Forklift Management

In many fields, such as logistics and material handling, forklifts are essential operational tools for ensuring efficiency and speed across a wide range of operations, from warehousing to industrial activities. Forklifts come in various types, such as electric, diesel and LPG models, each suited to specific operational environments.

Despite their benefits, forklifts present inherent risks if not properly managed.

This document provides an overview of these risks and offers practical guidelines, with a particular focus on prevention and risk management.

Electric Forklift

Among the different power solutions available for electric forklifts, the most widespread battery types are lead-acid and lithium‑ion.

Lead - Acid Batteries

Lead-acid batteries are a well-established technology widely used in material handling vehicles. They operate through a chemical reaction between lead and sulfuric acid, generating electrical energy to power the forklift’s motor.

Hazards of lead-acid batteries charging

Lithium-ion batteries

The transition from lead-acid battery systems to lithium ion technology is becoming increasingly common in the industrial sector, driven by the advantages in energy efficiency, lifespan, and reduced maintenance. Lithium-ion batteries offer higher energy density, faster charging times, and eliminate the need for electrolyte refilling, making them particularly suitable for intensive applications such as electric forklifts. However, this technology also introduces new risks.

Other risks associated with charging lithium-ion batteries

Guidelines for fire protectione and risk management

CHARGING AREA

• Charging operations should be carried out in an external area such as under an outdoor canopy, provided the equipment is installed next to a non combustible external wall with no openings. Alternatively, charging can take place in designated cut-off fire rated areas equipped with explosion-proof electrical equipment.
• Ensure charging operations take place in a well-ventilated area to minimize risks from battery gas emissions. Ventilation openings should be positioned so that airflow moves through the charging zone and is exhausted at the upper part of the room.
• To ensure safe charging conditions, make sure the charging area is not subject to frost or flooding.
• Electrical chargers should not be placed within storage racking.
• Combustible materials must not be stored or present within a 3-meter radius of the battery charging area.

PROTECTION CONSIDERATIONS

• Indoor charging areas should be at least equipped with automatic fire detection systems to ensure immediate alarming. To better control an initial fire and prevent fire spread, sprinkler protection is advised for these areas.
• Implement an interlock system to shut down electricity to chargers when fire detection is activated.
• Battery chargers should be equipped with protective devices against overvoltage, overcurrent, short circuits, and overheating.
• Since the BMS (Battery Management System) contains the battery control logic and its reliability strongly depends on the quality of the manufacturer, it is essential to select only reputable and trustworthy suppliers. The BMS should be able to detect any anomaly, trigger an alarm, and automatically interrupt the charging process to prevent hazardous conditions.
• Provide physical protection around the battery chargers to prevent mechanical damage from material handling vehicles.
• Ensure that an adequate number of fire extinguishers are available and properly positioned within battery charging areas.
• The cross-sectional area of the charging cables must be determined based on the maximum expecting charging current. For mechanical strength reasons, it should not be less than 10 mm².
• When charging cables are not in use, provide suitable supports (e.g. hooks) to protect them from mechanical damage, such as cutting or forklift traffic.

RISK MANAGEMENT, CONTROLS AND TESTING

• Always use accessories and components provided or approved by the equipment manufacturer.
• Identify the charging area with appropriate signage.
• Include charging areas in the weekly and monthly inspections. All maintenance must be carried out by qualified personnel in accordance with the manufacturer’s instructions.
• Ventilation systems should be inspected regularly to ensure proper functionality.
• Implement yearly testing and IR thermography inspections for all chargers. This should be conducted by a specialized contractor or specially trained employees of the electrical maintenance department.
• Train employees on the fire risks associated with batteries, including potential thermal runaway and fire scenarios, as well as hazards related to electrolyte handling.
• For lithium-ion batteries in thermal runaway consider one of the following options:
  • Identify an outdoor area located at a safe distance from buildings and combustible materials where the forklift can be allowed to burn without causing damage to surrounding assets.
  • If multiple vehicles are present, such as in a logistic environment where the likelihood of such events are higher, keep an adequate distance between forklifts that are being charged and provide an external water basin to allow immersion of the battery.

Establish a specific procedure for managing this event within the emergency plan, ensure training of designated personnel, and define the appropriate means and equipment needed for safely transporting the battery outside. Approval from the Public Authority is recommended.

Diesel Forklift

Diesel forklifts, although less commonly used compared to electric models, remain an important solution in specific contexts. They are typically employed in outdoor environments,  heavy-duty operations, or situations where long operating hours and high lifting capacities are required. In general, diesel forklifts tend to be less risky than electric models in terms of battery-related hazards, but they still require proper management. Some potential risks include fire caused by contact with hot exhaust components or ignition from a spark.

