In brief
The Regulation on Work Equipment requires people to be lifted only with work equipment and accessories provided for that purpose; equipment not manufactured for lifting people can be used only in exceptional or emergency situations, with the necessary measures and under supervision. Lifting a person on forklift forks, on a pallet or in a cage made in the workshop therefore cannot be a routine working method. For work above racking, on ceilings and on lighting, equipment designed for lifting people is used, such as scissor lifts, vertical personnel lifts or order pickers.
Lifting people with a forklift: what does the legislation say?
When a box needs to be taken down from the top of the racking, a ceiling light changed or a sensor adjusted in a warehouse, the first solution that comes to mind is often the nearest forklift: someone climbs onto the pallet or the forks and the operator lifts them up. This practice seems to save time; but it is both contrary to the legislation and a known cause of serious fall accidents in warehouses.
Annex II of the Regulation on Health and Safety Requirements for the Use of Work Equipment contains clear provisions on this:
- Item 3.1.2: Only work equipment and accessories provided for this purpose are used to lift people.
- Item 3.1.2.1: Work equipment not manufactured for lifting people may be used to lift people only in exceptional or emergency situations, provided the necessary measures are taken and there is supervision.
- Item 3.1.2.2: While employees are on equipment designed to lift loads, there is always a person on duty at the controls; the people lifted have reliable means of communication and reliable means of evacuation in case of danger.
- Item 2.4: On mechanically moved mobile work equipment, people may not be carried unless the production standard or user manual explicitly states that people can be lifted, and not where safety cannot be fully ensured.
The conclusion from these provisions is clear: lifting people with a forklift cannot be “something we do every day”. The exception is for an exceptional or emergency situation; even then, measures, supervision, communication and a means of evacuation are essential.
A person on forklift forks: why is it so dangerous?
A forklift is designed to lift, carry and stack loads. No protection is provided for a person standing on the forks or the pallet. The main hazards when a person is lifted on forklift forks are:
| Hazard | How does it happen? |
|---|---|
| Falls | There are no guardrails, toe boards or handholds; the pallet slides or tips over |
| Crushing and trapping | A hand or arm gets between the mast, chains and pulleys; the person is trapped against a racking beam |
| Sudden movement | The operator accidentally touches the tilt or lowering lever; the forks drop due to a hydraulic leak |
| Lack of visibility | The operator cannot see what the person above is doing or where they are standing |
| Tipping over | A person reaching out at height shifts the centre of gravity; floor slopes and movement increase the risk |
| Striking objects | If the forklift is moved, the person above strikes the racking, ceiling or services |
None of these hazards can be controlled by “being careful”, because control lies not with the person above but with the operator below and the machine. Climbing onto a pallet is no safer than standing directly on the forks; the pallet can slide off the forks or break.
Forklift cages: does buying a cage solve the problem?
A cage attached to the forklift forks looks like a solution at first glance. But the wording of the regulation is clear: a cage does not turn the forklift itself into equipment designed for lifting people. A forklift cage can be considered only in the exceptional situations described above and if the following conditions are all met:
- The forklift’s user manual or manufacturer must permit such use and specify its conditions. If the manual prohibits it, the cage cannot be used.
- The cage must be a product made for this purpose, locking onto the forks, with guardrails, toe boards, a self-closing gate and a screen on the mast and chain side preventing hands and arms from reaching in. A cage welded together in the workshop does not meet these conditions.
- The load capacity and number of persons must be marked on the cage.
- The person in the cage must wear a safety harness attached to an anchor point.
- A trained operator must be at the controls at all times, and the forklift must not be driven while someone is in the cage.
- There must be reliable communication between the person above and the operator, and how the person will be lowered in the event of a breakdown must be planned in advance.
