Reducing operational costs is a priority for every business, and one overlooked area for savings is insurance. Forklift training not only enhances workplace safety but also plays a crucial role in lowering your business insurance costs. By ensuring your operators are trained and certified, your company can mitigate risks, minimise claims, and enjoy reduced premiums.
In this blog, we’ll explore the connection between forklift training and business insurance savings. Whether you’re in logistics, warehousing, or construction, proper training is a key factor in fostering a safe and cost-efficient environment.
The Importance of Forklift Training in Business
How Forklift Accidents Impact Insurance Costs
Benefits of Effective Forklift Training
Key Takeaways for Reducing Business Insurance Costs
Forklift Training FAQs
The Importance of Forklift Training in Business
Forklift training ensures that operators have the skills and knowledge to handle equipment safely and efficiently. This is vital in environments where forklifts are integral to operations, such as warehouses, manufacturing plants, and construction sites.
What Does Forklift Training Cover?
Understanding forklift controls and mechanics.
Workplace safety protocols and hazard awareness.
Proper lifting, loading, and unloading techniques.
Emergency procedures and accident prevention strategies.
By equipping employees with these skills, businesses can significantly reduce workplace accidents, a primary factor in high insurance costs.
How Forklift Accidents Impact Insurance Costs
Forklift-related accidents are among the most common workplace incidents, often leading to property damage, injuries, or fatalities. Insurers view these risks as liabilities, which can drive up your business insurance costs.
Financial Consequences of Forklift Accidents
Claims for property damage: Repairs to damaged goods or infrastructure can be costly.
Worker compensation claims: Injuries to employees may lead to expensive settlements.
Legal liabilities: Accidents involving third parties can result in lawsuits.
Effective training reduces the frequency and severity of these incidents, showcasing your business as a lower risk to insurers.
Benefits of Effective Forklift Training
1. Lower Insurance Premiums
Insurance providers often reward businesses with lower premiums when they demonstrate a commitment to safety through certified training programs. A well-trained workforce reduces the likelihood of costly claims, which insurers consider when determining premiums.
2. Enhanced Workplace Safety
Trained operators are better equipped to identify and avoid potential hazards, ensuring a safer environment for everyone. This reduction in accidents can lead to fewer interruptions, maintaining productivity and profitability.
3. Compliance with Regulations
Adhering to safety standards and training requirements, such as those outlined by the HSE (Health and Safety Executive), not only avoids fines but also reassures insurers that your operations are compliant and well-managed.
4. Reduced Equipment Damage
Proper training minimises wear and tear on forklifts, reducing maintenance costs and claims related to equipment misuse or failure.
5. Improved Employee Morale
Employees feel more confident and valued when they receive proper training, resulting in increased job satisfaction and productivity. A safer workplace also reduces stress and absenteeism.
Key Takeaways for Reducing Business Insurance Costs
Comprehensive forklift training mitigates risks and reduces the likelihood of claims.
Insurers favour businesses that demonstrate a proactive approach to workplace safety.
Effective training supports compliance with legal and regulatory requirements, avoiding potential fines and penalties.
Minimising accidents not only saves on insurance costs but also enhances productivity and morale.
Forklift Training FAQs
How does forklift training directly impact business insurance costs?
Forklift training reduces accidents and claims, which insurers consider when calculating premiums. A safer workplace signals lower risk, leading to reduced insurance costs.
Is forklift training a legal requirement in the UK?
Yes, under the Health and Safety at Work Act 1974, employers must ensure that forklift operators are adequately trained to operate equipment safely.
How often should forklift training be refreshed?
The HSE recommends refresher training every three to five years or whenever an operator demonstrates unsafe practices or uses new equipment.
Make Forklift Training a Priority with HL Training
Investing in forklift training is not just about compliance—it’s a cost-effective strategy to improve workplace safety and reduce your business insurance costs. By minimising risks, lowering claims, and enhancing productivity, proper training provides long-term benefits for any business that uses forklifts.
Ensuring the safety and efficiency of forklift operations is crucial for workplace safety. Regular checks, both daily and weekly, are essential to prevent accidents, reduce wear and tear, and maintain productivity.
