FIRE SAFETY GUIDE

FOR FORKLIFT TRUCK

OPERATIONS

This document is designed to assist NFU Mutual

customers in managing the fire risks associated
with forklift trucks
 INTRODUCTION
Many fires are attributed to forklift trucks. Their use creates a range of fire hazards associated
with the trucks, associated chargers, batteries, and the environment in which they operate with
significant potential ignition sources including:
1. Electrical short circuiting
2. Sparks from electrical equipment
3. Exhaust systems
4. Heat emissions from engine components
5. Vehicles powered by flammable fuels which introduce the risk of leakage of diesel or LPG

Forklift trucks and chargers are often stored in warehouse environments with heavy fire
loads that can aid rapid fire growth.
Careless use of forklift trucks may cause impact damage to passive fire protection measures
such as fire doors/shutters, or the metal skins of composite panels which may contain a
combustible insulation core. Impact damage may also be caused to active fire protection
measures such as fire alarm systems, or sprinkler heads which could lead to escape of water
and associated damage.
The following guidance covers some of the main fire safety considerations for fork-lift
trucks and is also relevant to other mobile plant such as powered pallet trucks, sweepers,
mobile elevated work platforms, and other specialist lifting equipment used in business
premises. Automated systems and equipment are outside the scope of this guidance.

FIRE RISK ASSESSMENT

A fire risk assessment to be undertaken to competent person and any necessary control
identify and evaluate the potential for a measures carried out to reduce the risk and
serious fire at your premises. Responsibility effects of fire.
for the fire risk assessment rests with
The selection of the correct type of forklift
occupiers and owners of business premises
truck for the environment is essential to
and should include the construction of the
ensure the fire risk is mitigated as far as
premises, working practices within, fire
possible.
inception hazards, likely fire spread potential
and the suitability and standard of fire We recommend the local Fire & Rescue
protections including your fire alarm, fire Service are invited to visit the premises to
doors, emergency lighting, escape signage assess the water sources and familiarise
and fire extinguishing appliances. The risk themselves with the layout and the location
assessment to be carried out by a suitably of the premises.

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ELECTRICAL INSTALLATION
Electrical testing of the fixed installation All fixed wiring systems to machines to be
to be undertaken in accordance with the connected to an independent isolator or
current edition of BS7671 Requirements junction box fitted with an independent
for Electrical Installations. IET Wiring Residual Circuit Device (RCD) of suitable
Regulations by a member of National fuse rating.
Inspection Council for Electrical Installation
Consider annual thermographic inspections,
Contractors (NIC EIC), who is regulated for
by a competent person, of the machinery and
commercial installations. The frequency
fixed wiring systems with any remedial action
of electrical inspection of the premises to
identified to be rectified without delay.
be every 3 years in accordance with the
recommendations of BS 7671 or Electricity Further guidance can be found in the Fire
at Work Regulations, or more frequently if Safety Guide for Electrical Installations
advised by your electrician and any remedial
action to be corrected without delay.

AUTOMATIC FIRE SUPPRESSION SYSTEMS

Consider fitting a direct, low pressure relay switch. If lithium-ion batteries are
application, fixed fire suppression system present, it should be ensured that the
to the machinery and electrical switch extinguishment medium is appropriate.
cabinets. Any such system to comply
Further guidance can be found at https://
with LPS1666: Requirements and test
www.redbooklive.com/download/pdf/
procedures for the LPCB approval of
LPS1666-Issue-Direct-Low-Pressure-
direct low pressure (DLP) application
Application-Fire-Suppression-System-
fixed fire suppression systems and
Standard.pdf
upon activation isolate the power supply
and activate the fire alarm system via a

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 FIRE DETECTION
Consider installation of, or upgrading existing and maintenance in accordance with the
system, to an automatic fire alarm system installer’s recommendations to be in place
conforming to BS5839: Fire Detection and and documented.
Alarm Systems for Buildings: Part 1:
Early smoke detection and monitoring for
Code of Practice for Design installation,
explosive and/or toxic gases produced by
commissioning and maintenance of systems
battery chargers to be considered, via the use
in non-domestic premises, specifically
of aspirating smoke detectors (ASD), in close
designed to provide early warning fire
proximity to the charger units. Activation of
detection. The fire alarm system should also
the ASD to isolate the power supply to the
give a warning remotely to nominated staff
chargers and raise an alarm through the main
via an approved alarm receiving centre. A
fire alarm system.
programme of testing, servicing, checking

