Thorough examination requirements for fork trucks are one of the most overlooked safety measures in warehouses and industrial facilities.
Most operators think they know what they’re doing. But here’s the reality – Between 35,000 and 62,000 forklift injuries occur annually because people don’t understand proper examination standards.
Here’s what’s even more shocking:
11% of all forklifts are involved in some kind of accident every single year. That’s roughly 1 in 10 machines causing problems.
The good news?
A solid thorough examination programme can prevent most of these accidents and keep operations running smoothly. But there’s a catch – not every examination is actually thorough.
Pretty cool, right?
Below, we’ll break down everything needed to understand fork truck thorough examination standards and why they matter so much.
Your roadmap to safety:
- Understanding Legal Requirements for Fork Truck Safety
- The Real Difference Between Maintenance and Thorough Examination
- Key Components Every Proper Inspection Must Cover
- Choosing the Right Competent Person for Your Needs
- Common Mistakes That Leave Your Operation Vulnerable
What Makes Thorough Examination So Critical?
Think of thorough examination like an MOT for cars.
It’s basically a mandatory safety check that ensures mechanical parts are in safe working order. Just like driving a car without a valid MOT is illegal, operating a forklift without a current thorough examination certificate is also against the law.
But here’s where it gets interesting…
Regular maintenance isn’t the same thing as thorough examination. A forklift could have been serviced yesterday, but if it doesn’t have a valid thorough examination report, it’s still illegal to operate.
Why?
Because thorough examination covers both LOLER 98 (Lifting Operations and Lifting Equipment Regulations) and PUWER 98 (Provision and Use of Work Equipment Regulations). That means checking everything from hydraulics and chains to brakes and steering systems.
It’s comprehensive. It’s detailed. And it’s required by law.
The Legal Framework You Need to Know
Here’s something most operators don’t realise…
Thorough examination requirements come with serious legal consequences. Getting caught operating without valid documentation can result in prosecution, insurance problems, and massive liability issues.
The regulations are pretty straightforward:
- LOLER 98 covers all lifting equipment components
- PUWER 98 addresses safety-related vehicular mechanics
- Health and Safety at Work Act 1974 sets the overall framework
Fork trucks need examination at least once every 12 months. But that’s just the baseline – many operations need more frequent checks depending on how hard the equipment works.
Want to know the best part?
Forklifts working 40+ hours weekly need examination every 6 months. Those exceeding 80 hours or operating in tough environments need checks every 4 months.
That means the harder the equipment works, the more often it needs checking. Makes sense, right?
Essential Components of a Proper Thorough Examination
Not every thorough examination is actually thorough.
Here’s the problem – lots of inspection services only check the lifting mechanism. They completely ignore critical safety components like brakes and tyres. This leaves operations unsafe and non-compliant.
A proper thorough examination must cover:
Lifting Equipment (LOLER Requirements)
- Mast and fork carriage systems
- Hydraulic cylinders and hoses
- Lift chains and attachments
- Load handling equipment
- Safety valves and controls
Driving Mechanisms (PUWER Requirements)
- Brake systems and performance
- Steering components and responsiveness
- Tyre condition and inflation
- Electrical systems and controls
- Visibility and lighting systems
But here’s what really matters…
The examination should take proper time. A 1.5-tonne electric forklift needs minimum 45 minutes for proper inspection. Anything less probably means corners were cut.
Choosing the Right Competent Person
This is where most operations mess up.
Just because someone offers thorough examination services doesn’t mean they’re qualified to do the job properly. The right examiner needs proper credentials and follows industry standards.
How to spot a genuine professional:
Look for CFTS accreditation. Consolidated Fork Truck Services maintains strict standards with nearly 600 member companies and over 2,500 registered competent persons across the UK and Ireland.
The CFTS “Kitemark” guarantees:
- Examination follows strict quality procedures
- Inspector has proper training and accreditation
- Report satisfies both LOLER and PUWER regulations
- Standards meet legal requirements
Without this accreditation, there’s no way to verify examination quality or legal compliance.
Pretty straightforward, right?
Common Examination Mistakes That Cost Big
Let’s be honest…
Many operators make critical errors that expose them to serious risks. These mistakes can invalidate insurance, lead to prosecution, and worst of all – put people in danger.
The Insurance Inspection Trap
Some insurance companies offer “free” inspections with policies. But here’s the catch – these aren’t necessarily thorough examinations. Always check for a document headed “Report of Thorough Examination.”
Frequency Confusion
Different forklifts need different examination intervals. Don’t assume annual checks work for every operation. High-usage equipment needs more frequent inspection.
Incomplete Coverage
Many services only check lifting components and ignore driving mechanisms. This leaves critical safety systems unchecked and operations non-compliant.
Setting Up Your Examination Programme
Want to streamline thorough examination requirements?
Smart operators establish comprehensive programmes that ensure all equipment gets examined at proper intervals.
Here’s how to build an effective system:
- Catalog all lifting equipment requiring examination
- Determine appropriate examination intervals for each unit
- Schedule examinations to minimize operational disruption
- Create solid record-keeping systems for compliance tracking
- Monitor examination due dates actively
The key is treating thorough examination as ongoing safety management, not just compliance paperwork.
Managing Examination Outcomes
Here’s something that gets overlooked…
What happens when thorough examination finds problems? A good examiner provides clear guidance on any defects found and their severity.
Critical defects need immediate action – equipment can’t be used until repairs are completed. Non-critical issues might allow continued operation with monitoring or scheduled maintenance.
Smart operators work with examination providers who can also handle necessary repairs. This speeds up the process and gets equipment back into service faster.
Cost-Effective Examination Strategies
Don’t let examination costs surprise you.
Thorough examination pricing varies significantly based on equipment type and complexity. Basic powered pallet trucks start around £55, while larger diesel forklifts can cost £165 or more.
But here’s the smart approach:
Multi-truck operations often negotiate package deals that reduce per-unit costs. Some providers offer maintenance packages that include examination services, creating predictable annual costs.
Remember – examination costs are tiny compared to the potential liability exposure of operating non-compliant equipment.
Pulling Everything Together
Thorough examination isn’t just about ticking compliance boxes – it’s about creating a safety culture that protects people and businesses.
The statistics are clear. With thousands of forklift incidents happening annually, proper examination programmes are essential risk management tools. They catch problems before they become accidents and ensure legal compliance.
Working with qualified CFTS-accredited examiners and following appropriate examination intervals creates solid protection for operations.
The investment in proper thorough examination pays off through reduced accident risk, maintained insurance coverage, and most importantly – peace of mind knowing equipment is safe to operate.
Take action today and set up examination programmes that meet both legal requirements and operational needs. People, businesses, and bottom lines will benefit from this essential safety investment.