This blog outlines the necessary forklift truck checks, providing a guide for operators, supervisors, and health & safety managers. By conducting these checks, you can help your business remain compliant with safety regulations, reduce downtime, and boost efficiency.
What is a Forklift Check?
Why Should I Perform Forklift Truck Checks
Daily Forklift Checks
Weekly Forklift Checks
Forklift Truck Check FAQs
What is a Forklift Check?
A forklift check is a routine inspection performed on a forklift to ensure it is safe and operational before and during use. These checks are crucial for identifying any issues or potential hazards that could affect the forklift’s performance or safety, helping prevent accidents and breakdowns.
Why Should I Perform Forklift Truck Checks?
Forklift checks are important for several key reasons:
Legal Compliance
Health and safety regulations, such as the Provision and Use of Work Equipment Regulations 1998 (PUWER), require that work equipment is regularly inspected and maintained. Failing to perform required forklift checks can result in legal penalties, fines, or even the suspension of business operations. Regular checks also ensure the forklift remains compliant with safety certifications and accreditation requirements.
Ensuring Safety
Forklifts are powerful machines that can pose significant risks to operators and nearby workers if not properly maintained. Regular checks help identify potential hazards, such as faulty brakes, worn tyres, or malfunctioning safety features (e.g., seatbelts), reducing the likelihood of accidents, injuries, or fatalities. Ensuring that a forklift is in safe working condition protects both the operator and everyone else in the workplace.
Preventing Downtime
Minor issues, if left unchecked, can turn into major mechanical failures, leading to costly repairs and prolonged downtime. Daily and weekly forklift checks help catch problems early, allowing for timely maintenance and reducing the risk of unexpected breakdowns. This leads to increased operational efficiency and productivity.
Extending Equipment Lifespan
Proper maintenance through regular checks helps extend the lifespan of the forklift. By addressing small issues early, you can prevent wear and tear from escalating into irreparable damage. Well-maintained forklifts tend to last longer, providing a better return on investment.
Improved Performance
Forklifts in good working order operate more smoothly, reducing fuel consumption and wear on mechanical parts. Regular checks ensure optimal performance, contributing to more efficient and safer operations.
By implementing routine forklift checks, businesses can enhance safety, comply with regulations, reduce operational costs, and maintain high productivity.
Daily Forklift Checks
Daily forklift checks are quick, pre-operation inspections performed by the operator at the start of each shift or when taking over from another operator. These checks focus on ensuring that the forklift is safe to use throughout the day and helps in detecting any immediate issues that could pose a danger to the operator or others in the workplace.
The main inspection checks include:
Visual Inspection
This step involves a thorough walkaround to identify any visible defects or damage to the forklift. There are 22 components of a forklift that should be assessed, but it is mandatory for the operator to carry out a full and correct check of 14 of these items:
Fork Arms/Attachment – Each fork arm should be checked for wear, cracks and
distortion. It is critical to pay attention to the fork hooks and carriage plate as the constant movement between these points causes wear and fracture.
Carriage Plate – The carriage plates should have no signs of damage and sit square to the mast. The end stop bolts must be engaged and secure. The fork locking pins must fully engage into the castellations.
Mast – Checks should be made to the outer mast sections for damage, distortions and cracks. In addition the inner mast channels or runners must be inspected for undue wear, scoring or excessive dirt.
Mast Rollers and Slides – Mast slides must be intact and not loose, the mast guide rollers, including reach channel rollers must not show signs of uneven wear, incorrect tracking, flat spots and scoring.
Lift Chains – Check lift chains for evidence of deterioration, loose or worn pins, damaged pin rivet heads,worn, cracked or missing links and signs of rust on link plates.
Lift Chain Pulleys – Chain pulleys should have no obvious damage, uneven wear
and flat spots. The chains running over pulleys should show signs of tracking correctly between the riveted end of the chain pins and the inner walls of the pulley flanges
Rated Capacity Plate – The rated capacity plate must be fitted, it must be secure, clear and legible and display, at least, the maximum weight the lift truck can pick up, the load centre and the
maximum lift height.