PORTABLE FIRE EXTINGUISHERS

Suitable portable fire extinguishing and maintenance to be undertaken and
appliances to be located throughout the recorded by an approved supplier. Staff
premises, with at least one dry powder should be provided with instruction and
appliance located within the vicinity of any training in the correct use of extinguishers.
charging equipment. Regular inspection

BUSINESS CONTINUITY
Even a small fire can have a disproportionate emergency plan and carrying out a
effect on a business if it occurs in a business impact analysis which can
critical piece of equipment/machinery. form the basis of a continuity plan to be
All businesses to therefore take steps to put into place in the event of a loss.
ensure the continued smooth running
of the business by making a suitable

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GENERAL GUIDANCE
1. Lift trucks to be inspected regularly and 5. Protective covers and guards on the
subjected to preventive maintenance in equipment to remain in place at all times
strict accordance with the manufacturers’ during the operation of the unit, for
schedules. Lift trucks to be kept free of example to prevent the build-up of hot
accumulations of oil, grease & easily material on exhaust pipes.
ignitable materials such as fluff and dust.
6. Adequate gangways and aisles to be
Non-combustible agents to be used for
maintained to facilitate safe truck
cleaning.
operations.
2. A competent person to make a daily
7. Particular attention to be given to
start-up inspection to check for oil, fuel
avoiding impact with fire doors,
and hydraulic fluid leaks and the integrity
compartment walls, racking, protective
of fuel lines. Checks to also be made to
coatings on structural steel, and other
ensure battery connections and protective
key elements of passive fire protection.
covers are in place following charging,
Impact with composite insulated panels
and safety devices are operational. A
to be avoided, particularly if exposure to
visual inspection of the charging leads to
combustible insulated core materials is
be completed to ensure the connections
likely. The driving of unloaded forklift
and cable insulation are undamaged. All
trucks with elevated forks to be prevented
reported defects to be corrected before
and impact protection, such as bollards or
the equipment is used and records of the
barriers, may be required near vulnerable
inspections to be retained.
access openings, plant or equipment.
3. The use of lift trucks to be restricted to
8. The potential fire hazards of the materials
personnel trained in their operation by
being transported to be considered. For
an HSE accredited training body in
example, drums of flammable liquid to
accordance with the HSE Approved Code
only be handled by lift trucks that are
of Practice & Guidance “Rider Operated
adapted for use in hazardous atmospheres.
Lift Trucks – Operator Training & Safe
Use” (L117) and HSG6 Safety in working 9. When not in use forklift trucks to be
with lift trucks. kept in a designated area, preferably a
detached building separated from any
4. Driving performance to be monitored
manufacturing or storage areas.
and a record of each driver’s training,
refresher training, accidents and near 10. Keys to the vehicles to be removed when
incidents maintained, with the objective of not in use to prevent unauthorised use.
preventing accidents and damage arising
from careless driving

