When this template fits
This RAMS is for UK contractors and plant teams carrying out forklift (flt) operation — typically because a principal contractor or client has asked for a risk assessment and method statement before work can start. It covers the recognised lifting & plant hazards for this task, with the controls a reviewer expects to see.
What this RAMS includes
- ✓ 9 task-specific hazards scored on a 5×5 matrix (initial → residual)
- ✓ Specific control measures for each hazard, in hierarchy-of-control order
- ✓ A 10-step method statement (sequence of works)
- ✓ PPE, plant/equipment, permits and competence requirements
- ✓ Emergency arrangements and operative briefing / sign-off section
Scope of works
Operate counterbalance/reach forklifts — pedestrian segregation, loads and stability.
Sequence of works
- 1Pre-operation: Confirm you hold a valid FLT licence (RTITB/ITSSAR/AITT) and site-specific written authorisation. Review the RAMS/briefing for the task and sign on.
- 2Pre-use inspection: Complete a formal pre-use check (fluid levels, tyres, forks, backrest, safety devices, seatbelt, lights, horn, LPG hose or battery charge). Record defects and take out of service if safety-critical faults are found. Do not use a defective FLT.
- 3Site awareness: Identify all pedestrian routes, exclusion zones, speed limits, one-way systems and any specific hazards (e.g. blind corners, slopes, overhead obstructions) before commencing work.
- 4Load assessment: Inspect the load — check pallet condition, load weight against the FLT data plate, load centre and securing (banding/wrap). Reject unsuitable pallets. Ensure forks are correctly spaced and fully engaged under the pallet.
- 5Travel: Lower forks to the safe travel height (150–200 mm above ground), tilt mast fully back, travel at or below the posted speed limit. Sound horn at junctions and blind spots. Maintain safe stopping distance from other plant and pedestrians.
- 6Placing and stacking: Approach the stack location at slow speed. Raise the load only when stationary or moving very slowly, check for persons below, place load accurately and lower forks before withdrawing. Never travel with load raised.
- 7Reversing and blind-spot management: Use a banksman (signaller) whenever reversing is required in areas where pedestrians may be present or sightlines are restricted. Sound horn before reversing.
- 8Refuelling / recharging: Park in the designated refuel/recharge area with engine off. Follow LPG cylinder-change procedures outdoors; recharge electric FLTs in a ventilated area away from ignition sources.
- 9End of shift: Park FLT in the designated safe area on level ground, lower forks fully, apply handbrake, switch off, remove key, and complete post-use inspection record. Report any defects to the supervisor immediately.
- 10Incident and near-miss reporting: Report all collisions, overturns, near-misses, and racking damage immediately to the supervisor. Preserve the scene pending investigation.
Hazards, risk rating & controls
Risk = likelihood × severity (1–25). Initial is before controls; residual is with controls applied.
Pedestrian struck by forklift
Who’s at risk: Operatives, Other trades on site
- › Install permanent physical barriers (Armco, Rackend guards, painted zones) to create dedicated pedestrian walkways completely separated from FLT travel routes.
- › Implement a one-way FLT traffic system with clearly signed routes to eliminate opposing vehicle movements and reduce conflict points.
- › Fit FLTs with pedestrian detection technology (e.g. radar or ultrasonic sensors) that alerts the operator and triggers an audible/visual warning.
- › All persons working in or near FLT operating areas must wear high-visibility vest or jacket to EN ISO 20471 Class 2 minimum.
Forklift overturning
Who’s at risk: Operatives, Other trades on site
- › Inspect travel routes and operating surfaces for potholes, camber, drainage channels and gradients before each shift. Repair or barricade defective surfaces.
- › Operators must check the FLT data plate before each lift; never exceed rated capacity or load centre. Loads must be lowered and tilted back before travelling.
- › Ensure the FLT is fitted with a Roll-Over Protective Structure (ROPS) and operator seatbelt; the operator must wear the seatbelt at all times. If overturn occurs, operator must stay within the protective frame.
Falling load from forks
Who’s at risk: Operatives, Other trades on site
- › Operator inspects pallet integrity, load centre and securing (banding/shrink wrap) before engaging forks. Reject damaged or unstable pallets.
- › Establish and enforce a strict exclusion zone: no person is permitted to stand or pass under a raised load at any time.
- › FLT must be fitted with a suitable backrest extension to prevent loads sliding rearward onto the operator. Use load attachment accessories (e.g. side-shift, clamps) where loads are non-palletised.
- › Wear a safety helmet (EN 397) in areas where overhead load movement is unavoidable.
Unauthorised or untrained FLT operation
Who’s at risk: Operatives, Other trades on site
- › Keys/PINs must be held by the authorised operator or supervisor only. Keyless start or coded immobilisers prevent unauthorised use.
- › Only persons holding a recognised FLT licence (e.g. RTITB, ITSSAR, AITT) AND site-specific authorisation issued by management may operate FLTs. Records to be maintained.
- › All operators, including experienced ones from other sites, complete a site-specific familiarisation covering routes, hazards, speed limits, load types and emergency procedures before unsupervised use.
Collision with fixed structures or racking
Who’s at risk: Operatives, Other trades on site
- › Fit all exposed racking uprights and structural columns with robust floor-level impact protection guards (e.g. column guards, end-of-aisle barriers).
