Safety protocols for operating forklifts on ramps and slopes

Risks increase significantly when forklifts drive on ramps and slopes. Health and safety managers, warehouse managers, and forklift operators must be especially vigilant when considering these inclined surfaces.

Understanding the risks

Before diving into the safety protocols, it’s important to understand the unique risks that ramps and slopes pose. The most significant risk when operating a forklift on a ramp or slope is tipping. The shift in the centre of gravity when the forklift is on an incline can cause it to tip over, especially if the load is not properly balanced or if the forklift changes speed or direction too quickly.

On slopes, the load could shift or slide if it is not properly secured; securing the load could be as simple as a strop over the top. A load that moves can cause the forklift to become unbalanced, increasing the risk of a tip-over or load spillage.

The effectiveness of a forklift’s brakes can be compromised on inclines, making it more difficult to stop or control the vehicle when moving downhill. Operators travel in reverse down inclines, and this means that the braking wheels (the front wheels) are following the steering wheels, and the centre of gravity is moved towards the steering wheels. This adds up to less braking power and more likelihood of a wheel lockup or skid.

Some inclines can obscure the operator’s view, making it harder to see obstacles, other workers, or hazards. This limited visibility increases the risk of collisions.

Safety protocols for operating forklifts on ramps and slopes

Know your equipment and load limits

Before attempting to operate a forklift on any incline, it’s essential to understand its capabilities and limitations. This includes:

• Load capacity: Always check that the load is within the forklift’s capacity, and bear in mind that a slope might mean you can lift less without tipping.
• Stability pyramid: Be aware of the forklift’s stability pyramid (the triangular area between the front wheels and the centre of the rear axle, rising up to a point above the forklift). Maintaining the centre of gravity within this pyramid is crucial for preventing tip-overs.

Additionally, ensure that the load is evenly distributed and secured. The load should always be tilted back so it rests on the backrest.

Approach ramps and slopes with caution

When approaching a ramp or slope:

• Assess the incline: Determine the slope’s angle and whether it is within the operational limits of the forklift. If the incline is too steep, do not attempt to drive the forklift on it.
• Check the surface conditions: Ensure that the ramp or slope is clear of debris, moisture, or other hazards that could reduce traction or cause slippage.

Proper load orientation

• Driving uphill loaded: When driving uphill, always keep the load facing uphill. This helps prevent the load from tipping forward and ensures that the centre of gravity remains within the stability triangle. You may need to use a spotter to help you if you can’t see ahead of the forklift. Spotter training is available here.
• Driving downhill loaded: When driving downhill, the load should also face uphill. This means the operator will be driving the forklift in reverse. This orientation helps maintain control and prevents the load from shifting dangerously as it remains resting against the backrest.
• Driving unloaded: when carrying no load, the forks can be pointing downhill.

Controlled speed and smooth operation

• Slow and steady: Always drive slowly and steadily when ascending or descending a slope. Avoid sudden acceleration, braking, or sharp turns, as these actions can destabilise the forklift.
• Smooth braking: Apply the brakes gently and evenly. Abrupt braking on a slope can cause the forklift to skid or tip. If the forklift begins to skid, avoid overcorrecting, which could lead to loss of control.

Avoid turning on ramps and slopes

Turning on a ramp or slope can significantly increase the risk of tipping. Always approach ramps and slopes head-on and avoid making turns while on the incline. If a turn is necessary, complete it before or after the slope, when the forklift is on level ground.

Use ramps designed for forklift use

Ensure that ramps used by forklifts are designed for this purpose and meet the required specifications:

• Proper incline: Ramps should have a safe gradient, typically not exceeding 10% (a 1-metre rise for every 10 metres horizontally) for most forklifts.
• Non-slip surface: Ramps should have a non-slip surface to provide adequate traction, especially in wet or icy conditions.
• Edge protection: Ramps should have side barriers or curbs to prevent the forklift from accidentally driving off the edge.

Maintain clear communication and visibility

• Spotters and signals: Use a spotter to guide the forklift operator when visibility is limited, especially on busy sites or when navigating complex inclines. Ensure that standardised hand signals or radio communication are used to relay instructions clearly. Spotter training is advisable.
• Lighting: Ensure that the forklift is equipped with proper lighting, especially in poorly lit areas or during night operations. This helps the operator see the path ahead and any potential hazards.

Training and regular refresher courses

All forklift operators should be thoroughly trained in operating forklifts on ramps and slopes as part of their forklift licence or forklift operator’s certificate. This training should include:

• Understanding the specific risks associated with inclines
• Proper load handling techniques on slopes
• Emergency procedures in case of a tip-over or other incident

Regular refresher courses can help operators stay sharp and up-to-date on best practices, ensuring they are always prepared to handle the challenges of working on slopes.