Personnel platforms and other safe options
Equipment designed for lifting people comes with guardrails, controls in the hands of the person on the platform, safety devices against falls and overloading, and an emergency lowering system. The options most often used in warehouses and workshops are:
| Equipment | Suitable work | Point to watch |
|---|---|---|
| Scissor lift | Ceilings, lighting, services maintenance, vertical access over wide areas | Level floor, rules on moving while elevated |
| Vertical mast personnel lift | Single-person access in narrow aisles, work between racks | Load capacity, outrigger legs |
| Order picker | Regular picking of products from racking | Operator’s safety harness, aisle guidance |
| Mobile scaffold tower | Long-duration work at a fixed point | Wheel brakes, guardrails, erection check |
| Platform stepladder | Short, low-level work | Top platform with guardrail, level floor |
A personnel platform is both safer and often more efficient than using a forklift at height, because the person operates the controls themselves and does not depend on an operator. Mobile elevating work platforms are subject to periodic inspection at least once a year under Annex III of the Regulation on Work Equipment. For selection and rules of use, see our article on scissor lifts and boom lifts, and for ladders, our article on portable ladder safety.
Planning work requiring access at height: decision steps
For every task where an employee needs to go up high, follow this sequence:
- Can it be done without going up? Solutions such as long-handled tools, replacing lighting with lowerable fittings and moving frequently used products to lower shelves are considered first.
- Is the work regular or exceptional? For regular work, equipment designed for lifting people is provided; if buying it is not possible, hiring is considered.
- Is there really an exceptional or emergency situation? For example, a leak in a fire sprinkler or a load about to fall. Even in this case, the time needed to obtain suitable equipment is assessed.
- If the exception is used, a written permit is issued. The risk assessment, the responsible person, the cage, harness, communication and rescue method to be used are written on the permit form. For the permit system, see our article on permit-to-work systems.
- Supervision is provided. Apart from the operator, there is a person watching the work and closing off the area.
- It is reviewed when the work is finished. If the same exception recurs, the work is now regarded as regular and the equipment decision is made again.
For the general rules of work at height, read our article on what is work at height.
Operator training and warehouse organisation
Preventing people from being lifted with forklifts is achieved not just by prohibition but by organisation. Annex II, item 2.1 of the regulation requires self-propelled work equipment to be used by employees who have received appropriate training in its safe use. In operator training, the rule “no people on the forks” should be explained clearly, and the operator should be given the authority to refuse such a request. On certificates and training, see our article on the forklift operator certificate, and for start-of-shift checks, our article on the forklift operator’s daily check.
Warehouse layout is also decisive: the racking layout is set up so that frequently used products are at a height that can be reached by hand, equipment is planned for work requiring access to high racking, and pedestrian and forklift traffic is separated. For these topics, see our articles on forklift and pedestrian traffic plans in warehouses and industrial racking safety.
In warehouses, logistics and production facilities in Bursa and the surrounding provinces, we carry out the risk assessment of work requiring access at height and the selection of suitable equipment within our OHS specialist service. For other risks in the sector, see our logistics and warehousing page.
Frequently Asked Questions
Is lifting people with a forklift completely prohibited?
It is prohibited as a routine working method. The regulation requires people to be lifted only with equipment provided for this purpose; equipment not manufactured for lifting people can be used only in exceptional or emergency situations, with measures taken and under supervision.
Is using a forklift cage legal?
A cage alone does not make the use legal. The forklift’s user manual must permit it, the cage must be manufactured for this purpose and use must be limited to an exceptional or emergency situation. For regular work, a personnel platform is used.
Is going up on a pallet with a forklift safer?
No. The pallet can slide off the forks, break or tip over; there are no guardrails or handholds. This practice is as dangerous as standing directly on the forks and is contrary to the legislation.
What should be used to reach products at the top of racking?
For regular access, equipment designed for lifting people is used, such as an order picker, a vertical mast personnel lift or a scissor lift. Moving frequently used products to lower shelves also reduces the need to go up high.
A certified specialist matched to your hazard class: site inspections, approved logbook, training plan, annual plan and report follow-up.
Bursa SİSTEMER OSGB Technical Team — written from the field experience of our OHS specialists and workplace physicians. Legal information is valid as of the publication/update date; contact us for an assessment specific to your business.