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 LEAD–ACID BATTERY POWERED TRUCKS
1. To minimise the risk of fire, battery 7. Over-current and over-charge protection
charging to be undertaken in a separate to be provided for all battery chargers
building of non-combustible construction, and electrical connecting leads to be kept
and only used for this purpose. as short as possible to reduce the risk of
Alternatively, an enclosed charging area accidental damage and unnecessary wear.
separated by fire-resisting construction, Leads and connections to be maintained in
including doors, and providing at least good condition and inspected frequently.
60 minutes fire resistance to be installed.
8. Portable chargers (i.e. those with a
Care to be taken to ensure that piped
13-amp plug) are more susceptible to
services, ducts and cables passing through
damage and are to be subject to regular
the walls, floors and ceilings of the
visual inspection and formally inspected
compartment are suitably fire stopped to
periodically, Portable Appliance Test
the same standard as the fire rating of the
(PAT), at least annually.
charging area walls and ceiling.
9. Hydrogen can be produced during
2. Where the above is impractical, charging
charging, particularly under boost
to be confined to a designated area (or
charging and where overcharging
areas) which are kept entirely clear of
occurs, and this can present an explosion
combustible materials. A clearance of at
hazard. Manufacturer’s guidance to be
least 1.5m to be maintained between the
consulted to determine the appropriate
charging unit and truck and any proximate
ventilation requirements for the batteries
adjacent combustible materials/stock.
being used. Battery charging areas are
This area is to be defined by barrier rails
to be included in the fire and explosion
of adequate strength and/or by prominent
assessment conducted in accordance with
floor markings.
the Dangerous Substances and Explosive
3. Battery chargers to be supported on a Atmospheres Regulations (DSEAR).
non-combustible stand approximately
10. When charging is undertaken in enclosed
0.5m above a concrete floor or other non-
areas, such as in buildings, adequate
combustible surface in order to prevent
natural or mechanical ventilation to be
water damage. Alternatively, they could
provided: ATEX rated motors are likely
be securely wall-mounted against a non-
to be required for mechanical ventilators.
combustible structure.
Where this cannot be achieved, hydrogen
4. Battery chargers are not to be mounted gas monitoring equipment to be installed,
on walls constructed with combustible together with suitable interlocks to isolate
insulated composite panels, and vehicle the charging devices automatically in
battery charging is not be undertaken the event of gas accumulation beyond
within 3 metres of such panels unless: safe limits. Advice to be obtained from a
specialist ventilation contractor.
5. Charger units are mounted on metal
stands or brackets, at least 250 mm from 11. All personnel authorised to change
the panels, which are not fixed directly to or charge batteries to be adequately
the panels; and trained and equipped and all tools used
in the installation and maintenance of
6. The panels behind the charger units are
batteries to be suitable for the purpose, e.g.
protected by non-combustible material
electrically insulated and acid resistant.
such as metal checker plate extending at
least 1m around the chargers.

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12. Suitable handling equipment, such as operators (such as bracelets and neck
an overhead hoist, to be provided for chains) to be removed before working on a
the handling of batteries. Uncovered battery to prevent short-circuiting.
batteries to be covered with a suitable
13. Hot work and the use of open flames to be
non-conducting material to prevent the
prohibited in battery charging areas.
hoist chain from shorting terminals or
connections. Metallic items worn by

LITHIUM-ION BATTERY POWERED TRUCKS

1. If a lithium-ion cell reaches high 5. The equipment to be subject to a full
temperatures or is subject to over- maintenance contract with competent
charging, the structure of the metal oxides contractors.
can be damaged. This damage is highly
6. Only batteries approved by the equipment
exothermic, resulting in high energy
manufacturer to be used.
release, producing oxygen and causing
the electrolyte fluid to boil. This produces 7. Ensure the equipment is suitable for cold/
highly flammable gas. If the temperature damp environments where applicable e.g.
increases to the flash point, thermal within cold or freezer stores.
runaway (the process by which each cell
8. Batteries to be checked and maintained
bursts on ignition to ignite the next cell)
regularly in accordance with
starts. Extinguishing the fire is difficult
manufacturers’ instructions.
because lithium-ion cells produce oxygen
by themselves. 9. Excessive vibration of the batteries could
increase the risk of fire. Ensure batteries
2. Owing to the risks associated with such
are appropriately secured and vibration is
batteries additional consideration to be
kept to a minimum.
addressed within the fire risk assessment.
Consequently, the following control 10. Any spare batteries to be kept in a
measures to be adopted in connection with purpose-built cabinet providing at least
lithium-ion batteries: 60 minutes fire resistance.
11. Any damaged batteries to be immediately
Low level fire detection to be provided in taken out of the building and removed to a
the vicinity of any charging stations, as distance of at least 10m from any buildings
recommended by the fire alarm design or plant.
company.
12. During charging, and as much as possible
3. Purpose designed fire extinguishers for when they are not in use, lift trucks to
use on lithium-ion battery fires to be be contained in a fire rated container
provided and fire wardens and staff to or cabinet with at least 90 minutes fire
be trained in their safe use e.g. F500 EA resistance, and sited as recommended by
approved extinguishers. the supplier.
4. No charging to be undertaken when the
premises are unattended.

