Pallet trucks and trolleys are simple but effective mechanical aids that reduce manual handling injuries when moving materials around a construction site. However, they cause foot and ankle injuries when used incorrectly, and overloaded or poorly maintained equipment can fail during use. This talk covers the safe operation of hand pallet trucks and trolleys and the checks that prevent injuries on site.
Key Hazards
Foot and ankle crush injuries from pallet truck wheels running over toes
Overloaded pallet trucks tipping or losing steering control on slopes
Back strain from pushing heavy loads on rough or uneven ground surfaces
Equipment failure from damaged wheels, forks, or hydraulic mechanisms
Control Measures
Inspect pallet trucks and trolleys before each use for damaged wheels, forks, and hydraulic function.
Wear safety footwear with metatarsal protection when operating pallet trucks on site.
Check the safe working load of the equipment and do not exceed it with any load.
Push rather than pull pallet trucks to maintain visibility and control of the load.
Use pallet trucks only on firm, level, smooth surfaces — not on rough ground or steep gradients.
Ensure loads are stable, balanced, and secure on the forks before moving the pallet truck.
Keep feet clear of the wheels and forks at all times during operation and steering.
Lower the forks fully before travelling to maintain a low centre of gravity and stability.
Report any defective pallet truck or trolley immediately and take it out of service.
Remember
Inspect pallet trucks before each use for wheel damage, fork condition, and hydraulic function
Wear safety footwear and keep feet clear of the wheels and forks at all times during use
Check the safe working load and never exceed it with the materials being transported
Push rather than pull the pallet truck to maintain visibility and control of the load
Use pallet trucks only on firm, level surfaces — not on rough ground or steep gradients
Lower the forks fully before travelling to keep the centre of gravity low and stable
Applicable Legislation: Manual Handling Operations Regulations 1992 · PUWER 1998 · Health and Safety at Work etc. Act 1974 · CDM Regulations 2015