Today’s warehouses and distribution centres are a hive of activity, bringing order and efficiency to the movement and storage of products across all phases of operations, from goods-in to dispatch. The use of forklift trucks remains an integral part of daily life but wherever you have material handling equipment and people interacting, there is always a real risk of a collision. As warehouse traffic continues to intensify with the growth of e-commerce and fast delivery requirements, finding the right balance between operational speed and safety has become more crucial than ever.
Why Managing Forklift Speed Is Crucial
Enforcing a site speed limit is an excellent way to improve site safety for both forklift drivers and workers, however, slowing down forklift truck movements should not have a negative impact on productivity. In the quest to find a happy medium, Transmon offers integrated Adaptive Speed Control systems that provide operators of warehouses, loading yards and production areas with the all-important sweet spot of optimising both safety and productivity for forklifts and material handling equipment. A balanced approach to forklift speed management delivers multiple operational advantages.
Enforcing a slower site speed not only enhances site safety, but it also supports sustainable practices and reduces forklift wear and tear. Slower forklifts mean lower emissions, reduced fuel usage, and a prolonged lifespan for the forklift’s tyres. Similar benefits can be achieved using our intelligent and programmable Auto Gear Change or Tyre Saver systems. These are designed to protect transmissions from abuse and burnouts by preventing the operator from ‘hot-shifting’ i.e. using the engine and transmission to slow and brake the truck when changing from forward to reverse (or vice versa) at high speed, rather than slowing and applying brakes.
How To Determine Safe Forklift Speed Limits
The process of establishing safe forklift speeds begins with understanding your specific environment. There are several critical factors to consider when conducting a site assessment, each playing a vital role in determining safe forklift speeds.
Workplace Environment
- Indoor vs. outdoor operations: Indoor operations usually require slower speeds due to confined spaces, while outdoor settings may allow for slightly higher limits depending on the available space, surface conditions, and other vehicles and infrastructure.
- Obstructions and visibility – areas with frequent obstacles, high pedestrian traffic, or limited visibility require lower speed limits.
Load characteristics
- Weight & stability of the load – heavy or unstable loads need slower speeds to avoid loss of control or tipping.
- Load height & width – higher loads impact the forklift’s centre of gravity, making it more unstable particularly around corners or on ramps.
- Load centre & weight overload – operating the forklift outside of the manufacturer’s specifications.
Type of Forklift
- Forklift model and capacity – larger forklifts operating well within their capacity can potentially operate safely at slightly higher speeds but may find movement more restrictive in tight spaces. In all cases, it’s vital that the type of forklift used for all warehouse, depot, or production operations, is suitable for the load and operational tasks it is required to handle.
- Braking & steering capabilities – forklifts with advanced braking or steering systems can handle higher speeds more safely but should be adjusted to specific operations settings. Intelligent systems may cover the steering angle or sensors on the steering column or axle can slow the truck down to prevent toppling and avoid braking or steering issues from developing.
- Using the forklift for its intended purpose – accidents occur when the wrong equipment is used for a task outside of its designed capabilities.
Operator skill & training
- Experienced and well-trained operators can handle speeds more safely, but ensuring that all operators are trained to adhere to set speed limits is essential.
- Consider additional speed restrictions during training periods or for less experienced operators.
Technology and Speed Control Systems
- Speed Limiters – some forklifts have built-in speed limiters that can restrict maximum speeds in certain areas.
- Proximity Sensors and Alarms – forklifts with proximity sensors can slow down or alert operators when near obstacles, improving safety in sensitive or high-risk areas such as those close to pedestrians or other automation equipment.
Traffic and Pedestrian Presence
- Pedestrian – areas with high footfall should enforce stricter speed limits.
- Vehicles – in facilities where multiple forklifts or other vehicles are operating simultaneously, lower speed limits can help prevent collisions.
Local Regulations and Industry Standards
- Regulatory bodies may set specific speed guidelines or recommendations, which serve as a good baseline.
- Industry standards from associations such as the UKMHA (UK Materials Handling Association) can also provide guidance on safe operational speeds.
Weather and Lighting Conditions
- Weather – in outdoor environments, factors like rain, snow, and wind may impact speed limits.
