Managing vehicle and pedestrian safety – forklift trucks

Vehicles like forklift trucks are essential in many workplaces – but without the right safety controls, they can become a major hazard. In this safety update, we’ll go through what you need to know to stay safe, compliant and in control when it comes to vehicles and pedestrian safety at work, with a focus on forklift trucks.  

It’s important to note that, as an employer or someone in charge of a premises, you need to make sure that you have controls in place to keep vehicles and pedestrians separate. That could be delivery lorries, forklift trucks, or even in your work car park.  

So, here’s how to do just that.  

First things first: keeping pedestrians safe 

Even if you don’t have forklifts on site, if you take regular deliveries or have visiting vehicles, similar safety rules apply. It’s your duty to take reasonable steps to spot the risks and manage them effectively.  

Remember: only trained and authorised staff should be operating forklift trucks. When things go wrong – whether it’s poor maintenance or misuse – the consequences can be serious, like collisions, tipping over or injuries to others nearby. 

 

What the law says  

When it comes to forklift safety, a few key regulations set out what’s expected of you: 

• Health and Safety at Work etc. Act 1974 – you’re legally responsible for protecting the health, safety and welfare of your people and anyone else affected by your work activities, as far as is reasonably practicable – this includes how forklift trucks are used. 

 

• Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) – if you’re using forklifts for lifting, LOLER applies. You’ll need to make sure the lifting gear is stable, clearly marked with safe working loads, and inspected by a competent person at least every 12 months, or more often if needed. 

 

• Provision and Use of Work Equipment Regulations 1998 (PUWER) – forklift trucks must be right for the job and kept in safe working order. Operators have to be trained and supervised properly, and daily checks and regular maintenance need to be documented. 

 

• Management of Health and Safety at Work Regulations 1999 – you have to carry out risk assessments on forklift truck use and put the right safety controls in place.  

 

Vehicle and people segregation 

Keeping people and vehicles apart is one of the simplest and most effective ways to prevent workplace accidents. Poor segregation is a leading cause of serious injury in UK workplaces, so it’s best to start with a documented traffic management plan supported by a robust risk assessment, and consider these controls: 

 

Physical separation (engineering controls) 

• Barriers and guardrails between walkways and vehicle routes 

• Pedestrian crossings clearly marked with high-visibility paint 

• One-way systems for vehicles where possible 

• Gates or barriers at high-risk entry and exit points 

Signage and markings 

• Floor markings to define pedestrian and vehicle zones. 

• Warning signs, mirrors, and lights at blind corners. 

• Clearly marked safe walkways using colour coding and symbols 

Designated routes 

• Separate, designated walkways for pedestrians. 

• Keep vehicle and foot traffic apart, especially near loading bays, doorways, or corners. 

Administrative controls 

• Site rules and inductions covering segregation zones. 

• Supervise high-risk areas and enforce safe movement practices. 

• Limit pedestrian access to vehicle operating zones unless necessary and controlled. 

Training and PPE 

• Train all staff, including visitors, on safe routes. 

• Use hi-vis clothing in shared areas. 

• Appoint banksmen or spotters where needed. 

 

 

What are the risks of using a forklift truck? 

 

• Collisions with pedestrians or objects due to poor visibility, distracted driving or shared traffic routes. 

• Overturning caused by to uneven surfaces, excessive speed or poor load handling. 

• Falling loads from unstable, unbalanced, or badly secured cargo. 

• Lack of training or supervision leading to unsafe operation. 

• Mechanical failure from poor maintenance, damaged parts or missed inspections. 

• Working at height or on ramps which raises the risk of tipping, falling objects, or loss of control. 

• Reversing accidents particularly in tight or blind spots. 

 

Key safety checks and procedures 

 

What daily checks should you carry out? 

Operators must check the forklift before every shift: 

• Are the tyres undamaged and at the correct pressure? 

• Are there any cracks or bends in the forks and mast? 

• Are there any leaks in the hydraulics? 

• Are the brakes and steering working properly? 

• Are the lights and horn fully functional? 

• Is the seatbelt in good condition? 

• Are warning devices including alarms, beacons and mirrors working? 

• Are the controls responding normally? 

• Are the fuel and battery safe and secure? 

• Is the load plate clear and readable?                                                                                             

Make sure these are all recorded on a daily inspection sheet. 

 

Safe use of forklifts 

• Wear a seatbelt. 

• Stick to site rules and speed limits. 

• Keep loads low and within limits. 

• Drive slowly, especially near people. 

• Use spotters if visibility is poor. 

• Never carry passengers. 

 

Parking forklifts 

• Lower forks to ground 

• Apply handbrake. 

• Switch off and remove key. 

• Park in a safe, marked area. 

 

 

Thorough examinations of forklift trucks (LOLER) 

Under the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER), forklift trucks have to go through a thorough examination to make sure they’re safe to use, especially when used for lifting operations. 

 

What is a thorough examination? 

Think of a thorough examination like an MOT, but for your forklift. It’s a detailed check-up of the lifting parts (e.g. forks, mast and chains) by a competent, impartial expert. 

 

When is it required?

• Every 12 months as a minimum (though this can be more frequent depending on how the forklift is used).
• After major damage or changes
• Before first use (if second-hand or newly installed trucks)

But remember – this doesn’t replace your daily or routine checks – it’s an extra layer of safety.

 

Who can do it? 

Only a competent person from an independent inspection body. They’ll need the right qualifications and a good understanding of the equipment.  

 

Records you have to keep 

• The inspection report – keep this for at least two years. 

• A list of defects and how they’ve been resolved. 

• The next due date clearly displayed on the truck or maintenance record. 

 

What happens if you don’t comply? 

• You may face Health and Safety Executive (HSE) enforcement, legal action, or serious incidents. 

• Failure to conduct LOLER exams can invalidate insurance. 

 

 

Need a second opinion or some expert advice? 

Remember, your Health & Safety advice line is here 24/7* – just give us a call and we’ll help you with friendly, practical support. 

 

*Applicable for all clients who’ve purchased Citation’s HR & Employment Law and/or Health & Safety core service, including H&S and HR Workplace Expert. Please note that our H&S and HR Virtual Assistance clients have access to our advice line Monday to Friday 9am-5pm.