Forklift & Mobile Equipment Risk Assessment

Forklifts and other mobile equipment are essential in industries like construction, manufacturing, warehousing, and logistics. But these machines come with risks—collisions, rollovers, dropped loads, blind spots, and more.

A thorough Forklift & Mobile Equipment Risk Assessment helps minimize hazards, protect lives, and keep operations running smoothly. Let’s dive into how to properly assess and control these risks.

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📜 Regulations and Safety Guidelines

OSHA (USA)

• 29 CFR 1910.178: Covers powered industrial trucks (including forklifts).
• Requires operator certification and daily equipment inspection.

HSE (UK)

• L117: Rider-operated lift trucks – Approved Code of Practice
• Emphasizes operator competence and safe site layout.

Indian Standards

• IS 3696 (Part 2) for mechanical material handling
• Factory Rules and Dock Safety Rules also apply

Employer Responsibilities

• Provide training, maintenance, and safe layout
• Conduct risk assessments and inspections

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⚠️ Common Hazards of Forklifts and Mobile Equipment

Hazard	Description
Collision	Striking pedestrians, structures, or other vehicles
Overturning	Taking corners too fast or uneven ground
Falling Load	Poor load stability, incorrect stacking
Blind Spots	Limited rear and side view, especially with large loads
Slippery Surfaces	Rain, oil spills, or dusty floors
Mechanical Failure	Brake or tire failure due to poor maintenance
Battery/Gas Leaks	Fire or inhalation hazard from LPG or diesel forklifts

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🛠 Types of Mobile Equipment

• Forklifts (Counterbalance, Reach, Order Picker)
• Pallet Stackers
• Telehandlers
• Mini Loaders and Bobcats
• Skid Steer Loaders

Each has its own risks based on function, visibility, weight, and operating environment.

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📋 Forklift Risk Assessment Procedure

1. Identify the Tasks

Loading, unloading, stacking, driving, reversing, etc.

2. Identify the Hazards

Check for proximity to pedestrians, poor lighting, unstable loads, sharp turns, etc.

3. Evaluate Risk

Use the 5×5 Matrix (below) to classify risk levels.

4. Implement Controls

Apply engineering, administrative, or PPE controls.

5. Review and Monitor

Update assessments after incidents, near-misses, or layout changes.

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📊 5×5 Risk Assessment Matrix

Severity ↓ / Likelihood →	Rare (1)	Unlikely (2)	Possible (3)	Likely (4)	Almost Certain (5)
Insignificant (1)	1	2	3	4	5
Minor (2)	2	4	6	8	10
Moderate (3)	3	6	9	12	15
Major (4)	4	8	12	16	20
Catastrophic (5)	5	10	15	20	25

• 1–3: Low (Acceptable)
• 4–6: Medium (Control Required)
• 7–15: High (Immediate Control Required)
• 16–25: Extreme (Stop Work Until Eliminated)

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📌 Sample Forklift & Mobile Equipment Risk Assessment Table

S.No	Task	Hazard	Risk (L×S)	Risk Level	Control Measures	Responsible
1	Operating forklift near people	Collision with pedestrian	4×5 = 20	Extreme	Designated forklift lanes, use barriers, spotters for tight areas	HSE Officer
2	Driving on uneven surface	Tip-over	3×5 = 15	High	Avoid inclines >10°, operate at reduced speed, no sharp turns	Operator
3	Handling tall pallet loads	Obstructed visibility	3×4 = 12	High	Use mirrors, drive in reverse, keep load low, horn at intersections	Operator
4	Reversing in tight warehouse	Blind spot collision	2×4 = 8	Medium	Rear-view camera, reversing alarm, clear floor markings	Supervisor
5	Refueling diesel forklift	Fire/explosion hazard	2×5 = 10	High	Refuel outdoors, no smoking, use proper PPE and grounding	Operator
6	Battery charging (Electric FLT)	Acid leak, fire risk	3×4 = 12	High	Proper ventilation, acid-proof PPE, spill kit available	HSE Officer
7	Pallet stacking at height	Falling load	4×4 = 16	High	Do not stack above safe height, check load center, use cage if needed	Warehouse Lead

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🌦 Operating Conditions to Consider

• Indoor vs Outdoor: Wind and visibility play larger roles outdoors.
• Weather: Rain increases slip hazards and reduces visibility.
• Floor Conditions: Cracks, ramps, slopes can destabilize forklifts.
• Obstructions: Tight aisles and overhead hazards must be accounted for.

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✅ Pre-Operational Inspection Checklist

Daily checks are mandatory. A quick walkaround helps prevent breakdowns and injuries.

Component	What to Check
Forks	Cracks, bends, alignment
Mast	Hydraulic leaks, free movement
Brakes	Test for response
Tires	Inflation, cuts, wear
Lights/Horn	Functionality
Seatbelt	Intact and usable
Battery/Gas	No leaks or corrosion

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👀 Visibility and Blind Spots

• Use wide-angle mirrors and rear-view cameras
• Add flashing lights and reverse alarms
• Install convex mirrors at blind corners

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🚧 Speed Limits and Traffic Rules

• Set indoor speed limits (e.g., 5 km/h)
• Use one-way routes for aisles
• Create zebra crossings for pedestrians
• Install stop signs and mirrors at intersections

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📦 Load Handling and Stability

• Always check load capacity from forklift data plate.
• Center the load on forks.
• Keep load low and tilted back while driving.
• Never allow anyone to ride on the forks.

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🎓 Operator Training and Licensing

• Only authorized operators should use forklifts.
• Must receive training in:
  • Equipment type
  • Operating environment
  • Load management
  • Emergency response

Training should be renewed every 3 years or after an incident.

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🚨 Emergency Preparedness

Possible Scenarios:

• Brake failure
• Battery short-circuit
• Pedestrian hit
• Load drop
• Forklift rollover

Control Actions:

• Emergency stop switch
• First-aid kit available
• Fire extinguisher mounted on equipment
• Operator must stay in seat during tip-over

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✅ Conclusion

Forklifts and mobile equipment may look easy to operate, but every turn, lift, and stop can hide a hazard. A comprehensive Forklift & Mobile Equipment Risk Assessment helps you eliminate those risks before they turn into incidents.

With the right training, inspection, layout, and awareness—you can move materials without endangering people.

Lifting & Rigging Operations Risk Assessment

Electrical Work Risk Assessment

Hot Work Risk Assessment

Confined Space Entry Risk Assessment

Working at Height Risk Assessment

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❓FAQs

1. What is the legal age for forklift operation?

Most jurisdictions require forklift operators to be at least 18 years old.

2. Do electric forklifts require risk assessment too?

Yes, electric forklifts pose risks like battery acid burns, fire, and blind spots.

3. Is a seatbelt mandatory on forklifts?

Yes. It prevents the operator from being ejected during tip-over.

4. Can I carry passengers on a forklift?

No, unless the forklift is specifically designed to carry more than one person.

5. How often should forklifts be inspected?

• Daily before use (visual check)
• Quarterly or Annually by a certified mechanic