Hydraulic Systems – All hydraulic rams, seals and couplings must be checked for damage and leaks. Particular attention should be given to where the piston emerges from the outer cylinder for any oil, corrosion and scoring on the piston
Wheels – The wheel rim and hub should be examined for damage, cracks and scoring. Inspect the stub axles and steering assembly for excessive dirt or any foreign bodies. There should also be no obvious signs of missing or loose wheel nuts.
Tyres – Individual tyres should be checked for punctures and pressures, adequate and even tread across the same axle, damage, flat spots and deep cuts. Check the tyre side wall for evidence of deterioration and cracks.
Hydraulic Controls – All hydraulic driven parts (mast height, reach carriage, tilt mechanisms etc.) must be run to their end positions, to lubricate all the moving parts, checking for their serviceability, smooth operation, obvious leaks and that there is sufficient oil in the tank.
Drive and Braking – Forward and reverse should be engaged to ensure their smooth operation and positive response to the accelerator pedal. The parking brake should be tested by slowly driving and then applying the brake, the truck must stop.
Steering – Check for excessive play in the steering wheel before starting the truck. Avoid turning the wheels of the truck whilst stationary, this may subject the steering mechanism and tyres to unnecessary wear or strain.
Audible Warnings – If there is an audible warning device, check that it activates and can be heard. The machine must not be operated if the horn is defective.
Safety Features Check
Forklifts have various safety systems designed to protect both the operator and those working in the vicinity. During the daily check, the operator should ensure all these systems are fully functional before using the forklift. These checks include:
Seatbelt: Ensure the seatbelt is working properly and isn’t frayed or damaged.
Horn, Lights, and Warning Alarms: Check that all safety alarms (such as the reversing alarm), horn, and lights (headlights, brake lights, and warning lights) are functioning properly.
Mirrors: Make sure mirrors are clean, adjusted, and intact for good visibility around the vehicle.
Emergency Stop Controls: Test emergency stop switches or buttons to ensure they are working correctly.
Interlocks: Physically and visually check any additional interlocks or gauges to ensure they are functioning in accordance with the specific manufacturer’s operating handbook.
3. Operational Checks
After the visual and safety checks, the operator should conduct a brief operational test to verify that the forklift runs smoothly. Failure to carry out these operational checks can result in accidents or breakdowns that could pose a risk to life to the operator and those around the forklift.
Brakes and Parking Brake: Ensure both the service brakes (foot brake) and parking brake are functioning properly. The parking brake should hold the forklift securely in place when engaged.
Steering: Check for smooth and responsive steering. Any stiffness or unusual noises during steering could indicate a problem.
Hydraulic Controls: Test the forks by raising, lowering, tilting, and extending them to ensure the hydraulic system is working correctly without any delays or abnormal sounds.
Transmission and Movement: Engage the forward and reverse gears to check the smoothness of movement and acceleration.
4. Documentation
Most workplaces require operators to complete a daily inspection checklist, this can be completed digitally. Any issues identified during the daily checks should be reported to the supervisor or maintenance team immediately, and the forklift should not be used until repairs are made.
Weekly Forklift Checks
Weekly forklift checks are more detailed inspections typically performed by a supervisor, maintenance technician, or trained personnel. These checks go beyond the daily visual and operational checks to assess the long-term condition of the forklift. Weekly inspections help prevent mechanical failures by addressing wear and tear issues that aren’t always visible during daily checks.
The areas covered in weekly checks include:
1. Battery Check (Electric Forklifts)
For electric forklifts, weekly checks should include an inspection of the battery’s condition such as charge level, water levels and connections and cables.
2. Tyre Pressure and Wear
Proper tyre maintenance is crucial for forklift stability and handling, especially when carrying heavy loads. A weekly tyre check involves checking and adjusting the tyre pressure, inspecting the tyres for excessive wear, punctures or other damage, and ensuring that the tyre tread is not too worn down.
3. Lubrication of Moving Parts
Forklifts have various moving components that require proper lubrication to function smoothly. A weekly check should ensure that the mast rollers and chains should be properly lubricated to reduce friction and wear. These parts are under constant stress when lifting and lowering loads. Also, ensure the steering joints and linkages are lubricated for smooth operation.
4. Fork Condition and Attachments
In addition to the daily visual check, a more detailed inspection of the forks and attachments should be done weekly. Ensure the forks are not bent or misaligned as bent forks can reduce load stability leading to accidents. Also, verify that all locking pins and attachment mechanisms are secure and functioning correctly, especially if you use specialised attachments (e.g., side-shifters or carton clamps).
