Forklift Safety: The CFTS Thorough Examination Explained

In the fast-paced world of logistics and warehousing, the forklift truck is an indispensable piece of equipment. However, their prevalence in the workplace unfortunately correlates with a concerning number of accidents. Recent revelations highlight that lift trucks are involved in a staggering 50 per cent more serious accidents than large goods vehicles (LGVs). This stark statistic underscores a critical need for enhanced safety protocols and a deeper understanding of the examination requirements for these powerful machines. While LGVs are subject to annual MOTs, forklifts, though not requiring an MOT, are mandated by law to undergo a Thorough Examination under the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) and the Provision and Use of Work Equipment Regulations 1998 (PUWER). Ensuring this examination is conducted to the highest possible standard is not merely a procedural step; it is paramount for the safety of all personnel and the integrity of operations within the industry.

Understanding the Risks: Forklift Accidents and HSE Statistics

The Health and Safety Executive (HSE) recently presented at the National Forklift Safety Conference, revealing that approximately 1,300 serious forklift accidents occur annually. This figure is a significant 50 per cent higher than the accident rate for LGVs. This disparity demands attention and a proactive approach from all stakeholders. For logistics and transport managers, the message is clear: the inspection and maintenance regime for your forklifts must be as rigorous, if not more so, than that for your road-going fleet. While many managers are well-versed in the inspection protocols for LGVs and Public Service Vehicles (PSVs), the often-overlooked thoroughness of forklift examinations can leave organisations vulnerable. A lack of clarity surrounding the frequency and documentation of these examinations can lead to confusion, potentially exposing employees to grave danger.

LOLER and PUWER: The Regulatory Framework

The legal backbone for forklift examinations lies within two key pieces of legislation: LOLER and PUWER.

• LOLER (Lifting Operations and Lifting Equipment Regulations 1998): These regulations specifically address the safety of lifting equipment, including forklifts. They stipulate that lifting equipment must be in a safe condition, fit for purpose, and regularly inspected by a competent person. The aim is to prevent injury from falling loads, crushing, or striking by the equipment.
• PUWER (Provision and Use of Work Equipment Regulations 1998): PUWER extends to all work equipment, including forklifts. It places a duty on employers to ensure that work equipment is suitable for the intended use, properly maintained, and inspected to ensure it remains safe. This covers aspects like the structural integrity of the forklift, its controls, and safety devices.

While these regulations are distinct, a comprehensive Thorough Examination effectively addresses both, ensuring a holistic approach to forklift safety.

Introducing CFTS: A Unified Standard for Forklift Examinations

Recognising the need for clarity, consistency, and a higher standard in forklift examinations, two leading authorities in the forklift industry, the British Industrial Truck Association (BITA) and the Fork Lift Truck Association (FLTA), joined forces to create Consolidated Fork Truck Services (CFTS) in 2004. CFTS established a voluntary, industry-led standard for Thorough Examinations that specifically covers the requirements of both LOLER and PUWER within a single, quality-assured process. This initiative was born from the understanding that the rigorous inspection of LGVs, with their well-defined MOT and safety check programmes, demonstrated the benefits of absolute clarity around standards, schedules, methods, and documentation.

The CFTS Thorough Examination: What Does it Entail?

The CFTS Thorough Examination is a comprehensive inspection designed to ensure that a forklift truck is safe to operate and compliant with all relevant legislation. Unlike ad-hoc inspections, the CFTS standard provides a structured and detailed checklist, covering a wide range of critical components. An accredited CFTS examiner will meticulously inspect:

Key Components Inspected by CFTS:

A thorough examination by a CFTS-accredited organisation will typically include, but is not limited to, the following checks:

The Advantages of CFTS Accreditation

Opting for a CFTS-accredited provider offers distinct advantages over non-accredited examinations:

• Unified Compliance: The CFTS Thorough Examination satisfies both LOLER and PUWER requirements in a single, streamlined process, simplifying compliance for businesses.
• Expertise: CFTS accredited engineers are specialists in forklift trucks, possessing in-depth knowledge of their specific safety requirements.
• On-the-Spot Repairs: A significant benefit is that if an accredited specialist identifies a fault during the examination, they can often rectify it immediately. This contrasts sharply with non-accredited inspections where a retest might be required after repairs, leading to extended downtime.
• Reduced Disruptions: The ability to fix issues concurrently with the examination minimises operational downtime, ensuring your fleet remains productive.
• Lower Maintenance Costs: Early detection and prompt repair of minor issues prevent them from escalating into more significant and costly problems.
• Quality Assurance: CFTS accredited providers adhere to a strict code of conduct and a standardised inspection methodology, ensuring a consistently high level of service.
• Traceability: Companies accredited to the CFTS scheme are easily identifiable by their distinctive 'kite' certification mark, providing an easily recognisable symbol of quality and compliance.

Why CFTS is Superior to HGV Inspections (in some ways)

While both LGVs and forklifts require rigorous safety checks, the CFTS Thorough Examination for forklifts offers a unique advantage: it consolidates the requirements of both LOLER and PUWER into one quality-assured process. For LGVs, a separate annual MOT and ongoing PUWER safety checks are necessary. The CFTS approach, when carried out by an experienced forklift specialist, means that any identified faults can be addressed and rectified during the same visit. This integrated approach not only simplifies the process but also potentially reduces the overall downtime and administrative burden compared to managing separate inspection regimes.

The CFTS Kite Mark: A Symbol of Trust

The CFTS 'kite' certification mark is more than just a logo; it represents a commitment to quality, safety, and regulatory compliance. Over 400 companies across the UK are accredited to the CFTS scheme. When you see this mark, you can be confident that the examination has been conducted according to a rigorous, industry-backed standard, ensuring your forklift fleet is safe and legally compliant. This accreditation also signifies that the provider is part of a programme that includes ongoing engineer and management training, as well as a mechanism to monitor and maintain inspection standards.

Frequently Asked Questions about Forklift Thorough Examinations

Q1: How often does a forklift need a Thorough Examination?
A1: While there isn't a fixed statutory interval for forklifts, the general recommendation, and often a requirement by insurers and internal safety policies, is for a Thorough Examination to be carried out at least every 12 months. However, the frequency should be determined by a risk assessment, taking into account the type of equipment, its usage, and the operating environment. For equipment used in particularly demanding conditions or carrying out critical lifts, more frequent examinations may be necessary.

Q2: Who is a 'competent person' to carry out a Thorough Examination?
A2: A competent person is someone with the necessary knowledge, experience, and qualifications to conduct the examination and identify any defects. For CFTS examinations, this means an engineer accredited by CFTS, who has undergone specific training and adheres to their methodology.

Q3: What happens if a forklift fails its Thorough Examination?
A3: If a forklift fails its Thorough Examination, it must not be used until the defects have been rectified and it has passed a subsequent examination. CFTS-accredited providers can often carry out these repairs on-site, minimising disruption.

Q4: Is a Thorough Examination the same as a pre-use check?
A4: No. A Thorough Examination is a comprehensive, in-depth inspection conducted periodically by a competent person. A pre-use check is a daily visual inspection carried out by the forklift operator before starting work to identify any obvious faults.

Q5: Why are forklift accidents so common?
A5: Common causes include operator error, inadequate training, poor maintenance, overloading, unsafe operating practices, and environmental factors like poor lighting or floor conditions. The CFTS Thorough Examination directly addresses the maintenance and safety aspect.

Conclusion: Prioritising Safety with CFTS

The statistics are undeniable: forklifts are involved in a disproportionately high number of serious accidents. The CFTS Thorough Examination offers a clear, compliant, and effective solution to mitigate these risks. By adopting the CFTS standard and engaging accredited providers, businesses can ensure their lift trucks are maintained to the highest safety benchmarks, protecting their workforce, their assets, and their operational continuity. It is time for the industry to embrace this unified approach, learn from the clarity provided by established standards, and significantly reduce the number of avoidable accidents involving these vital pieces of equipment.