GUIDELINES FOR FIRE PROTECTION AND RISK MANAGEMENT

• Refuel diesel powered material handling vehicles outdoors or in a well-ventilated, detached building.
• Always keep all enclosures and protective covers around the engine and exhaust system securely in place whenever material handling vehicles are operating, to minimize the risk of accidental ignition caused by contact with combustible materials.
• Equip the forklift with a spark arrestor on the exhaust system to minimize the risk of fire caused by sparks.
• Use clear signage and enforce a strict no-smoking policy in all refueling areas.
• Use spill-proof fuel containers to prevent leaks of diesel.
• Place unused forklifts in an external storage area, ensuring a minimum distance of 15 meters from the building.
• Ensure that a fire extinguisher is on board the forklift to allow immediate response in case of fire and ensure proper training for employees.

LGP Forklift

Another type of forklift is the one powered by LPG (liquefied petroleum gas), a flammable gas mainly composed of propane and butane. This type involves risks similar to those of diesel-powered forklifts, as well as additional hazards related to pressurized flammable gases. Improper handling during use or refueling may lead to fires or gas buildup, potentially resulting in explosions.

GUIDELINES FOR FIRE PROTECTION AND RISK MANAGEMENT

In addition to the fire protection and risk management guidelines that apply to diesel forklifts, consider also the following LPG specific measures:

• LPG containers shall be equipped with a pressure relief valve and a shutoff valve. The pressure relief valve must communicate with the vapor space, ensuring that any overpressure is vented as gas only, not liquid LPG.
• Containers shall be securely mounted and protected from impacts, heat, and mechanical damage, verifying that valves, hoses, and regulators are correctly installed and tightened.
• Refuel or replace LPG containers outdoors or in  well‑ventilated, detached building, keeping the engine switched off and following the manufacturer’s instructions.
• Containers shall not exceed the
  maximum permitted filling level.
• Operators shall be trained in proper container replacement procedures, leak detection, and emergency response measures.
• Periodically inspect cylinders, valves, and connections to check for signs of damage, corrosion, damaged hoses, or leaks. Never use containers that appear compromised.
• Store empty and full cylinders separately. Empty cylinders should be treated as though full and kept in a separate designated area with valves closed.
• Always store cylinders outside, keep away from heat sources and sunlight, store them in a purpose built secure store, upright and chained, on firm ground and well ventilated area.
• Avoid storing excessive amounts of spare cylinders in general.

Notable Losses

Hundreds of incidents involving electric forklift trucks have been reported over time. Most losses were caused by collision, leading to collapsed storage racks, damaged equipment, ruptured utility lines, and water damage from broken sprinkler systems. Fire-related events have proven particularly severe, with ignition sources often linked to battery failures during charging. These failures can generate flammable gases such as hydrogen if ventilation is inadequate. Electrical faults in charging systems, combined with poor maintenance or improper procedures, have also contributed to catastrophic outcomes.

• USA (2019)
  A massive fire broke inside an 18.500 m2 storage facility containing paper, plastic, and other highly combustible materials. Investigators determined that the fire was likely sparked by a forklift. Firefighters from multiple departments fought the flames for an entire week. Despite the extensive response, the warehouse was completed destroyed, and the economic impact was severe.
   
• France (2022)
  In a facility dedicated to the production of agricultural machinery, a fire broke out in the area designated for charging electric forklifts, likely caused by an electrical fault in the charging system. The intense heat compromised structural elements, including brick walls and load bearing supports. Despite the rapid intervention of multiple fire brigades, the flames spread quickly, causing extensive damage across several sections of the plant. In addition to fire and heat damage, smoke contamination affected large areas of the building. The total losses were significant, amounting to tens of millions of euros.
   
• Norway (2025) 
  During fishing operations on a Norwegian vessel, smoke was detected in the cargo and freezer room, triggering the fire alarm. The fire originated from an electric forklift, most likely due to a short circuit in the battery casing or its connection to the charger. Dense smoke quickly filled the compartment, forcing the fire team to work with limited visibility. After nearly 30 minutes, the crew managed to extinguish the burning forklift and cut the battery cables to prevent reignition. The event caused the loss of the cargo and several days of operational downtime. Moreover, one crew member suffered smoke exposure. Although the potential for severe damage was high, rapid response and effective onboard training prevented a far more dangerous escalation.

Conclusion

Implementing best practices for forklift operations is essential to minimize operational risks and ensuring workplace safety. By prioritizing proper charging or refueling procedures, regular maintenance, and adequate operator training, companies can significantly reduce hazards associated with forklifts.

References

_{NFPA 70 – National Electric Code
NFPA 70E – Standard for Electrical Safety in the Workplace
NFPA 10 – Standard for Portable Fire Extinguishers
NFPA 58 – Liquefied Petroleum Gas Code
FMDS 0739 – Material Handling Vehicles
FMDS 7112 – Lithium-ion Battery Manufacturing and Storage
VDS2259 - Battery charging systems for electric vehicles
https://www.osha.gov/etools/powered-industrial-trucks
https://www.sdir.no/en/lessons-learned/brann-i-truck-ombord-pa-fiskefartoy- laring-av-hendelse/
https://eu.gadsdentimes.com/story/news/local/2019/10/07/}