- Lighting – areas with low lighting call for reduced speeds to ensure safe navigation and reaction time.
Recommended Forklift Speed Limits
The Health and Safety Executive (HSE) recommendations for operator training and safe-use emphasise that forklift operators must always drive at safe speeds suitable for the specific working environment.
- Safe Speed Guidance: HSE advises employers to conduct risk assessments to determine safe speeds based on workplace factors and specifies that speeds should be such that forklifts can stop safely within their operational area.
- Pedestrian Safety: The HSE stresses that areas with pedestrian traffic should have clearly marked pedestrian walkways and that lower speeds are critical in zones where pedestrians and forklifts interact.
The UK Materials Handling Association (UKMHA) is a prominent UK organisation that brings together the two most respected trade associations in the forklift sector – BITA (British Industrial Truck Association) and the FLTA (Fork Lift Truck Association). The UKMHA suggests a typical speed limit of 5 mph (8 kph) as a safe upper limit within warehouses but recommends speeds as low as 3 mph (5 kph) in pedestrian-heavy or high-risk areas.
- Speed Reduction in Pedestrian Areas: To reduce the risk of accidents, a lower speed limit is recommended in areas with heavy foot traffic and at intersections.
- Zone-Specific Policies: Warehouses should be encouraged to implement speed controls that vary by zone. These can be managed with speed governors on forklifts, particularly where vehicles enter areas with narrow aisles or loading docks.
Typical Warehouse Speed Limits
| Zone | Speed Limit (mph) | Speed Limit (kph) |
|---|---|---|
| Main Aisles | 5–8 mph | 8–13 kph |
| High Pedestrian Areas | 3 mph or less | 5 kph |
| Crossings/Intersections | 2–3 mph | 3–5 kph |
| Storage/Racking Areas | 3–5 mph | 5–8 kph |
| Dock Areas | 3 mph or less | 5 kph |
| Curves and Turns | 3 mph or less | 5 kph |
Best Practices for Implementing Safe Forklift Speeds:
- Conduct thorough risk assessments to identify safe speeds based on pedestrian traffic, visibility, and floor conditions
- Use speed-limiting technology to cap speeds in specific zones
- Install clear signage and floor markings to indicate speed limits in different areas
- Provide regular operator training and refresher courses to reinforce zone-specific speed limits
- Monitor and audit forklift driver performance using telematic data to track speed compliance.
How To Manage Forklift Speeds
Our UK-manufactured Adaptive Speed Controller is a fully integrated system suitable for diesel, LPG and battery-powered forklift trucks. The system becomes activated in designated zones that require a slower speed. As soon as the forklift truck enters the zone, the speed limiter is activated, automatically slowing the truck to the required speed. Once it leaves the zone, a higher, safe speed can be resumed. This added layer of technology security eliminates the reliance on each driver to adhere to the site speed, further enhancing safety in the workplace.
Our Dynamic Speed Management solutions can take site safety to an even higher level. We provide a range of tailored anti-collision solutions incorporating technologies such as AI forklift cameras, wireless Proximity Warning Systems, and Building Protection Systems. These sensing technologies are readily available and are often used in combination with our Adaptive Speed Control systems to ensure truck speeds are dynamically managed in accordance with the changing working environments or level of hazard.
All our Adaptive Speed Control and Auto Gear Change systems can be integrated on new forklifts or retrofitted to existing trucks, offering maximum flexibility for your operational needs. Plus, its modular configuration allows the system to be tailored to specific requirements. As operators across warehouses, production facilities, depots, and loading yards strive to find a balance between safety and productivity, utilising smart technologies such as an Adaptive Speed Control system hits the mark for operational and sustainable benefits.
Summary
Maintaining safe forklift speed limits involves setting appropriate limits based on the specific warehouse layout and adhering to HSE and industry body guidelines. By conducting risk assessments, using technology for speed control, and ensuring clear signage, warehouse operators can comply with safety regulations and reduce the risk of forklift accidents.
Transmon Engineering has been designing and installing forklift and MHE speed and safety solutions for nearly 30 years. With expert knowledge and a clear understanding of the challenges forklift operators face, we provide innovative solutions that perfectly balance safety and productivity.
Contact our team today to start your journey. Speak to our friendly team by calling 0116 260 4200.