Safety Protocols for Operating Material Handling Equipment
- Carey
- Sep 12
- 6 min read
A practical guide for pallet trucks, stackers and everyday manual handling kit
Keeping people safe while moving goods isn’t complicated, but it does require clear rules, competent operators and equipment that’s fit for purpose. This guide answers common questions we hear from customers using pallet trucks, pedestrian stackers and other manual handling equipment, and points to sensible steps you can take today.
Key takeaways
Train and authorise operators; match the equipment to the task and the environment.
Check equipment before use and keep it maintained; defective kit must be removed from service.
Understand when lifting laws apply (LOLER) versus general work-equipment duties (PUWER).
Plan safe routes that separate pedestrians and equipment; manage speed, visibility and surfaces.
Use good manual handling technique - push where possible, keep loads stable, and respect rated capacities.
UK Law
PUWER (Provision and Use of Work Equipment Regulations 1998)
Covers all work equipment. Employers must ensure equipment is suitable, maintained, inspected, and that users are trained and competent. This applies to hand pallet trucks, powered pallet trucks, pedestrian stackers and similar kit.
LOLER (Lifting Operations and Lifting Equipment Regulations 1998)
Applies to lifting equipment and operations. It sets rules for safe planning of lifts and independent “thorough examination” at set intervals. Pedestrian stackers and high-lift pallet trucks normally fall under LOLER; simple hand pallet trucks that only raise a load a small distance typically do not.
Requires you to avoid hazardous manual handling where reasonably practicable and to assess and reduce risk when handling can’t be avoided. It underpins training, task design and technique.
HSE’s practical guide on separating people and vehicles, site layouts, traffic routes and control measures - vital wherever pallet trucks and stackers share space with pedestrians.
Pre-use checks: quick routine that prevents incidents
Before each shift, operators should carry out simple visual and functional checks and tag out any defective kit:
Identification & capacity: Rating plate legible; attachments (if any) match the truck; maximum capacity known for the actual lift height.
Structure: Forks straight and crack-free; mast and chains undamaged; backrest (if fitted) secure.
Hydraulics: No leaks; smooth lifting/lowering; holds a load without drift.
Controls & brakes (powered units): Drive, lift/lower, horn, emergency stop and parking brake work correctly.
Wheels/rollers & steering: Free from flat spots; secure; steer smoothly.
Battery/charger (electric): Charge level OK; cables sound; charging area ventilated and marked.
Environment: Floor condition, ramps, thresholds and lighting suitable for the task.
These checks support PUWER’s requirement to keep equipment maintained and safe.
Competence, training and authorisation
Only trained and authorised staff should operate pallet trucks and stackers. Training should cover the specific model, the loads you handle, the site layout and your local rules. Record who is authorised and refresh training when tasks or equipment change. This is part of your duty under PUWER.
Looking to standardise on the right kit? Browse our range to match equipment to operator capability and environment - manual, semi-electric and fully powered options are available.
Safe operation: hand pallet trucks (HPTs)
Plan the route. Keep to designated walkways and marked travel paths; avoid steep slopes and rough or contaminated surfaces.
Push rather than pull where possible to reduce strain and maintain better visibility/control.
Keep the load low and stable. Check pallets are sound; band or wrap if needed; don’t stack so high you lose forward view.
Speed & spacing. Walk at a controlled pace and keep clear of pedestrians’ heels and fixed objects.
Ramps and thresholds. Use only within manufacturer limits; maintain two-hand control and don’t rush kerbs or dock plates.
Hands and feet clear. Never place feet under forks; watch for pinch points at thresholds and lift tables.
Upgrade option: If gradients, long routes or heavier loads are part of the job, consider a powered pallet truck to reduce manual handling risk and improve control.
Safe operation: pedestrian stackers & high-lift trucks
LOLER applies. Plan lifting operations, keep loads within the rated capacity at the intended lift height, and ensure thorough examinations.
Stability first. Keep the load low when travelling; raise only to stack; avoid side slopes; maintain clear overhead space.
Visibility. Travel in the direction with best view; use a banksman in tight aisles if needed.
No riders. Pedestrian units aren’t for carrying people.
