A typical forklift incident happens in seconds: a tight corner, an obstructed aisle, a moment of distraction. Collisions, overturns and near misses are among the most common, and costly workplace accidents in UK warehouses, factories and logistics operations. Many incidents share a root cause: risks were either not identified or not properly controlled.
Forklift risk assessments are essential for preventing accidents, ensuring compliance with UK health and safety law, and creating safer working environments. Yet many employers, site supervisors and safety officers are unsure where to begin, what hazards to look for, and how detailed assessments should be.
This guide offers a clear, step-by-step method for conducting a forklift risk assessment that meets legal expectations and protects workers. It is designed for employers, warehouse managers, health and safety professionals, and supervisors responsible for lift truck operations. The following sections introduce the fundamentals before moving into practical assessment steps, hazard identification, control measures and checklists.
What Is a Forklift Risk Assessment?
A forklift risk assessment is a structured process used to identify hazards associated with forklift operations, evaluate the level of risk they present, and implement suitable control measures. Because forklifts are classed as work equipment, employers must treat their use as a significant safety priority.
A well‑carried‑out assessment improves operational safety, reduces the likelihood of accidents and ensures compliance with PUWER, LOLER and wider UK health and safety legislation.
Definition and Purpose
A risk assessment involves identifying hazards (anything that can cause harm) and assessing risk (the likelihood and severity of harm). In the context of forklifts, this means considering factors such as vehicle movement, load handling, operator behaviour and environmental conditions.
A documented assessment is essential because it:
- Demonstrates legal compliance
- Records decisions and rationale
- Supports consistent safety practices
- Helps prioritise improvements
Legal Basis in the UK
Employers must complete risk assessments under several regulations:
- PUWER 1998 requires employers to assess and control risks arising from work equipment, including forklifts.
- LOLER 1998 applies where lifting operations involve loads or people, requiring planning, supervision and safe systems of work.
- Health and Safety at Work etc. Act 1974 places a general duty on employers to protect employees from foreseeable harm.
Together, these create a clear requirement to assess and manage forklift risks.
Who Should Be Involved
Forklift risk assessments should involve:
- Competent health and safety professionals with suitable experience
- Operators and supervisors who understand the work environment and common issues
- External consultants, where additional expertise or oversight is needed
Collaborative assessments ensure real‑world hazards are identified and controls are practical.
Step-by-Step How to Conduct a Forklift Risk Assessment
The following process provides a structured approach for completing a thorough, compliant forklift risk assessment.
Step 1 – Preparation and Scoping
Begin by defining the scope of the assessment. Identify:
- Areas where forklifts operate (e.g., warehouses, yards, loading bays)
- Task types (loading, unloading, transporting, stacking)
- Forklift types (counterbalance, reach trucks, pallet trucks)
Gather supporting documentation such as accident and near‑miss records, training logs, maintenance reports and existing safe operating procedures. Establish who will conduct the assessment and ensure they are competent to do so.
Step 2 – Identify Hazards
Look for hazards that could cause injury or damage, including:
- Collisions with people, racking or vehicles
- Tipping or overturning due to unstable loads or uneven surfaces
- Pedestrian interactions in shared workspaces
- Environmental risks such as poor lighting, wet floors or blind spots
- Task-specific hazards like high-level stacking or lifting irregular loads
Step 3 – Evaluate Risks
Assess the likelihood and severity of each hazard. Use a risk matrix or scoring method to categorise risk levels and prioritise actions.
High‑risk situations include:
- Frequent pedestrian‑vehicle crossover
- Operators working at speed or under pressure
- Tight turning areas with poor visibility
Any hazard with high likelihood or severe potential harm must be addressed immediately.
Common Forklift Hazards to Look For
Forklift operations involve a combination of mechanical, environmental and human‑factor risks. Understanding these helps employers conduct thorough assessments.
Vehicle-Related Hazards
Common forklift‑specific hazards include:
- Poor maintenance leading to brake, steering or hydraulic failure
- Faulty horns, lights or warning devices
- Battery charging risks such as fumes or incorrect procedures
- Fuel storage and handling problems for diesel or LPG trucks
Workplace Environment Risks
Issues within the working environment can significantly increase accident risk:
- Obstructed aisles, narrow routes and inadequate turning space
- Slippery floors, potholes or uneven ground
- Poor housekeeping creating avoidable hazards
- Shared pedestrian‑vehicle zones without segregation
Human Factors and Behaviours
Many forklift incidents stem from behavioural or competence issues, including:
- Inexperienced, untrained or uncertified operators
- Fatigue, distraction or rushing to meet deadlines
- Complacency and lack of supervision
- Poor communication between team members
Control Measures and the Hierarchy of Risk Control
Control measures must be selected following the hierarchy of risk control, which prioritises eliminating hazards wherever possible.
