 5 years, re-registration is dependent upon the outcome of update training and re-examination by RTITB. Eligibility to become an RTITB Accredited organisation is subject to the provision of RTITB Registered Instructors with appropriate industrial experience. See www.rtitb.co.uk or contact 0044 1952 520200.
IIPMM (The Irish Institute of Purchasing and Materials Management) formerly the IIMH, operate an accreditation scheme for organisations providing forklift training. It also maintains a Register of Approved Instructors and Training Organisations. Seewww.iipmm.ie or contact 01 8559257.
ITSSAR (Independent Training Standards Scheme and Register) is a self financing, non-profit making organisation, who offer accreditation to training instructors and organisations supplying industrial truck training services to industry. See www.itssar.org.uk or contact 0044 118 989 3229.

My company runs its own in-house training scheme, which is not accredited by any of these bodies – is this legal?
Yes, so long as the training is relevant, adequate and properly supervised.

What is the minimum level of training required for lift truck operators?
It is wrong to assume that because employees hold a licence to drive, for example, a motor vehicle on the public roads, they also have the skills necessary to operate a lift truck. An ‘operator’ is anyone who operates a lift truck, even as a secondary or occasional part of their job, and is not limited to people specifically designated as lift truck operators.

Therefore, employers should not allow anyone to operate, even on a very occasional basis, any lift trucks who have not satisfactorily completed basic training and testing such as that described in the HSA Code, except for those undergoing such training under adequate supervision.

Hence, basic training must be given on all the types of lift truck and attachments that operators will or could be required to use in their work. If the operator is subsequently required to operate another lift truck, or there is a change of handling attachment, additional, practical conversion training will be required.

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What must be included in a basic training course?
The content of the training course will depend upon the lift truck operations the trainee will be expected to carry out. Each course needs to be tailored to fit all the lift truck operations to be undertaken by the operator. However, the main objectives that each trainee must achieve from the course are:

they must know and be able to state the reasons for operator training, the risks associated with lift truck operations and the causes of lift truck accidents
they must know and be able to state the responsibilities of operators to themselves and to others, including their duties under Section 13 of the Safety, Health & Safety at Work Act, 2005
they must be able to identify the basic construction and main components of the lift truck, stating its principles of operation and load handling capabilities and capacities
they must be able to identify, as appropriate, handling attachments which may be used with the lift truck
they must be able to locate and state the purpose and method of use of all controls and instruments
they must be able to place the forks or other handling attachment in pre-determined positions employing the appropriate controls
they must be able to identify various forms of load, and state the procedures for their stacking, de-stacking and separation; assess the weight, and, where relevant, the load centre of a load; and decide if the load with its known weight and load centre is within the truck's rated/derated capacity
they must be able to state the factors which affect machine stability, including turning, especially related to speed and sharpness of turn; load security and integrity; rated capacity and rated load centres; centres of gravity; and speed and smoothness of operation
they must be able to observe correct procedures when loading and unloading vehicles
they must be able to make visual checks to ascertain the safety and suitability of structures designed to receive loads, and be able to place and remove loads on and from those structures at various heights
they must be able to pick up and place loads, and drive and manoeuvre the machine in forward and reverse motions laden and un-laden on inclines, in restricted spaces and on level ground (including rough terrain as applicable), observing correct procedures and precautions
they must be able to park the machine, observing correct procedures and precautions
where applicable, they must be able to state the purpose, and demonstrate the procedures, for the use of safety devices, including stabilisers, level indicators, and load indicators, if fitted
they must be able to carry out inspection and maintenance tasks as required by the machine manufacturers and any relevant legislation
they must be able to state the actions to be taken in an emergency while in control of a lift truck, for example, action to be taken in the event of tipover
they must be able to state why it is essential to have vehicle key custody arrangements
they must know and be able to state the general precautions to be observed to prevent collisions with pedestrians

How long should this training last?
Employers should satisfy themselves that any training given covers all aspects of the work to be undertaken, and so training must be of sufficient length to enable trainees to acquire the basic skills and knowledge required for safe operation, including knowledge of the risks arising from lift truck operations. Training should not be altered to suit immediate operational or production needs. Therefore, the length of training can vary depending on the objectives to be covered, the trainee/instructor ratio and the ability and previous experience of the trainees. (for instance, an agricultural tractor driver may need less training on a rough terrain truck than a complete novice).

However, as a rough guide, the normal length of a course for novice operators would be five days. In all cases the time devoted to training needs to be sufficient to ensure that the basic training objectives can be achieved.

How often should operators receive refresher training and/or assessment?
There is no specific requirement to provide refresher training after set intervals. However, even trained and experienced lift truck operators need to be re-assessed from time to time to ensure that they continue to operate lift trucks safely. This assessment, which should form part of a firm’s normal monitoring procedures and be formally timetabled to ensure that it is done at reasonable intervals, will indicate whether any further training is needed.

In addition to routine safety monitoring, re-assessment might be appropriate where operators have not used trucks for some time, are occasional users, appear to have developed unsafe working practices, have had an accident or near miss, or experience a change in their working practices or environment.

Employers can, of course, decide that automatic retraining after a set period of time is the best way of ensuring that employees are adequately trained, but where this approach is adopted, it will still be necessary to monitor performance in case retraining is required before the set period ends. The guiding principle is that employers need to maintain the competence of operators to use lift trucks safely through a laid down, formal process of monitoring and assessment.

Conversion training, to enable operators to extend the range of trucks they are qualified to drive, may also be appropriate. Refresher and conversion training should be approached with the same attention to detail as basic training to ensure that all gaps in, and variants on, existing skills and knowledge are identified and covered during training.

Training will not in itself ensure the competence of individuals: this will develop with experience and should be monitored. Continued supervision will be necessary to ensure that good standards of operation are maintained.

