Forklift Trucks
INTRODUCTION
Forklift trucks are common in most industrial premises and have historically been involved—directly or indirectly—in many significant fire losses and serious accidents. This Technical Bulletin provides a framework for uniform and consistent risk assessment and control practices regarding forklift trucks. While the focus is on forklifts, many principles apply equally to other mobile industrial plant.
GENERAL PRECAUTIONS
Irrespective of the method of power, general fire safety precautions applicable to forklift trucks include the following: -
Routine Inspection and Maintenance
Forklifts must be inspected and maintained in line with manufacturers’ schedules. Compliance with the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) is mandatory, with maintenance records retained.
Designated Parking Areas
Idle forklifts should be parked a minimum of 1.5 m from all combustibles or within a 60-minute fire-resistant enclosure. Where servicing occurs in the same area, a 10 m separation or fire-rated division is required. LPG-powered trucks require further precautions see below.
Operator Training
Operators to receive adequate training which must be administered by an accredited trainer (e.g. AITT; ITSARR; CITB; RTITB; Lantra accredited trainers).
Daily Inspections
A responsible person should carry out start-up checks for:
Fuel, oil, hydraulic leaks
Battery connections
Braking systems
Audible warning signals
Lifting/tilting functions
General truck safety
Housekeeping
Forklifts must be kept clean of grease, oil, dust, and fluff.
Impact Prevention
Special care is needed to avoid damage to:
Fire doors
Fire-resisting structural elements
Composite cored panels
Racking systems
Damage must be reported and rectified promptly.
Sprinkler Protection Risks
Where sprinkler systems are installed, conduct a detailed risk assessment for impact to:
Sprinkler heads
Range pipes
Main control valves
Install suitable mechanical protection where necessary.
Fire Extinguishers
Every truck should carry a suitable extinguisher. Additional extinguishers are required near charging stations. On-board suppression systems (manual or automatic) are available and recommended in high-risk areas.
Leading truck manufacturers, such as Linde, working in conjunction with the fire protection industry, have the capability of offering an on-board automatic fire suppression systems for the protection of the engine bays of diesel and LPG powered trucks where employed in high risk environments. Such protection can also normally be retrofitted and is therefore a measure for consideration where merited by the risk.
Explosive Atmospheres (ATEX Zones)
Where explosive atmospheres are encountered, it is essential that the use of forklift trucks and, for that matter, any other form of mobile plant is restricted to equipment that has been designed and certified for use in the appropriate Zone in question, in accordance with the “ATEX Equipment Directive” (Technical Bulletin 23 refers).
Electric and diesel trucks can be converted for ATEX environments.
LPG trucks are not ATEX convertible.
Specialist provider: Pyroban Group Ltd
Protective Enclosures
All enclosures and protective covers about the engine and exhaust system should be kept in place at all times trucks are in operation. In respect of battery-operated trucks designed for use in explosive atmospheres, safe operation will be dependent on the enclosure of the electrical system.
BATTERY POWERED TRUCKS
Battery-powered trucks are generally preferred to minimise fire load. However, battery charging introduces its own risks:
Charging Area Requirements:
Ideal: A separate, non-combustible building or 60-minute rated enclosure (This would particularly apply to major storage and distribution facilities).
Minimum: Designated area with 2 m clearance from combustibles and marked boundaries using floor markings or barrier rails.
Special Environmental Precautions:
In dusty environments, charging should occur in a positively pressurised, fire-rated room to reduce dust accumulation near equipment.
Installation Requirements:
Chargers must be wall-mounted to non-combustible surfaces or placed directly on concrete floors.
Never mount chargers on composite panels or timber pallets.
Operational Practices:
Inspect charging equipment and leads regularly.
Support brackets should hold charging leads off the floor.
Ensure over-current and overcharge protection is fitted (standard on modern units).
Avoid charger placement within storage racking.
Keep charging areas clean and tidy.
· To avoid sparks, the charger should be switched off before the battery is connected/ disconnected.
Hydrogen Management:
Risk of hydrogen accumulation should be assessed per DSEAR.
Single charging facilities in a lofty, naturally ventilated building are unlikely to pose an issue, whereas multiple charging in an enclosed area or a separate truck charging building may warrant the provision of mechanical ventilation sufficient to maintain the atmosphere at or below 25% of the Lower Explosive Limit.
Hydrogen gas detectors, interlocked with automatic charger shutoffs, may be required in high-risk scenarios.
DIESEL POWERED TRUCKS
Key risk assessment and control measures are summarised as follows:
Diesel fuel should be contained in drums or tanks in a safe position in the open, suitably bunded to contain any leaks or spillages.
All refuelling operations are to be carried out in the open at a suitably designated location and from approved dispensing pumps.
Engines are to be switched off prior to the commencement of refuelling and are to remain off throughout the refuelling process.
Care to be taken to ensure that the engine bay, exhaust system and other hot surfaces are maintained free of combustible materials, including loose waste material that can be drawn into the engine compartment.
A spark arrester should be fitted to the exhaust outlet where the truck is to be employed in a “combustible environment” – e.g. paper warehouse, furniture factory, etc. and/or where deemed prudent following a risk assessment.
LPG POWERED TRUCKS
Key risk assessment and control measures:
The use and storage of LPG should be assessed as part of a DSEAR risk assessment and appropriate fire precautions taken.
LPG cylinders to be kept in a safe manner in the open, or in a purpose designed detached storage building of non-combustible, lightweight construction.
When not in use trucks should preferably be kept in an outdoor shelter, or detached building constructed as above.
The fuel valve on the LPG cylinder to be closed when the truck is not in use.
Refuelling/cylinder exchange to be carried out in the open by trained personnel. In the case of refuelling from a bulk LPG tank, earth bonding as a precaution against static electricity should be in place.
Where cylinder exchange is required to be carried out internally, this may be permitted subject to there being no open flames or other ignition sources in close proximity and, that prior to disconnecting an empty cylinder, the fuel supply is shut off and the engine is operated until all fuel in the system is consumed.
Exposure of LPG powered trucks to high temperatures near ovens, furnaces and other hot processes is to be avoided except for extremely short intervals. Trucks should never be parked unattended near ovens or other sources of heat.
Precautions as regards cleanliness around the engine bay and the provision of spark arresters are as per those for diesel powered plant, as detailed above.
ACCIDENT PREVENTION
According to the HSE, over 8,000 forklift-related accidents occur annually in the UK, many of them serious or fatal. These most commonly include people being hit or run over, being hit by unstable items falling from the vehicle and drivers being injured by falling from the truck or when it overturns.
Effective safety management of forklift truck operations can be considered as falling into the following key areas:
Develop and implement Safe Systems of Work (SSoW).
Provision of adequate training for operators, supervisors and managers.
Match equipment suitability to task and load.
Optimise site layout for safe movement and segregation of pedestrian/vehicle traffic.
Maintain equipment and site infrastructure regularly
REFERENCE MATERIAL:
HSE L117: Rider-operated lift trucks – Operator training and safe use (Approved Code of Practice)
RISCAuthority RC11: Recommendations for fire safety in the use of lift trucks (Available via ATLAS)
SUMMARY
Forklift trucks introduce both fire and life safety hazards into workplaces and require a comprehensive risk management approach. Key elements include:
Strict adherence to maintenance, inspection, and safe operation protocols.
Selection of suitable power types and charging/refuelling controls.
Assessment under DSEAR and ATEX where applicable.
Effective accident prevention through training and workplace design.