Doc. No.

: L3-022-HSE-02
AZN Procedure
Rev. Date: 25-Dec-2018
Issue No Issue Date Revalidation Safe Operation of Forklift
3 28-Jun-2015 24-Dec-2020 Trucks
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Distribution List
Department/Section Recipient Department/Section Recipient
Management GM Stores All staff
Operations All staff Chemistry All staff
H.R. & Administration All staff Electrical All staff
I.T. All staff Mechanical All staff
Finance All staff Instrumentation & Control All staff
Procurement All staff Engineering All staff
H.S.E. All staff
Security All staff
 Doc. No.: L3-022-HSE-02
AZN Procedure
Rev. Date: 25-Dec-2018
Issue No Issue Date Revalidation Safe Operation of Forklift
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Revision Record
Revision
Issue No. Description of Change Effective date
No.
1 0 First issue 28/06/2015
2 1 Routine review; minor updates 23/05/2017
3 2 Format change 31/12/2018
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Rev. Date: 25-Dec-2018
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Contents
1.0 PURPOSE.................................................................................................................. 5
2.0 PRINCIPLE ................................................................................................................ 5
3.0 SCOPE....................................................................................................................... 5
4.0 RESPONSIBILITY ..................................................................................................... 5
5.0 DEFINITIONS/ ABBREVIATIONS ............................................................................. 5
6.0 REFERENCES ........................................................................................................... 5
7.0 HSE AND BUSINESS RISK....................................................................................... 6
8.0 PROCEDURE ............................................................................................................ 6
8.1 Nominated persons ................................................................................................... 6
8.2 Formal training requirements ................................................................................... 6
8.3 Risk Assessment ....................................................................................................... 6
8.4 Lifting Plans............................................................................................................... 6
8.5 Maintenance requirements ....................................................................................... 7
8.6 Health Screening Requirements............................................................................... 7
9.0 AUDIT / REVIEWS ..................................................................................................... 7
10.0 ATTACHMENTS ........................................................................................................ 7
Appendix 1 Fork Lift Truck inspection guidance ..................................................... 8
Appendix 2 Confidential Health Screening Questionnaire .................................... 11
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AZN Procedure
Rev. Date: 25-Dec-2018
Issue No Issue Date Revalidation Safe Operation of Forklift
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1.0 PURPOSE
There are a range of requirements that are required to be carried out to allow the use of
Fork Lift Trucks on site. This procedure provides guidance for the management of the use
and inspection of these vehicles on site.

Before an employee is permitted to operate a Fork Lift Truck they must undergo a Health
Assessment with the occupational health advisor. All nominated persons will receive
suitable and sufficient training to discharge their duties detailed within this document.

The UK Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) require that
all lifting operations are to be planned by a competent person and that any equipment
used for lifting or lowering loads should be of adequate strength and stability and
thoroughly examined at regular intervals.

The FLT must not be left with the starting key in the vehicle; the driver must remain in
possession of the key at all times.

2.0 PRINCIPLE
This procedure shows how the site complies with Engie procedures on use of site mobile
plant.

3.0 SCOPE
This procedure is applicable to the use and inspection of the site’s fork lift trucks and
reach truck. This includes the assessment of risks, consideration of a lifting plan, the
requirement to nominate persons who have sufficient knowledge and experience to
operate the site’s fork lift trucks, formal training requirements & competencies, equipment
checks and the recording of such checks and detail medical screening requirements prior
to permitting an employee to operate Fork Lift Trucks.

4.0 RESPONSIBILITY
The Lead Mechanical Engineer is responsible for ensuring that all Fork Lift Trucks and
any other site vehicles are kept properly maintained and serviced in line with manufacturer
recommendations.

5.0 DEFINITIONS/ ABBREVIATIONS

FLT Any Fork Lift Truck used on site, including reach trucks, counterbalanced
riders, rough terrain mast types and telescopic jib types

6.0 REFERENCES
For further information UK HSE Approved Code of Practice L117
Rider-operated lift trucks; operator training and safe use
 Doc. No.: L3-022-HSE-02
AZN Procedure
Rev. Date: 25-Dec-2018
Issue No Issue Date Revalidation Safe Operation of Forklift
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H&S PROC 024 Lifting Operations

7.0 HSE AND BUSINESS RISK

Without effective controls, there is a high risk of injury and plant damage.

