A warehouse fleet is a mix of cycles. Some trucks are examined every 6 months, some every 12, and some equipment is not under LOLER at all but still has to be inspected under PUWER. The mistake most sites make is putting everything on one annual visit. This guide sets out which cycle each item is on and what has to be recorded.
In short: Under LOLER 1998, the lifting parts of a forklift, reach truck or pallet stacker are thoroughly examined at least every 12 months. An order picker, where the operator rises with the load, lifts people and is examined at least every 6 months. Conveyors, dock levellers, racking and the non-lifting parts of every truck are work equipment under PUWER 1998 and need maintenance and inspection at suitable intervals.
Which cycle each truck is on
| Equipment | Regulation | Thorough examination at least every |
|---|---|---|
| Counterbalance forklift (lifting parts: mast, chains, forks, carriage, cylinders) | LOLER | 12 months |
| Reach truck | LOLER | 12 months |
| Powered pallet truck and pallet stacker | LOLER | 12 months |
| Order picker, man-up VNA truck, any truck that raises the operator | LOLER | 6 months |
| Fork attachments fitted to the truck (clamps, rotators, extensions, drum handlers) | LOLER | 12 months, with the truck |
| Work platforms used on a forklift | LOLER | 6 months, and only in exceptional circumstances |
| Conveyors, dock levellers, racking, balers, compactors | PUWER | At intervals set by risk assessment |
The HSE's position on forklifts is that the lifting chains, forks, mast, cylinders and fork attachments are subject to thorough examination at 12 month intervals or as specified in a written scheme of examination, while the rest of the truck, such as brakes, steering, tyres and lights, comes under PUWER maintenance and inspection.
Why order pickers are different
An order picker raises the operator with the load. That makes it lifting equipment for lifting persons under LOLER, and the interval drops to 6 months. The same applies to man-up very narrow aisle trucks and to any work platform fitted to a forklift. Sites with mixed fleets often examine everything on a 12 month cycle and miss this, because the order pickers were bought as "forklifts".
PUWER for the rest
PUWER covers every item of work equipment in the warehouse, whether or not LOLER applies:
- Regulation 4, suitability. The truck must be suitable for the load, the aisle width and the floor.
- Regulation 5, maintenance. Kept in efficient working order, with a maintenance log where one is kept.
- Regulation 6, inspection. Where deterioration could lead to danger, inspect at suitable intervals and record the result. For trucks this is the daily pre-use check and the periodic engineer's inspection. For racking, the HSE expects a weekly visual check by staff and an expert inspection at least annually.
- Regulation 9, training. Every operator trained for the type of truck they drive, with refresher training.
Dock levellers and conveyors are a common gap. Nobody owns them, they are not on the forklift contract, and they get inspected when they break.
Hired and owned trucks together
Most warehouses run a mix: owned trucks examined by their own contractor, hired trucks examined by the hire company, and short-term hires that arrive with a certificate and leave before anyone files it. Under LOLER Regulation 9(4), hired equipment must arrive with evidence of its last thorough examination, and the user must make sure the examination happens if the hire runs past the due date. The record needs to show, for every truck on site today, who examined it, when and when it is next due.
Trucks move, paperwork does not
A group with several warehouses moves trucks between them. The truck goes to the new site, its report stays at the old one. The site manager at the new warehouse cannot show the truck is in date, and the site manager at the old one has a report for a truck that is not there.
LolerFlow records each truck as an asset that moves between sites, with its own cycle and its own due date, so the record follows the truck. Order pickers sit on 6 months, counterbalance trucks on 12, and racking, conveyors and dock levellers are tracked under PUWER in the same register, so the warehouse manager sees everything due across every site from one screen.
Sources
- The Lifting Operations and Lifting Equipment Regulations 1998 (SI 1998/2307), Regulation 9, legislation.gov.uk
- The Provision and Use of Work Equipment Regulations 1998 (SI 1998/2306), Regulations 4, 5, 6 and 9
- HSE: Equipment and machinery frequently asked questions, hse.gov.uk
- HSE L117: Rider-operated lift trucks, Approved Code of Practice and guidance
- HSE HSG76: Warehousing and storage, a guide to health and safety
Frequently asked questions
How often does a forklift need a LOLER inspection?
The lifting parts, meaning the mast, chains, forks, carriage and cylinders, need a thorough examination at least every 12 months, or as set out in a written scheme of examination. Attachments fitted to the truck are examined with it. Loose lifting accessories used with the truck, such as a jib, hook or sling, are examined every 6 months.
Why is an order picker examined every 6 months?
Because it raises the operator with the load, which makes it lifting equipment for lifting persons under LOLER. The same applies to man-up VNA trucks and any work platform used on a forklift.
Does racking come under LOLER?
No. Racking is work equipment under PUWER. The HSE expects regular visual checks by staff and an expert inspection at least once a year, with damage recorded and repaired.
Who examines a hired truck?
The hire company must supply it with evidence of its last thorough examination. If the hire runs past the due date, the user must make sure it is examined. Agree in writing who arranges it on long hires.
Is the daily pre-use check the same as the thorough examination?
No. The pre-use check is a PUWER inspection by the operator every shift. The thorough examination is by a competent person under LOLER. Both are required and both should be recorded.