Stop, then lift. Don’t raise/lower while turning or travelling unless the manufacturer explicitly allows it.
Not sure which stacker suits your aisle widths and lift heights? See our Stackers for compact, semi-electric and fully electric models designed for narrow spaces.
Loads and pallets: do the basics well
Respect the rating plate. Capacity reduces as lift height increases or the load centre shifts outward - check the chart, not just the headline SWL.
Check the pallet. Damaged or unsuitable pallets can fail suddenly; use correctly rated pallets and store them properly.
Secure awkward loads. Use stretch-wrap, bands, corner boards or containers so the centre of gravity stays centred between the forks.
Inspections, maintenance and “thorough examination”
PUWER maintenance: All work equipment must be maintained in a safe condition with appropriate inspections and records.
LOLER thorough examination:
Every 12 months for lifting equipment not used to lift people;
Every 6 months for lifting equipment used to lift people and for all lifting accessories;
Or as specified by a written examination scheme set by a competent person. Keep reports available.
Do HPTs need LOLER? Generally, hand pallet trucks that raise loads less than 300 mm are not considered lifting equipment under LOLER and are instead managed under PUWER (they still require maintenance and inspection). High-lift pallet trucks and stackers are typically within LOLER.
Need compliant, low-maintenance options? Our Manual Pallet Trucks, Powered Pallet Trucks and Stackers are selected for reliability and service support—ask about service plans aligned to PUWER/LOLER duties.
Site rules that prevent most incidents
Separate people and equipment. Marked walkways, one-way systems, mirrors at blind spots, and protected crossings.
Good housekeeping. Clean, level floors with adequate lighting; fix potholes, lips and dock edges; control spills promptly.
Speed control. Set and enforce sensible speed limits for powered units; require slow travel in congested areas.
Loading bays and vehicles. Use rated dock plates/bridges; chock when required; agree hand signals; never overload tail lifts.
PPE. Safety footwear is a must; add hi-vis and gloves based on your risk assessment.
Charging, parking and storage
Parking: Lower forks to the floor, neutral/park, and isolate power. Keep forks tucked in to prevent trip hazards.
Charging: Ventilated, signed area; correct charger for the battery; cables kept tidy; no smoking or ignition sources.
Storage: Keep equipment dry and away from impacts; store pallets properly to prevent collapse.
Frequently asked questions
Do I need training to use a hand pallet truck? Yes, operators must be competent and authorised. Even for simple HPTs, employers have a PUWER duty to provide training and safe systems of work.
What inspections do we need to document? Record your pre-use checks, in-service inspections and maintenance (PUWER). For stackers and other lifting equipment, keep LOLER thorough examination reports at the required intervals (or per your examination scheme).
Is a LOLER certificate required for a hand pallet truck? Usually no for standard HPTs that only raise a load a small distance (<300 mm). They’re managed under PUWER. High-lift HPTs and stackers generally are within LOLER. If in doubt, ask us or your competent examiner.
How do we reduce manual handling strain with pallet trucks?Plan routes, keep loads within rated capacity, and push rather than pull where practicable. Consider powered options for long distances, slopes or heavier loads.
How often is a “thorough examination” needed for our stackers?Typically 12 months; 6 months if lifting people or for any lifting accessories—unless your written scheme specifies otherwise.
Safer choices with Nationwide Handling
Whether you’re upgrading from hand pallet trucks to powered units, equipping a new line with pedestrian stackers, or standardising site-wide, we can help you choose compliant, easy-to-use equipment:
Manual Pallet Trucks: Robust, low-maintenance models for everyday moves.
Powered Pallet Trucks: Reduce strain and improve control on ramps and long routes.
Stackers: Compact lifting for tight aisles and consistent pallet stacking.
All Products: Explore the full range and talk to our team about PUWER/LOLER-aligned servicing.
Train and authorise your operators; choose the right truck for the job; separate people and equipment; keep loads within rated limits; check equipment before use and maintain it. Manage pallet trucks under PUWER and apply LOLER to stackers/high-lift equipment, including independent thorough examinations at the correct intervals. If you need help selecting or servicing compliant kit, Nationwide Handling is ready to assist.
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