5. Exhaust System
If the forklift is powered by gas, diesel, or propane, the exhaust system should be checked weekly for leaks, blockages, or excessive emissions. A malfunctioning exhaust system can cause harmful fumes to build up in the work area, creating health hazards.
6. Record Keeping
Weekly checks should be documented in a maintenance log. This helps keep track of the forklift’s condition over time, making it easier to spot recurring issues or predict when major repairs might be needed. Regular records also serve as proof of compliance with safety and maintenance regulations, therefore these records must be kept for a minimum of two years.
Forklift Truck Check FAQs
What happens if I skip regular forklift checks?
Skipping regular forklift checks increases the risk of accidents, mechanical failures, and costly repairs. It can also lead to non-compliance with health and safety regulations, resulting in fines or legal consequences for your business.
Can I perform checks myself, or should a professional be involved?
Operators are responsible for daily checks, but weekly checks should ideally be done by a supervisor or a trained maintenance technician to ensure any potential issues are identified early.
How long does a forklift check take?
A daily forklift check usually takes around 10-15 minutes, as it focuses on quick visual and operational checks. Weekly checks can take longer, anywhere from 30 minutes to an hour, depending on the level of inspection required and the condition of the forklift.
How long to keep forklift inspection records?
For annual forklift truck inspections, a thorough examination must be performed. For these inspections, records must be kept for a minimum of two years to ensure legal compliance.
Forklift Operator Training with HL Training
Regular forklift truck checks are an essential part of workplace safety and forklift maintenance. By performing daily and weekly checks, you can reduce the risk of accidents, extend the life of your equipment, and ensure compliance with health and safety regulations.
Elevate the forklift safety in your workplace by enrolling your team in HL Training Forklift Operator Training designed for a vast range of forklift types to help them stay up-to-date with best practices for daily and weekly forklift checks.
Forklifts are essential equipment in various industries, from warehousing to construction. Ensuring that forklift operators are up-to-date with their training is not just a legal requirement but also critical for maintaining workplace safety. Over time, skills can decline, regulations can change, and new equipment can emerge, making it vital to periodically refresh training.
This blog will explore the importance of forklift refresher training, who needs it, how often it’s required, and what it entails.
What is Forklift Refresher Training?
Why is Forklift Refresher Training Important?
When is Forklift Refresher Training Required?
Benefits of Forklift Training Courses
How Long Does Refresher Forklift Training Take?
Forklift Truck Refresher Course FAQs
What is Forklift Refresher Training?
Forklift refresher training is a course designed to update and reinforce the skills and knowledge of forklift operators who have already completed initial training. Refresher training typically covers both theoretical and practical aspects of forklift operation, focusing on accident prevention, safe driving techniques, and workplace safety procedures.
Refresher Course Content
A review of the basics: operating principles, controls, and pre-use inspections
Updated safety practices and accident prevention techniques
Practical exercises that assess the operator’s current skills
Evaluation of the operator’s performance in real-world scenarios
Why is Forklift Refresher Training Important?
Forklift refresher training is crucial for ensuring that operators maintain their competency and keep up-to-date with current safety practices and regulations.
A significant number of forklift accidents are caused by operator mistakes. These could be the result of complacency, forgotten techniques, or unfamiliarity with updated safety measures. A refresher course helps operators sharpen their skills, preventing these errors and promoting a safer work environment.
When is Forklift Refresher Training Required?
The need for a forklift operator refresher course depends on several factors, including the accrediting body and the status of your NORS registration. While ITSSAR and AITT certifications do not require mandatory refresher courses, as they remain valid indefinitely, RTITB-certified operators must complete a refresher course to renew their NORS registration. Ultimately, it is the employer’s responsibility to decide whether an operator can continue using a forklift after the expiration of their registration.
Even though refresher courses may not be mandatory, they are strongly recommended, and most employers will likely require periodic retraining. The Health and Safety Executive (HSE) advises that refresher courses be completed every three to five years.
If you operate forklifts infrequently or have taken an extended break from using them, a refresher course is particularly beneficial for maintaining current knowledge and ensuring safe operation.
