It is important that there is enough space for all traffic: pedestrians, lift trucks and other vehicles. Sufficient space reduces the risk of collisions, of someone being hit by a lift truck or of a lift truck falling off a loading bay or similar.

When a pedestrian-operated lift truck with a folding platform is used, the operator is relatively unprotected. Therefore, make sure that there are no fixtures, pallet racks or similar that pose an increased risk of the lift truck operator being trapped between them and the lift truck.

Ensure that pedestrians and other unprotected people are separated from lift truck traffic as far as possible. Plan so that, as far as possible, lift truck traffic is confined to designated areas, such as specific lift truck aisles, separate from other activities. This way you reduce the risk of someone being injured due to lift truck traffic.

Mark lift truck aisles and driving lanes clearly. For example, markings for lift truck aisles can be painted directly on the floor.

With marked lift truck aisles, it is easier for all employees to keep them clear of, for example, stored goods. Pedestrians are also made aware of the danger of lift truck traffic.

If it is not possible to separate lift truck traffic, other measures may be necessary to make it easier for pedestrians to spot the lift trucks and for lift truck operators to spot the pedestrians. Examples of measures:

• One-way lift truck traffic, so that pedestrians always know from which direction the lift trucks are coming.
• Set up traffic mirrors.
• Ensure that there is good lighting.
• Place goods so that they do not obstruct the view of lift truck operators or pedestrians.
• Use warning lights, warning systems or reflectors.
• Set speed limits.

Be especially careful with measures at locations where pedestrians enter areas with lift truck traffic, such as corners or doors. It may be necessary to provide a separating barrier to protect pedestrians, such as a railing. You can mark the separating barrier with warning markings.

Make sure the lift truck operator has the right kind of lift truck and equipment for the job they are going to do. By using the right lift truck for a task, you reduce the risks of both acute accidents and strain injuries. Lift trucks must be inspected and well-maintained. When damage occurs, it must be repaired before the lift truck is used.

Many accidents occur when the operator's feet are caught between the lift truck’s standing platform and another object. There are types of lift trucks available that offer good foot protection. There are also aids that prevent the lift truck operator from having to bend or twist their neck unnecessarily, such as a camera and monitor support in the cab.

Lift trucks used in refrigerated and freezer areas should have a heated cab.

The person operating the lift truck must have sufficient knowledge and competence for the tasks they are assigned to perform. It is also important that temporary agency workers has the right skills and receives the necessary instructions for your specific workplace.

Also give the lift truck operator time to learn good technique. Using the lift truck instead of lifting with, for example, a push cart or trolley can prevent bodily strain.

Studies show that ergonomic aids and good techniques when using lift trucks have many positive effects, including

• better precision
• fewer errors and failures
• shorter learning time
• less time needed to complete a task
• reduced fatigue
• reduced physical strain

It is therefore a good idea to invest in good ergonomics in the lift truck, especially for the operator's seat. This could include, for example, adjustable armrests and neck support and vibration damping. You can instruct the lift truck operator to start their work shift in the lift truck by adjusting the operator's seat and, if possible, the controls and steering wheel to fit their body.

Camera and monitor supports are good for preventing strain injuries. Especially when loading and unloading at height, they relieve the operator's back and neck.

High pallet racks can cause neck problems when the lift truck operator is constantly forced to look upwards. Frequent changes in direction can cause back problems because operators have to constantly twist their bodies. Arrange the work so that the risk of injuries to the operator's hips, back and neck is minimised.

Make it possible for the lift truck operator to vary their work, so that they do not drive the lift truck all day but also perform other tasks. If the operator switches to tasks involving manual handling of loads, it is important that the operator has a good knowledge of the risks of lifting, carrying, pushing or pulling loads.

If the load obscures the operator's view, it may in some cases be appropriate for the operator to drive the truck with the load behind them in the direction of travel. The operator may also need to seek help from a colleague who can assist.

There are aids to improve the operator's visibility, such as swivelling operator's seats and raised or height-adjustable cabs. A camera with a monitor or mirrors can improve the operator's ability to detect obstacles.

In special cases, such as container handling, the operator can drive with a raised load at low speed to maintain a clear view. However, this method entails particular risks and places high demands on lift truck choice and work organisation.

Lift truck operators are sometimes exposed to strong and rapidly changing lighting conditions. You should inform the operator to always stop and not continue driving until they have regained good vision and an overview of the driving lane. The operator may wear sunglasses when transitioning from low indoor lighting into bright daylight. The operator should immediately remove the sunglasses when driving indoors again.

As an operator, keep in mind:

• If the load obscures the view forward. Reverse! Get help from a colleague if needed.
• Signal to warn others when you must temporarily drive with limited visibility, such as when driving around a corner. Better to honk once too often than once too little.

Pedestrians can also contribute to a safe environment around lift trucks. For example, they can make themselves visible by making eye contact with the operator. As an employer, you can urge and encourage pedestrians to take responsibility, for example through signs and clear instructions.

Always follow the manufacturer's safety instructions for handling loads and ensure that the lift truck operator has sufficient knowledge for safe load handling in your workplace.