8.0 PROCEDURE
8.1 Nominated persons
No person may drive or operate a FLT unless they are trained and competent to do so.
They must be nominated in writing by the station management. A list of those persons
who are deemed to be competent is kept by the HR Department.

The nomination of fork truck drivers shall state the category/limit of type of fork truck that
the individual is nominated to operate.

8.2 Formal training requirements

Each nominated person must complete the specified fork truck licence certification. The
standard achieved is the national standard and is undertaken by external training
agencies.

Each operator is required to undertake a refresher course and re-test every three years
or as required by the training body.

8.3 Risk Assessment

A risk assessment must be in place before a FLT is used. A generic area assessment is
in place. If the generic assessment does not include the area or task intended, a specific
risk assessment should be produced. A Last Minute Risk Assessment (LMRA) should
also be completed.

8.4 Operation
Lifting operations can be categorised to determine the degree of planning required. Most
FLT operations will be Routine Lifts and therefore generic plans/procedures may suffice
and personal supervision is not required. Alternatively, Non Routine Lifts will require
specific lifting plans prepared by a lifting specialist. The requirements of H&S PROC 024
Lifting Operations apply.

The driver must be able to see where he is going. If a load obstructs forward vision, the
truck should be driven in reverse (except when going uphill). When negotiating inclines,
the load must be kept “uphill”. If driver’s vision is obscured a banksman may be required.
Consideration should be given to tying the load to the FLT with ratchet straps if required.

The speed of the lift truck must be appropriate to the circumstances, but on uneven
surfaces and rough ground, the vehicle must be driven at low speed with particular
attention to brakes and edges of floor slabs, and excavations, etc. The forks should be
kept as low as possible when moving loaded lift trucks, taking into account the load and
conditions. The mast should be tilted backwards. Particular attention should be paid to
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overhead obstructions. Unloaded lift trucks should be driven with the forks approximately
150 mm off the ground. Forklift trucks must not be used as cranes unless the correct
fitments are used and as recommended by the manufacturer.

8.5 Maintenance requirements

Inspections and maintenance must be carried out as required by the machine’s
manufacturer, and include a daily and weekly check plus a six monthly thorough
examination in addition to examination after an accident, major repair or modification. A
certificate of thorough examination must be issued by an approved third party such as the
insurer. Routine inspection guidance is shown in appendix 1.

8.6 Health Screening Requirements

In accordance with legislation, before an employee is permitted to operate a FLT they
must undergo a health assessment which is carried out by the occupational health
advisor.

Health assessments should be conducted every 3 years up to the age of 60 and annually
thereafter. The method for assessing medical suitability for operators is via a medical
screening review. Prior to the review, the employee will be asked to complete a screening
questionnaire (See appendix 2).

Health assessments will also be carried out where an employee has been absent due to
an illness or injury where it appears likely that the illness or injury may affect the individual
fitness for driving or in any instance where a manager has grounds for the employee to
be reviewed.

9.0 AUDIT / REVIEWS

This document will be reviewed every 2 years or as a result of audit findings.

10.0 ATTACHMENTS
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Rev. Date: 25-Dec-2018
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Appendix 1 Fork Lift Truck inspection guidance

Fork Arms
The fork arms shall be checked for wear, cracks, distortion and for thin jagged edges at the
tips. In particular, the fork arm hooks and the carriage plate shall be examined for wear and
fracture, as there is constant movement between these points. The fork arms shall be checked
to verify that they are equally spaced on the carriage plate, with each fork arm-retaining device,
engaged and secured.

Carriage Plate
The carriage plate shall be examined to ensure that it has no obvious damage or distortion
and the end stops are in place and secured.

Back rest extension

The load backrest extension shall be checked for distortion, cracks and security.

Mast
The mast sections shall be checked for, damage, distortion and cracks. Additionally the inner
mast channels or runners shall be inspected for undue wear, scoring, excessive dirt or foreign
bodies, which may foul the mechanism.
Mast roller/slides
Inspection shall ensure that the mast guide rollers show no signs of uneven wear, incorrect
tracking, flat spots or scoring. Mast slides, if fitted, shall be secure and intact.

