Telehandlers are versatile machines used on construction sites for lifting, placing materials, and loading. However, they have a forward-tipping risk that increases with reach and load, making them inherently less stable than a crane. The load chart must be consulted for every lift because the safe working load reduces significantly as the boom extends. Telehandler overturns are a common cause of fatal incidents, particularly when operating on uneven ground or with unapproved attachments.
Key Hazards
Machine overturn from exceeding the safe working load at extended reach
Pedestrians struck by the machine or swinging loads during travel and operation
Loads falling from forks due to incorrect placement or sudden braking
Unapproved attachments altering the machine's stability and load characteristics
Control Measures
Ensure the operator holds a current CPCS or NPORS card for the telehandler category.
Consult the load chart before every lift to confirm the safe working load at the required reach.
Operate on firm, level ground and avoid slopes that exceed the manufacturer's gradient limits.
Use only manufacturer-approved attachments and never modify the machine's fork arrangement.
Travel with the boom retracted and the load as low as possible to maintain maximum stability.
Check the ground conditions at the set-down point to ensure they can support the machine and load.
Maintain exclusion zones around the telehandler during lifting and placing operations.
Carry out a pre-use inspection covering brakes, steering, hydraulics, and boom condition each shift.
Never use a telehandler to lift personnel unless fitted with an approved man basket and LOLER compliant.
Remember
The safe working load of a telehandler reduces dramatically as the boom extends forward.
Always check the load chart before every lift — do not estimate capacity from experience.
Telehandler overturns are a leading cause of construction fatalities and occur very suddenly.
Travel with the boom retracted and load low to keep the centre of gravity stable.
Only manufacturer-approved attachments may be used because unapproved items alter stability.
Never use a telehandler as a crane or to lift people unless specifically equipped and LOLER compliant.
Applicable Legislation: LOLER 1998 · PUWER 1998 · CDM Regulations 2015 · BS 7121 (Safe Use of Cranes)