What are operators tested on to pass the basic training course in lift truck operation?
In order to test operators’ skills in the basic operation of lift trucks, the following should be examined:

operation of the truck within the safety limits defined by the manufacturer carrying out a pre-use check when the truck is to be used
correct mounting and dismounting procedure and correct driving position
competent use of controls
movement of the truck with forks or attachments in the correct travel position, laden and un-laden
correct insertion and withdrawal of forks or other handling attachments without damage to pallet or load
manoeuvring a loaded truck forward and in reverse in a narrowly confined area
performing both a left and a right 90 degree turn with a loaded truck in a narrowly confined area without touching the sides of the area
stacking and destacking loads (i) at different levels, (ii) in front of a fixed vertical face or (iii) on the floor alongside similar loads
loading/unloading a vehicle (a suitable simulation may be used where a vehicle is not available)
correct parking of the truck

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How do I know that the training instructor is competent to train my employees in lift truck operation?
Operator training should only be carried out by instructors who have themselves undergone appropriate training in instructional techniques and skills assessment. They should give instruction only on the types of lift truck and attachments for which they have been trained and successfully tested as operators. Instructors also need sufficient industrial experience to enable them to put their instruction in context and an adequate knowledge of the working environment in which the trainee will be expected to operate

The instructor should be asked to supply evidence of their training and post training experience on the type of truck to be used, both as instructor and operator, and their knowledge of and familiarity with conditions in the industry where trainees will work, to assist in determining their competence. This will include expertise in any requirements particular to the operation of the truck(s) and in the work trainees will be expected to undertake. Good instructors should:

have the ability to adapt their approach to suit the needs of different trainees
be able to communicate effectively
be able to lead and control
keep their own training and experience as instructors up to date, especially if not training regularly

Are there different courses for other rider operated lifting equipment, such as pallet trucks or straddle carriers, or would forklift training be sufficient?
Operators of types of lift truck not covered by the HSA Code of Practice for Rider-Operated Lift Trucks will also need training. In some cases, for instance, on pedestrian/rider-operated pallet trucks, training may follow a similar approach, but in others, such as straddle carriers, a very different training programme will be needed. Training organisations involved in lift truck training may be able to advise on suitable training.

What is ‘specific job training’?
Specific job training is a further essential element of training. It normally follows the completion of basic training, but may be combined or integrated with it. A trainee: instructor: truck ratio of 2:1:1 is ideal for specific training, as for basic training also.

Specific job training will be tailored to the employer’s special needs and include, where appropriate:

Knowledge of the operating principles and controls of the lift truck to be used, especially where these relate to handling attachments, or where the controls differ from those on which the operator has been trained. Routine inspection and servicing of that truck in accordance with the operator’s handbook or manufacturers instructions need to be covered, in so far as the operator may reasonably carry them out. This should be repeated whenever the design of truck is changed.
Use of the truck in conditions that the operator will meet at work, e.g. gangways, loading bays, racking, lifts, automatic doors, confined areas, cold stores, slopes, rough terrain, loading platforms and bad weather conditions.
Instruction in site rules, e.g. site layout, one-way systems, speed limits, general emergency procedures, use of protective clothing and devices, including operator restraints and eye and hearing protection, work near excavations, overhead lines and other hazards.
Training in the work to be undertaken, e.g. loading particular kinds of vehicle handling loads and materials of the kind normally found at that workplace, including assessment of weight; use of the fork truck to support working platforms where appropriate.
Safe systems of work, which should include custody arrangements to ensure that keys are never left in unattended trucks, or in a place where they are freely available, to prevent the use of trucks by unauthorised operators and safe operation in areas where pedestrians may be present.

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What is ‘familiarisation training’?
Familiarisation training is the third element of lift truck training. Training must be carried out on the job and under close supervision, by someone with appropriate knowledge (possibly the trainee’s usual supervisor). It should cover the application, under normal working conditions, of the skills already learned and include familiarisation with site layout, local emergency procedures and any other particular feature of the work which it is not practicable to teach off the job. In very exceptional circumstances, such as use of lift trucks by the emergency services at the scene of an accident or fire, where it is clearly not feasible to train on-site, realistic simulated training may be provided.

What general guidelines should be followed to ensure the safe operation of forklift trucks?

Only trained and authorised people may operate forklift trucks
A defective forklift must never be used
All defects must be reported to the appropriate manager/supervisor
Maintenance must only be carried out by a competent person
No inspection and/or maintenance work must be carried out under raised forks
Ensure brakes, fluid levels, mirrors, flashing beacon, reversing alarm, safety devices, etc. are in safe working order
Never drive over electrical cables, flexible pipes, timber, debris, etc.
Check for obstacles and/or persons before reversing
Obey all traffic controls and safety signs
Never carry passengers on any part of a forklift
Ensure the SWL is indicated on each forklift, and adhere to it
Assess all loads before lifting
Ensure all pedestrians in area of forklift wear suitable PPE, e.g. high visibility clothing
When descending slopes, drive very slowly
Never drive onto a grade or surface that could cause the forklift to slip, overturn, etc.
Avoid travelling with raised loads; always keep forks as low to the ground as possible
Do not use diesel operated trucks in enclosed areas
When parking the forklift, park in allotted parking area, fully lower forks, tilt forks forward, switch off engine, apply parking brakes and return keys to secure place.

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Where can I find further information?
Further information and guidance on forklifts can be found in the HSA's 'Code of Practice for Rider-Operated Lift Trucks: Operator Training and Supplementary Guidance' and 'Retail and Distribution Sectors' publications, available at www.hsa.ie or by contacting 1890 289 389.

Further information

HSE Guidance Working Platforms (Non-integrated) on Forklift Trucks - Guidance Note PM28 [3rd edition] December 2005