Lift chains and pulleys

Lift chains shall be checked for evidence of deterioration such as loose or worn pins, damaged
pin rivet heads, cracked or distorted links and signs of rust. Chain anchors shall be inspected
for damage and security, especially if fastened with locking nuts. Chain pulleys should be free
from damage, uneven wear and flat spots. Uneven wear of chain parts such as rivet heads or
inner flange of the pulley may indicate incorrect tracking of the chain over the pulley. The
adjustment of multiple chains should be checked to ensure that they share the load evenly.

Hydraulics
All hydraulic jacks, seals and couplings shall be checked for damage and leaks. The condition
of rams where they emerge from their cylinders, together with the seals at these points. The
extent of the hydraulic fluid present shall be examined. All hose reels for hydraulic fluids shall
be checked for leakage and proper running of the hose when extending and retracting.

Wheels
Wheels shall be checked for damage to the hub and rim and the security of wheels to their
axles. The steering mechanism shall be examined for wear, damage, dirt and foreign bodies,
which might impair its correct operation.

Tyres
Each tyre shall be inspected for excessive wear, wall deterioration and for cuts, chunking and
damage or potential damage due to foreign bodies. Uneven tread wear should be noted in
case it indicates wheel alignment. The pressures in pneumatic tyres should be checked.
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AZN Procedure
Rev. Date: 25-Dec-2018
Issue No Issue Date Revalidation Safe Operation of Forklift
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General
The general condition of the trucks under inspection shall be noted. This includes the integrity
of the overhead guard, protective covers such as those for the engine or battery, the doors
and panels. Inspection shall cover the condition of hinges and catches or other retaining
devices. If fitted, the transparency of the windscreen and other windows shall be checked,
together with the alignment of mirrors, etc. The unscheduled introduction of foreign objects
onto the top of the overhead guard or other similar places should be verified. The truck shall
be systematically checked to ensure that there are no leaks of fuel, water, hydraulic fluids,
lubricants or battery acid, etc.

Operating position
The operating position including all control areas shall be checked for freedom from damage,
excessive dirt and foreign bodies which may be fouling, or could cause fouling of, the controls.
All instruction and warning plates and especially the capability rating plate shall be checked
for applicability. All gauges shall be inspected to ensure they are functional and if appropriate,
visible from the operating position.

Operator’s seat
The seat anchor points, runners/sliders, end stops and adjusters including backrest adjusters
shall be checked to ensure they are secured, undamaged, functional and engaged. The
underside of the seat shall be inspected to ensure it is free of foreign bodies that may foul the
mechanism or interfere with any safety switches located there. The operator restraint shall be
in serviceable condition.

Engine trucks
The fuel, coolant and lubricant levels shall be verified and the ignition and starter switches
checked for correct functioning. The correct illumination of associated warning lights should
be verified. The stop control checked for function and the appropriate cold start device
effectiveness verified. All associated interlocks shall be checked to ensure they inhibit
appropriate motions. With the engine running, the oil pressure and charging rate shall be
checked to ensure they are registering correctly and that all other indicators are functioning
appropriately and in accordance with manufacturer’s instructions.

Battery electric trucks

The battery shall be checked for correct size, installation and fixing to the truck and all supply
cables checked for security and soundness of insulation. The state of charge of the battery
shall be verified and the power isolation checked that it can be appropriately activated and is
effective. All interlocks shall be tested for appropriate reactions. All gauges and indicators shall
be checked that they are functioning appropriately and in accordance with manufacturer’s
instructions. Charging of batteries must be done with the correct charging equipment in a well-
ventilated area.

Lights & audible warning devices

All lights shall be checked to ensure they are clean and in working order. The inspection shall
include all road going lights fitted such as head, side and tail lights, directional indicators,
reversing lights and audible warning device, flashing beacons and all working lights such as
spotlights.
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AZN Procedure
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All horns, klaxons, sirens and other acoustic devices shall be checked for operation and, in
the event of failure, the resultant safety actions shall be noted. The acoustic reaction when
applying certain controls or as a result of certain adverse/unsafe truck motions shall be verified
in accordance with the manufacturer’s instructions.

Controls
All controls shall be operated and the resultant motion fully exercised to ensure the movement
is in the correct direction, smooth in operation and free from fluid leaks.
Driving and braking
The trucks shall be carefully and slowly driven in both directions, the parking and service
breaks applied and their efficiency verified. Where a truck embodies regenerative or other
non-friction type braking, this shall also be checked for compliance with the manufacturer’s
specification.

Steering
The steering shall be checked in both directions, at standstill and whilst the truck is in motion.
There should be no excessive play in the mechanism and the power steering assembly.