Replace broken pallets and make sure you have clear procedures for handling those pallets that are not strong enough for certain tasks, such as storage in pallet racks. For example, goods on a disposable pallet can be placed on top of an EUR pallet or a support insert to avoid re-picking the goods.

Never exceed the load capacity of the lift truck. The lift truck's capacity plate indicates the load capacity, which is influenced by the load's centre of gravity and lifting height, among other factors. If you exceed the load capacity, the stability and strength of the lift truck cannot be guaranteed. The lift truck and load are at risk of tipping to the side or forward, which could have serious consequences.

The lift truck operator should be familiar with capacity plates, load charts, etc., that indicate the safe use of the lift truck and its equipment. For example, lift truck operators often perform tasks that require knowledge of specially adapted equipment that can alter the stability and lifting capacity of the lift truck, such as extension forks and clamping attachments.

The design and characteristics of the load are important for safety. Special measures to secure the load may be needed, for example if a lift truck is to transport several plastic-wrapped packages on top of each other on the truck's forks and there is low friction between the packages.

It is advisable that lift truck operators are given sufficient time and opportunities to control their own work to avoid stress and unnecessary strain.

Plan the work so that the operator does not work long shifts under stress and ensure that the operator gets enough rest.

Therefore, make sure that the lift truck operator can take a break every hour – so that they can sit down if they are standing or stand up if they are sitting. A good recommendation is to take a break of 5–10 minutes every hour to offer the body variation and recovery.

Variation and recovery are two important prerequisites for health, well-being and efficiency at work.

Use personal protective equipment when general protective measures are not sufficient to avoid or limit risks in the work environment. Lift truck operators and those who work with goods handling near lift trucks must always wear protective footwear.

Also, wear high-visibility work clothes where lift truck traffic occurs. Assess whether special high-visibility clothing is needed. When doing so, consider visibility, the risk of accidents and the conditions at the workplace.

Many lift trucks have seat belts. Make sure the operators use them. Regularly check that the belt is functioning properly and has no visible damage.

The belt protects the operator in the event of a collision or if the lift truck overturns, which could lead to serious accidents.

Speed ​​has a major impact on the likelihood of an accident occurring and its consequences.

Therefore, adjust the speed to the conditions – the floor surface, the size of the floor area, loads handled, turning radii, etc.

The lift truck manufacturer can often help you find a solution that suits your business. This could, for example, involve setting a lower maximum speed limit for lift trucks or providing functions for automatic speed reduction during tight turns or in designated zones.

It is important that the ground and floor are hard and even, that ramps do not slope too steeply, and that thresholds and quaysides do not cause vibrations or hard impacts, which could otherwise cause back and neck problems.

A smooth and even surface for the lift truck operator to drive on also reduces the risk of sudden accidents. Therefore, make sure to have clear procedures for cleaning and maintenance.

Address irregularities that could cause risks for the lift truck operator or pedestrians: holes or pits in the asphalt or floor, broken floor drains, spills, icy surfaces, etc. The area should be cordoned off until the risk is eliminated.

How to address fall risks

Understanding and good communication between the vehicle driver and the lift truck operator and their respective employers is a prerequisite for safe work with lift trucks on vehicle platforms.

Always secure the lorry or trailer when working with a lift truck on a vehicle platform and loading bay, so that the lift truck does not fall between the platform and the loading bay.

Anchor the swap body well to reduce the risk of tipping or slipping.

Make sure that there are clear instructions to ensure that the vehicle is not moved during loading or unloading. For example, the instructions may include the following:

The lorry driver's employer must ensure that the driver:

• engages the parking brake
• chocks the wheels (or secures the vehicle with another suitable method)
• places boards or similar under the support legs
• locks the support legs.

The lift truck operator's employer must ensure that the operator

• checks that the loaded lift truck does not exceed the load capacity of the vehicle platform
• ensures that the dock leveller between the quay and the vehicle platform cannot be displaced
• checks that roll-off protection is in place where needed to prevent the lift truck from driving over the edge.

Only free-stack stable and well-secured goods to prevent collapse. The items at the bottom must withstand high loads. It is inappropriate to free-stack near pedestrians.

Inspect lift trucks and perform maintenance at intervals adjusted to operating conditions and the manufacturer's recommendations. Do not use a lift truck with defects or damage that could compromise safety until the defects have been corrected or the damages repaired. There is an international standard for checking forks, ISO 5057, which specifies appropriate methods and intervals.

Also inspect interchangeable equipment regularly and perform maintenance.

Engage the parking brake before leaving the operator's position. Also secure the load and moving machine parts if necessary. You should lower the load completely before getting out of the lift truck.

A lift truck that is not braked can move unintentionally, for example if the ground is sloping. Leaving the direction selector on an internal combustion engine powered lift truck in drive mode may inadvertently set the lift truck in motion if the engine is running.

Lower forks to ground level when parking the lift truck to reduce the risk of someone walking into them and injuring themselves. Also, park lift trucks in a place and in such a way that no one risks tripping over the forks or colliding with the lift truck.