Forklift Safety Guide 2026: Rules, Risks, and Responsibilities

Safety is critical in every role but when you are operating a forklift or pallet jack as part of your daily workflow there are more risks to be aware of both to keep the individual operator safe and ensure the safety of those around them. Here we outline some of the key areas to keep in mind when you are responsible for managing forklift and pallet jack safety to stay compliant and more importantly, keep your workers safe and healthy. 

forklift safety improves most when engineering controls support training

Before getting into the details on the current dos and don’ts when it comes to forklift safety, it is useful to understand the research in the area. 

In 2004 a forklift safety demonstration project was carried out at two manufacturing sites in Victoria, Australia, with the aim of improving safety locally and developing practical, human centred interventions that could be applied more widely. 

The researchers used a before and after case study approach, first setting a baseline by observing forklift and pedestrian movements and surveying workers about perceived risks. They then proposed a package of traffic management and vehicle focused engineering changes, shaped through site visits, technical review, and consultation with managers and the workforce, and assessed the impact through follow up observations plus a post intervention survey on the acceptability of the new vehicle technology.

The extract highlights why this approach mattered. Forklifts are essential for materials handling but become a serious hazard when operating near pedestrians, with collisions often causing severe injury or death and manufacturing identified as a key high risk area due to busy foot traffic, narrow aisles and time pressure. 

The authors argue that many workplaces rely too heavily on training and operator protection, while leaving the broader risk environment largely unchanged. Their findings suggest that targeted traffic engineering can reduce potentially hazardous forklift interactions, and that on board Intelligent Transport Systems were broadly accepted by drivers and managers, with the intended safety benefits understood. Overall, the work supports a shift towards combining training with stronger engineering and operational controls that better manage how forklifts and pedestrians share space.

FAQs on Forklift Safety

Best practices for operating forklifts 

During the operation of a forklift truck the following checklist of do’s and dont’s from the Health and Safety Executive (PDF available here) guides you through some of the best practices to follow: 

Do:

• Complete a pre shift check.
• Use the seat belt or other restraint if fitted.
• Check all around before moving off and look in the direction you are travelling.
• Drive at a safe speed for the area and the load.
• Keep forks low but clear of the ground while travelling.
• Stay alert for pedestrians and obstructions.
• Avoid harsh braking and sudden stops.
• Slow down at corners, doorways, and other risk points, using the horn where needed.
• Apply the parking brake before leaving the truck.
• Get in and out safely using the steps and handholds, facing the truck.

Do not:

• Drive unless you are trained and authorised.
• Use a truck or equipment you know is faulty.
• Operate controls from outside the cab unless the truck is designed for it.
• Stand on or near controls to reach the load or anything outside the cab.
• Use a truck on uneven ground unless it is suitable.
• Drive over unprotected cables or flexible pipes.
• Attempt repairs unless you are a qualified maintenance engineer.
• Operate under the influence of alcohol or drugs.
• Use hand held phones or devices while operating or travelling.

Handling loads

Do:

• Follow floor loading limits and know the weight of the loaded truck.
• Check there is enough space for the truck and load, including overhead clearance.
• Lower loads at a controlled, safe speed.
• Use the right attachments for unusual or wide loads and follow the manufacturer’s instructions.
• Make sure you are trained and authorised to use the truck with any attachment fitted.

Do not:

• Lift loads above the truck’s rated capacity.
• Move loads that look unstable, unsuitable, or placed on damaged pallets.
• Travel with loads that block your view.
• Travel with a raised load unless the truck is designed for it.
• Use attachments unless the truck’s capacity has been officially reduced and confirmed by a competent person, authorised dealer, or manufacturer.

Working on slopes

Do:

• Travel slowly downhill.
• With a load, keep the forks facing uphill when travelling up or down slopes.
• Without a load, keep the forks facing downhill when travelling up or down slopes.
• Adjust tilt to suit the gradient and raise forks enough to clear the ground.

Do not:

• Turn on a ramp or slope, or travel across it.
• Leave the truck on a gradient unless it is an emergency, and then chock the wheels.

Keeping people safe

Do:

• Use a safe system of work for working platforms.

Do not:

• Lift people on the forks, pallets, or anything balanced on the forks.
• Carry passengers unless the truck is designed for this.
• Allow anyone to walk under raised forks or loads.
• Pick up a load if someone is standing close to it.

When you finish

• Park on level ground, not on a slope.
• Tilt the mast forward and lower the forks fully so the tips rest on the floor.
• Apply the parking brake, select neutral, switch off, and remove the key.
• Return keys or activating devices to secure storage.

Forklift and pallet jack safety is not just about training operators to do the right thing. It is about designing a workplace where the safe option is the easy option. The research highlighted above shows that engineering and traffic management controls can reduce risky interactions between vehicles and pedestrians, while the HSE guidance reinforces the day to day habits that prevent serious incidents, from pre shift checks and safe speeds to correct load handling, slope rules, and safe parking. Taken together, the key takeaway is simple: combine competent operators with clear site rules and practical controls that separate people and vehicles, improve visibility, and reduce opportunities for errors.

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