Reporting procedure
The reporting procedure comprises of filling in the routine check sheet (see appendix 1) and
also entering an electronic copy of the defect onto MMS. If the fault compromises the integrity
of the fork trucks operation then the keys required to operate the fork truck should be removed
from service and held in safe keeping. The truck shall remain isolated until the defect has been
rectified.
The operating keys are secured in the Workshop and are only to be issued by persons
authorised to do so.
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AZN Procedure
Rev. Date: 25-Dec-2018
Issue No Issue Date Revalidation Safe Operation of Forklift
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Appendix 2 Confidential Health Screening Questionnaire

New Operator: Repeat: Fork Lift Truck: MEWP:

YES / NO YES / NO YES / NO YES / NO

SECTION 1 – To be completed by Employee:

PERSONAL DETAILS

SURNAME: FORENAME(S):

TITLE: MR / MRS / MISS / MS / OTHER (please specify):

GENDER: MALE / FEMALE DATE OF BIRTH: / /

ADDRESS:

TELEPHONE:

COMPANY DETAILS

COMPANY:

DEPARTMENT:

JOB TITLE:

SECTION 2 - Medical History (to be completed by Employee)

We would like to know about current or historical medical issues you may have which could
affect your ability to work in the workplace environment as a driver of Fork Lift Trucks or
MEWP:
HAVE YOU EVER SUFFERED FROM ANY OF
YES NO PROVIDE DETAILS
THE FOLLOWING:
Fits, epilepsy, fainting, dizziness, blackouts, light-
headedness, vertigo

Disorder of the nervous system

Recurrent or persistent headaches

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Psychiatric illness or trouble with nerves, stress,

depression or anxiety early waking or unpleasant
dreams, difficulty sleeping, or any difficulties
concentrating
Disease of the heart or circulation including angina,
palpitation, chest pain, swollen ankles, leg cramps
when walking

High blood pressure

Asthma, Bronchitis or other chest disease such as

persistent cough or breathlessness
Stomach or duodenal ulcer, or indigestion, heart burn
or stomach pains

Bowel disorder or problems

Kidney or bladder disorder, pain, blood or frequency

in passing urine

Diabetes

Hernia or rupture

Disorder of the back, neck, shoulder, joints or

muscles

Disorder affecting the hands, arms or feet

Skin Disease or Dermatitis

Ear disease or deafness, earache or runny ears,

ringing in the ears

Eye disorders including colour blindness

Hepatitis or jaundice.

Have you ever had a serious injury including broken

bones?

Have you ever had an operation?

Have you visited your GP in the past 12 months for

any of the above?

Have you ever had hospital tests or treatment?

HAVE YOU EVER SUFFERED FROM ANY OF

YES NO PROVIDE DETAILS
THE FOLLOWING:
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Are you taking any drugs or medicines? If yes, please

list.

Have you left a job for medical reasons?

Have you ever had an illness caused by your work?

Have you had a spell of absence of at least two

weeks due to illness in the past two years?
Do you suffer from other health problems or
disability which is relevant to your job or proposed
job?

SECTION 3:

ALCOHOL:

DO YOU DRINK ALCOHOL? YES / NO

IF YES, HOW MANY DAYS PER

WEEK?
IF YES, HOW MANY UNITS PER
WEEK?
IN THE LAST YEAR, HAS YOUR INCREASED / DECREASED / REMAINED THE
ALCOHOL INTAKE: SAME

SMOKING:

DO YOU SMOKE? YES / NO

IF YES, HOW MANY CIGARETTES

PER WEEK?
IF YES, HOW MANY CIGARS PER
WEEK?
IF YES, HOW MUCH TOBACCO
PER WEEK? GRAMS OR OUNCES

DRUGS:

DO YOU USE RECREATIONAL

YES / NO
DRUGS?

The information in this questionnaire will be retained by HR and used as a record of

information about your health at the time of the health assessment.

I consent to a further health assessment or examination if necessary by a doctor.

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AZN Procedure
Rev. Date: 25-Dec-2018
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Please sign below when you have read, understood and accepted this declaration.

FAILURE TO SIGN THIS DECLARATION WILL INVALIDATE THIS QUESTIONNAIRE

Signature……………………………………………………… Date………………………………

Upon completion, please return the form to the Occupational Health Advisor.