Benefits of Forklift Refresher Courses
Undergoing refresher training offers numerous benefits to both employees and employers. Some of the key advantages include:
Operators:
Improved safety awareness and confidence
Enhanced knowledge of the latest equipment and techniques
Reduced risk of accidents and injuries
Strengthened skill set
Employers:
Compliance with health and safety laws
Lower insurance premiums due to fewer workplace accidents
Increased productivity and efficiency
A safer working environment
How Long Does Refresher Forklift Training Take?
The duration of a forklift refresher course depends on the experience level of the operator and the specific requirements of the job. A refresher course takes one day, but operators that do not meet the standard may be referred for further training.
The course typically covers both theoretical knowledge and practical assessments, ensuring that participants leave fully competent and confident in their abilities.
Forklift Truck Refresher Course FAQs
Is forklift refresher training a legal requirement?
Forklift refresher training is not explicitly a legal requirement in the UK; however, it is strongly recommended by the HSE. Employers have a legal duty under the Provision and Use of Work Equipment Regulations 1998 (PUWER) to ensure that employees operating forklifts are trained and competent, in this case refresher training may be required to keep knowledge and skills up to date.
Can refresher training replace initial forklift operator training?
No, refresher training is only suitable for experienced operators who have already been certified and need to update their skills or knowledge to stay compliant with regulations or adapt to new equipment or working conditions.
Can forklift refresher training be done on-site?
Yes, forklift refresher training can often be done on-site at your workplace. HL Training offers a on-site option that allows operators to practise in the actual conditions they will be working in, enhancing the relevance and practicality of the training.
Choose HL Training for Your Forklift Refresher Course
Choosing the right forklift training provider is crucial to ensuring you receive a high-quality refresher course. It is vital to select a provider that is accredited by recognised bodies such as RTITB or ITSSAR, and who have a deep understanding of forklift operations and safety regulations.
Look no further than HL Training, our team of experienced forklift instructors can provide tailored refresher training courses that best suit your requirements. Whether you need in-house, on-site or online training, we can help you refresh your forklift operator knowledge.
Contact us today to learn more about the courses we offer, and explore the opportunity to become a forklift instructor with HL Training.
Health and safety are crucial in any business, but they are even more vital in workplaces that handle machinery and equipment. In this guide, you can find our warehouse health and safety checklist to help guide you through exactly what tasks need to be completed to ensure your workplace puts the safety of your employees first and complies with various health and safety regulations.
What is Warehouse Safety?
Why Health and Safety in a Warehouse Matters
Key Health and Safety Regulations
The Most Common Warehouse Injuries and Safety Risks
Steps to Ensure Warehouse Safety
Our Warehouse Health and Safety Checklist
Ensure Your Staff are Trained in Health and Safety with HL Training
What is Warehouse Safety?
Warehouse safety is crucial for protecting workers and maintaining efficient operations. Several key practices must be followed, including training for all employees on general health and safety, equipment usage and safety protocols, and conducting risk assessments to analyse a workplace’s safety. Health and safety also includes supplying personal protective equipment, such as hard hats and high-visibility vests.
Why Health and Safety in a Warehouse Matters
Working in a warehouse comes with many risks, some of which can cause serious harm. From 2023 to 2024, the UK reported 25 fatalities in the workplace caused by being struck by a moving vehicle and a further eight fatalities involving contact with moving machinery.
A business was fined over £320,000 in 2024 for the death of an employee back in 2020. The company did not comply with health and safety regulations, and as a result, an employee died due to a faulty attachment on a forklift. This case emphasises the need for regular health and safety checks to identify risks promptly and reduce injury and fatalities.
Complying with health and safety regulations also ensures you:
Avoid hefty fines and prosecution
Minimise the amount of lost time due to injury
Promote a positive working environment
Key Health and Safety Regulations
There are several health and safety regulations you must follow in the UK. These are the key regulations you must be aware of and what health and safety measures they highlight:
Health and Safety at Work Act 1974: This regulation applies to all businesses, regardless of their sector.
Management of Health and Safety at Work Regulations 1999: Employers must carry out risk assessments and implement control measures to uphold health and safety measures.