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 DIESEL
Diesel fuel to be contained in drums or operations. Smoking and open flames to be
proprietary oil tanks located in the open, prohibited in re-fuelling areas. Consideration
away from buildings, and suitably bunded to be given to how any fuel spillage would be
to contain leaks or spillages. Spill kits to be able to be contained and cleared.
retained for emergency events. Re-fuelling
Particular care to be taken to ensure that
to be undertaken in the open and in a
the exhaust system, engine bay and other
suitably designated location. Diesel fuel to be
potentially hot surfaces to be kept entirely
dispensed from approved dispensing pumps
free from combustible items including loose
but if emergency re-fuelling is necessary,
waste material which may be drawn into
approved safety containers may be used.
the engine bay. Floors to, therefore, be kept
Overfilling and spillage to be avoided. Fork-
as clean as possible. Where possible, spark
lift trucks to be switched off and the operator
arresters to be fitted to exhaust outlets.
not to be on or in the vehicle during filling

LPG POWERED TRUCKS

1. LPG cylinder refilling to only be undertaken a separate, designated, appropriately
by trained personnel who are aware of the ventilated building to be used and LPG
fire hazards. to be stored away from other highly
flammable or oxidising agents. Prominent
2. The valve on the LPG cylinder to be closed
warning signs should be displayed at LPG
when the truck is not in use.
storage areas.
3. The total quantity of LPG on the premises
Further guidance can be found in the
is to be kept to a minimum.
document ‘RC8 Storage, Use and Handling
4. Where the LPG supply is in the form of Of Common Industrial Gases in Cylinders’
a bulk tank for the refilling of cylinders, available on the RISCAuthority website,
specialist advice concerning its installation, or from Liquid Gas UK – see https://www.
location and safe operation to be obtained liquidgasuk.org/.
from the installer.
For further information refer to Risk
5. Cylinders to be stored in a way and management programme for the safe use and
location outside the building that does storage of LPG Cylinders
not compromise fire safety. If storage of
LPG cylinders in the open is not possible,

FORKLIFT TRUCKS IN HAZARDOUS ENVIRONMENTS

In accordance with The Dangerous marked. Equipment used in potentially
Substances and Explosive Atmospheres explosive atmospheres, such as fork-lift
Regulations (DSEAR), the hazardous areas trucks, to comply with the recommendations
in all workplaces to be classified into zones, of HS(G)113 - Lift Trucks in Potentially
based on the frequency and duration of Flammable Atmospheres. Only explosion
an explosive atmosphere, and the zones proof fork-lift trucks may be used in such
checked by a competent person and properly hazardous areas.

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 This guidance is provided for general information purposes only. This guidance does not constitute,
nor should it be construed as constituting, legal or other professional advice. No warranty, whether
express or implied, is given in relation to this guidance. We shall not be liable for any technical,
typographical or other errors or omissions within this guidance and shall not be responsible for
any action or decision taken as a result of you or others using the guidance. You should consult a
professional adviser for legal or other advice where appropriate. We assume no responsibility for
the availability or content of any linked websites. The inclusion of any link should not be taken as
endorsement of any kind by us of the linked website or any association with its owners.

This guidance is provided on the strict understanding that you accept, without limitation, that
you retain sole responsibility for compliance with health and safety legislation and regulations, all
other legislation and any warranties/conditions attached to your insurance policies. We have not
conducted any site visits as part of producing this guidance and we have not, and are not, providing
any guidance in relation to your specific set up.

nfumutual.co.uk/rms

NFU Mutual Risk Management Services Limited (No. 3350057). Registered in England. Registered Office: Tiddington Road,
Stratford upon Avon, Warwickshire CV37 7BJ. A member of the NFU Mutual group of companies.
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