Elimination and Substitution
Where possible:
- Remove the need for forklift use entirely (e.g., use pallet jacks for low-level moves)
- Substitute forklifts with safer equipment such as conveyers or automated systems
- Redesign tasks to eliminate hazardous load movements
Engineering Controls
When elimination is not possible, physical controls can significantly reduce risks:
- Fixed barriers and segregated walkways
- Speed limiters, seatbelt interlocks and proximity sensors
- Improved lighting, signage and ventilation
- Mirrors to reduce blind spots
Administrative and PPE Controls
Administrative controls shape behaviour and ensure consistent safe practice:
- Traffic management plans and one-way systems
- Clear written procedures for loading, unloading and stacking
- Operator training, refresher sessions and supervision
- PPE such as hi‑vis clothing, safety shoes and helmets
PPE is a last line of defence and should complement, not replace, other measures.
Creating a Forklift Risk Assessment Checklist
A clear, structured checklist helps ensure assessments are consistent, thorough and repeatable.
Core Assessment Items
Key items to include:
- Operator competence, licensing and training certification
- Daily pre‑use checks and defect reporting procedures
- Forklift condition: brakes, hydraulics, tyres, warning systems
- Safe load capacities and stability controls
Operational Task Checks
Checklist sections should reflect real tasks, such as:
- Safe loading and unloading processes
- Pedestrian management and segregation
- Battery charging or fuel-handling procedures
- Parking, storage and shut‑down routines
Reviewing and Updating Checklists
Checklists should be reviewed:
- After incidents or near misses
- When the workplace layout changes
- When new forklifts or attachments are introduced
Involving operators in the review process improves accuracy and engagement.
Training and Competence for Forklift Safety
Competence is one of the strongest defences against forklift accidents. Training must be robust, workplace‑specific and regularly refreshed.
Operator Training Requirements
Legal expectations include:
- Formal training based on recognised standards
- Practical assessment to confirm competence
- Refresher training every 3–5 years or sooner if concerns arise
Accredited courses (such as RTITB, AITT or ITSSAR) ensure training meets industry standards.
Supervisor and Spotter Training
Supervisors play a critical role in monitoring behaviour and enforcing safe systems of work. They should understand:
- Traffic flow and segregation rules
- Spotter and banksman responsibilities
- Effective communication protocols during manoeuvres
Embedding a Safety Culture
Sustaining forklift safety requires organisational commitment.
Effective practices include:
- Toolbox talks and short daily briefings
- Encouraging near‑miss reporting and learning
- Recognising and reinforcing safe behaviours
Recording, Reviewing and Continuous Improvement
Risk assessments are not one‑off exercises, they must evolve with the workplace.
Documentation Best Practice
Good documentation helps organisations maintain compliance and traceability. Include:
- Templates for assessment forms and checklists
- Secure and accessible storage of digital or physical records
- Version control to track updates and authorship
Monitoring Controls and KPIs
Regular monitoring ensures controls remain effective. Useful indicators include:
- Number of incidents, near misses and equipment defects
- Audit outcomes and housekeeping standards
- Worker feedback and suggestions
When to Re-Assess
Re-assess forklift risks:
- After any accident or near miss
- When equipment, processes or routes change
- As part of planned periodic safety reviews
How Kingfisher Professional Services Can Help with Forklift Risk Assessments
At Kingfisher Professional Services, we provide tailored health and safety consultancy to help employers confidently manage forklift risks. While we do not carry out risk assessments on behalf of clients, we offer expert guidance on what a suitable and sufficient assessment requires.
Our support includes:
- Advice on PUWER, LOLER and legal compliance
- Guidance for employers, supervisors and safety officers completing assessments
- Assistance developing forklift checklists, procedures and documentation
- Bespoke training for operators and supervisors
- Ongoing audits and consultancy to maintain strong safety standards
With expert input from Kingfisher, workplaces can improve forklift safety, enhance competence and reduce the likelihood of preventable accidents.
Conclusion
Forklift risk assessments are essential for preventing accidents, protecting workers and meeting UK legal obligations. By identifying hazards, evaluating risk levels and applying a hierarchy of effective control measures, employers create safer, more efficient operations.
Training, supervision and ongoing review are central to maintaining safety standards. Regular documentation and continuous improvement ensure risks are managed consistently as workplaces evolve.
Employers who take a proactive approach to forklift risk assessment strengthen both compliance and worker wellbeing, and Kingfisher is ready to support at every stage.