MAN/Mechanical Aids/TBT-MAN-017

Pallet Trucks and Trolleys

Manual Handling › Mechanical Aids › Pallet Trucks and Trolleys

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Pallet trucks and trolleys are the most common mechanical aids for moving materials on construction sites.
Manual pallet trucks can move loads of over one tonne but require significant pushing effort on rough surfaces.
Foot and ankle injuries from pallet truck wheels running over toes are among the most frequent incidents.
Overloaded or unbalanced loads on pallet trucks tip over, crushing feet and striking nearby workers.
Trolley wheels must be suitable for the surface — small hard wheels on rough ground cause tip-overs.
Pulling a loaded pallet truck or trolley puts more strain on the back than pushing from behind.
Slopes and ramps amplify the risk — a loaded pallet truck rolling away on a gradient is extremely dangerous.
Pre-use checks should confirm wheels turn freely, forks lift and lower, and the handle is secure.
Routes must be planned on level, firm surfaces free from steps, cables, and debris.
Electric pallet trucks remove the pushing effort but introduce pedestrian collision risk from powered movement.

Foot injuries	Pallet truck wheels running over feet cause fractures, crushing, and lacerations — safety boots are essential.
Load tip-over	Unbalanced or overloaded pallet trucks topple, dropping heavy loads onto workers and bystanders.
Back strain	Pushing heavy loads on rough or sloping surfaces causes back injuries without proper technique and route planning.

Don't

Wear safety boots with steel toecaps when operating any pallet truck or loaded trolley
Check wheels, forks, handle, and lifting mechanism during the pre-use inspection
Push pallet trucks and trolleys rather than pulling them to reduce back strain
Plan routes on level, firm surfaces free from steps, cables, and obstructions
Centre loads on the forks and check they are balanced before moving off
Use wheel chocks or apply the brake when stationary on any gradient
Select trolleys with wheel sizes suitable for the surface conditions on your route
Keep feet clear of the sides and front of the pallet truck during all movements
Use electric pallet trucks for heavy or repetitive moves to reduce manual effort
Lower forks fully to the ground before leaving any pallet truck unattended

DON'T overload pallet trucks beyond their rated safe working load capacity
DON'T ride on a pallet truck — they are not designed to carry passengers
DON'T pull loaded pallet trucks when you can push them instead
DON'T use pallet trucks on slopes without controlling the load and using the brake
DON'T leave a pallet truck unattended with the forks raised or load elevated
DON'T use pallet trucks with jammed wheels, bent forks, or a faulty handle
DON'T push loaded trolleys over uneven ground, cables, or through standing water
DON'T stack loads too high on trolleys where they become unstable and top-heavy
DON'T walk alongside the load where your feet could be struck by the truck wheels
DON'T use a pallet truck in areas with pedestrian traffic without warning those nearby

See also: Manual Handling Awareness | Team Lifting and Mechanical Aids

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