- › Impose and signpost maximum speed limits (typically 5 mph indoors, 10 mph outdoors) and use physical speed-reduction measures (road humps, chicanes) where appropriate.
- › Carry out regular racking inspections by a competent person (SEMA-trained inspector annually; daily visual checks by staff). Any damage to racking must be reported immediately and the bay taken out of service.
Manual handling of attachments and accessories
Who’s at risk: Operatives, Other trades on site
- › Use quick-hitch hydraulic attachment systems where possible to eliminate manual effort in changing heavy attachments. Provide dedicated storage racks at ground level to reduce bending and awkward postures.
- › Attachments exceeding individual manual handling limits must be changed by two trained persons using a team-lift technique.
- › All operators receive task-specific manual handling training covering correct technique for FLT attachment management.
LPG / fuel leak and fire
Who’s at risk: Operatives, Other trades on site
- › Where operationally feasible, substitute LPG FLTs with electric-powered equivalents, eliminating combustible fuel storage and exhaust fume risks.
- › Before every shift, operator inspects LPG cylinder condition, valve, regulator and hose for damage, corrosion and leaks using soapy water test on connections.
- › Spare LPG cylinders stored upright in a ventilated, secured external cage away from ignition sources. Cylinder changes carried out outdoors or in a well-ventilated area by trained personnel only.
- › Suitable dry powder or CO2 fire extinguisher mounted on the FLT, inspected annually and accessible to the operator.
Exhaust fumes — diesel and LPG
Who’s at risk: Operatives, Other trades on site
- › Use electric FLTs indoors to eliminate exhaust emissions entirely.
- › Where combustion FLTs must operate indoors, provide adequate mechanical ventilation (extract and supply) to dilute and remove fumes below WEL levels. Monitor CO concentration.
- › Define and sign areas where combustion FLTs are prohibited (e.g. cold stores, enclosed dock levellers, internal aisles). Enforce operationally.
Whole-body vibration (WBV)
Who’s at risk: Operatives, Other trades on site
- › Maintain warehouse floors and yard surfaces in good repair; repair potholes, damaged expansion joints and uneven surfaces promptly to reduce vibration transmission.
- › Specify FLTs with fully-suspended operator seats and low-vibration chassis design when procuring or replacing plant.
- › Monitor daily vibration exposure (A(8) value) for regular FLT operators. Where Exposure Action Value (0.5 m/s²) may be exceeded, implement job rotation to limit duration.
PPE
- ✓ Safety footwear (EN ISO 20345)
- ✓ Hi-vis clothing
- ✓ Safety gloves (task-appropriate)
- ✓ Hard hat (EN 397) where overhead risk or site rules require
- ✓ RPE (FFP3 or as risk-assessed) with face-fit
- ✓ Hearing protection (to the assessed SNR)
Competence
- ✓ Site induction completed; CSCS or equivalent where the site requires it
Schemes (CSCS, PASMA, IPAF…) evidence competence; they are not statutory requirements in themselves.
Plant & equipment
- › Crane / telehandler / excavator as specified
- › Certified lifting accessories (slings, shackles)
- › Banksman radios or agreed signals
- › Exclusion zone barriers and signage
- › Wheel stops and edge protection for tipping
Permits & legislation
What principal contractors usually check
- ✓ A lift plan with appointed person for crane lifts
- ✓ Plant operator tickets (CPCS/NPORS)
- ✓ Exclusion zones and banksman arrangements
- ✓ The document is site-specific — real address, access arrangements and dates, not a generic template
- ✓ Hazards match the actual task and the controls are specific (not “take care” and “use PPE”)
- ✓ Named supervisor and competent person, with operative sign-off space
- ✓ Emergency and rescue arrangements that work for this site
The report builder runs these as pre-submission checks before you download — or run an existing document through the free RAMS pre-submission checker.
Frequently asked questions
Who should write a forklift (flt) operation RAMS?
Someone competent to plan the work — usually the contractor doing the job or their supervisor. A template like this gives you the recognised hazards and controls for forklift (flt) operation, but the person signing it off must review it as the competent person and confirm it matches the actual site and method.
How long is the RAMS valid for?
Until something changes — there's no fixed expiry in law. Review it if the method, site conditions, equipment or people change, after any incident or near miss, and at sensible intervals on longer jobs. Date the review and re-brief the team.
What regulations apply to forklift (flt) operation?
PUWER 1998 — Provision and Use of Work Equipment Regulations, Manual Handling Operations Regulations 1992, Regulatory Reform (Fire Safety) Order 2005 are the main ones, alongside Control of Substances Hazardous to Health Regulations 2002 (COSHH), Control of Noise at Work Regulations 2005. The Health and Safety at Work etc. Act 1974 and CDM 2015 apply to all construction work.
Does a RAMS need to be site-specific?
Yes — this is the most common reason documents get sent back. Principal contractors reject generic copy-paste RAMS. Your document should name the site, access arrangements, dates, supervisor and any site-specific hazards. The RamsDocs builder fills these in for you and flags what's missing before you download.
Is this template free?
Yes — everything on RamsDocs is free during early access, including building a site-specific version of this RAMS and downloading the PDF. No card required.