Work at Height Regulations 2005: Employees should only work at heights when necessary, and measures must be in place to prevent falls.
Control of Substances Hazardous to Health Regulations 2002: This regulation requires employers to assess the risks of working with hazardous substances and implement measures to control exposure.
Provision and Use of Work Equipment Regulations 1998 (PUWER): Employers must ensure all work equipment is safe and properly maintained to protect workers.
The Most Common Warehouse Injuries and Safety Risks
Warehouses can be full of risks, given the types of machinery that may be used and the tasks employees must carry out. Here are some of the main risks you should be aware of in a warehouse:
Manual Handling Injuries
Slips, Trips and Falls
Vehicle-Related Hazards
Collisions with Storage Racking, Goods or Equipment
Working at a Height
Fire and Explosions
Exposure to Chemical and Hazardous Substances
Noise Exposure
Electrical Hazards
Steps to Ensure Warehouse Safety
To create a safe working environment and comply with health and safety regulations, here is a step-by-step of the tasks you must complete to ensure all risks are identified and safety measures are implemented.
1. Conduct Thorough Risk Assessments
While it is only a legal requirement to conduct a risk assessment if your business has five or more staff members, we recommend you still identify all risks to ensure the safety of your workforce, no matter how small it may be. To ensure all risks are identified, you should cover all areas, including machinery, substances and work processes, and evaluate the risks. You should then record and review these risks regularly.
2. Inspect and Maintain the Facility
Preventative maintenance is key to identifying new risks and keeping the warehouse in good condition. By blocking regular warehouse inspections, you can identify new hazards, run-down equipment and other health and safety risks, such as blocked fire exits. All inspections should be recorded to keep a paper trail of your health and safety management efforts.
3. Provide Training and Supervision Where Necessary
All employees should be trained in general health and safety and job-specific tasks. This includes manual handling, fire safety and prevention, operating equipment, handling hazardous substances, working at height, and forklift operation.
4. Document Procedures
Any hazardous tasks should have complementary step-by-step guides on how to perform them following health and safety procedures. Some examples of hazardous tasks include working with dangerous substances and working at heights.
5. Provide Suitable Personal Protective Equipment
Health and safety isn’t just about ensuring procedures are followed but also making sure the correct equipment is supplied to employees to carry out their roles safely. This means employers must provide suitable personal protective equipment, including eye protection, hearing protection, steel-capped footwear and hi-vis jackets.
6. Report All Incidents
If any accidents are to occur, you must record them following your business’s incident reporting procedure. All injuries, safety observations and new perceived risks must be recorded. You should also implement new safety measures accordingly and conduct post-incident analysis to reduce the risk of the same incident occurring again.
7. Practice Emergency Protocols
All workplaces must have emergency procedures in place to ensure a quick response to a fire, chemical spill, injury or any other emergency. You are also advised to conduct drills to ensure all staff understand the procedures and are aware of their responsibilities in the event of an emergency.
Our Warehouse Health and Safety Checklist
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Ensure Your Staff are Trained in Health and Safety with HL Training
Training is one of the best ways to ensure health and safety regulations compliance. At HL Training, we pride ourselves on providing high-quality training in forklift operation, first aid, and other health and safety courses to ensure your staff can handle any situation calmly and safely. Book a training course with us today to protect your staff from avoidable harm!
FAQs
Is it illegal to leave keys in a forklift?
Never leave keys in an unattended forklift. It’s illegal and unsafe, and it violates health and safety regulations. Anyone could operate the forklift without proper training, increasing the risk of accidents and injuries.
Remember: Always remove keys when leaving a forklift unattended. This simple step helps prevent unauthorised use and keeps everyone safer.
What are the general safety rules for a warehouse?
To comply with health and safety regulations, you should ensure you abide by the following rules:
Conduct Risk Assessments
Inspect and Maintain the Facility
Provide Training and Supervision
Document Procedures
Provide Suitable Personal Protective Equipment
Report All Incidents
Practice Emergency Protocols
What is the biggest safety issue in a warehouse?
Warehouses can have many safety hazards, so it is crucial you understand them and how to avoid them. The main risks in a warehouse include manual handling injuries, slips, falls, and trips, vehicle-related hazards, and working at a height.