Every business using material-handling equipment has a strict legal and operational duty of care. Ensuring your forklifts are safe protects your operators, safeguards nearby pedestrians, and prevents catastrophic workplace accidents.
While risk assessments and driver monitoring are critical, fleet safety relies heavily on two primary inspection pillars: daily pre-shift checks and mandatory Thorough Examinations.
Here is what every employer and operator needs to know about keeping equipment safe and compliant.
1. Daily Pre-Shift Examinations
Operators must perform a quick pre-shift inspection before using a forklift at the start of every shift. Catching minor wear early prevents minor faults from escalating into costly repairs or dangerous mechanical failures.
A complete daily check covers two distinct phases:
The Visual Check (Static)
Before turning the ignition, the operator conducts a walk-around inspection to check:
- General Condition: Cleanliness, frame damage, or fluid leaks under the machine.
- Tires & Wheels: Inflation levels, severe tread wear, cracks, or embedded debris.
- Forks & Attachments: Proper alignment, cracks, and secure positioning.
- Power Source: Battery condition, cable corrosion, or fuel lines/cylinders.
The Operational Check (Dynamic)
Once the visual audit is complete, the operator tests key operational features:
- Braking Systems: Smooth performance of both the foot brake and parking brake.
- Steering & Controls: Responsive movement without excessive slack.
- Hydraulics & Mast: Smooth raising, lowering, and tilting of the forks.
- Safety Devices: Horn, seatbelt, warning lights, and backup alarms.
2. Mandatory Thorough Examinations (LOLER & PUWER)
While daily checks keep machines safe day-to-day, UK law mandates a Thorough Examination at least every 6 to 12 months (or every 4 months for specialised lifting applications).
Think of a Thorough Examination as the commercial MOT for your forklift. Conducted by a certified, competent engineer, it ensures the truck meets two primary statutory regulations:
- PUWER 1998 (Provision and Use of Work Equipment Regulations): Covers drive systems, steering, brakes, and general vehicle safety.
- LOLER 1998 (Lifting Operations and Lifting Equipment Regulations): Covers safety-critical lifting components, including the mast, chains, carriage, and forks.
Key Differences: Daily Checks vs. Thorough Examination
| Feature | Daily Pre-Shift Check | Thorough Examination |
| Frequency | Start of every shift / daily | Every 4, 6, or 12 months |
| Carried Out By | Trained forklift operator | Qualified, independent engineer |
| Legal Basis | Internal safety policy & general health/safety compliance | Statutory requirement (LOLER 98 & PUWER 98) |
| Scope | Visual walk-around & basic functional test | In-depth mechanical audit, wear measuring, & load testing |
| Documentation | Operator logbook or digital pre-shift checklist | Formal written report & compliance certificate |
Summary
Skipping daily checks or missing an annual Thorough Examination risks heavy fines, invalidates insurance, and jeopardises worker safety. Enforcing daily operator checklists alongside scheduled engineer audits ensures your fleet stays legal, productive, and safe.
Need to book a certified Thorough Examination for your fleet or upgrade your operator safety checklists? Contact our service team today.