Forklift Safety: Barriers, Signage and Pedestrian Segregation Best Practice

Forklifts are involved in about 25% of all workplace transport accidents in the UK. The Health and Safety Executive (HSE) identifies pedestrian-forklift collisions as a primary cause of fatal workplace accidents — and the vast majority are preventable through proper physical segregation.

The Legal Framework

Forklift and workplace transport safety is governed by several pieces of legislation:

• Health and Safety at Work Act 1974 — General duty of care
• Provision and Use of Work Equipment Regulations (PUWER) 1998 — Forklifts as work equipment
• Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 — Lifting operations
• Workplace (Health, Safety and Welfare) Regulations 1992 — Traffic routes
• Management of Health and Safety at Work Regulations 1999 — Risk assessment

The Hierarchy of Control for Forklift Safety

HSE guidance recommends the following hierarchy:

1. Eliminate — Can the task be done without a forklift?
2. Substitute — Use automated conveying or a less dangerous alternative?
3. Engineer — Physical segregation (barriers, dedicated routes)
4. Administrative — Traffic management rules, permit systems, training
5. PPE — High-visibility vests for pedestrians

Physical Segregation Design

Dedicated Pedestrian Routes

Designate and physically separate pedestrian routes from forklift operating areas. Use continuous barrier systems, not just floor markings (which forklifts and pedestrians frequently cross).

Pedestrian corridor minimum width: 1.2m clear for single-direction, 1.8m for two-way pedestrian traffic.

Forklift Route Design Principles

• One-way systems where possible
• Minimum 1m clearance each side of forklift operating width
• No 90° blind junctions — use angled junctions and convex mirrors
• Separate loading bay access from pedestrian circulation
• No pedestrian routes passing through loading bays

Crossing Points

Where pedestrians must cross forklift routes:

• Clearly marked crossing zone (yellow/black floor marking)
• Speed humps to slow forklifts at crossing point
• Convex mirror on both approaches
• Warning signage for forklift drivers
• Pedestrian wait areas defined by barriers

Key Safety Signs for Forklift Areas

• Industrial trucks operating (ISO 11684)
• Maximum speed limit signs
• Pedestrian crossing ahead
• PPE requirements (hi-vis mandatory)
• No unauthorised pedestrian access to forklift areas

Racking Protection

Statistics show that most warehouses suffer regular low-speed forklift impacts on racking. Racking collapse incidents can be catastrophic. Protect at:

• All racking end uprights — end protection guards
• Row ends adjacent to main truck routes — heavy-duty racking protectors
• Ground-floor uprights in narrow aisle areas
• Racking near loading bay doors

FAQ

Do I need a formal traffic management plan for my warehouse?

If forklifts and pedestrians share the same space, HSE strongly expects a written workplace transport risk assessment and a traffic management plan. This is especially important for warehouses undergoing HSWA or local authority inspections.

What colour should forklift segregation barriers be?

Yellow is the standard colour for industrial hazard barriers in the UK, following BS 5378. High-visibility yellow/black striping on lower sections increases visibility at night and in low-light areas.

How often should forklift barriers be inspected?

Monthly visual inspections are recommended as a minimum. After any forklift impact, the affected barrier must be inspected immediately and replaced if deformed.