As demand in the building materials sector grows, choosing the right forklift configurations is critical to balancing cost, productivity, and operational needs. Hyster provides guidance on how to avoid over- and under-specifying equipment and why application-specific configuration is key.

The building and construction materials sector is essential to the global economy, enabling the projects and infrastructure that keep industries and communities moving forward. To meet the demands of these tough applications, businesses may need to rethink what they expect from their forklift fleets. 

Capacity, environment, terrain, load, power, ergonomics all play a role when choosing a forklift. In addition to these standard criteria, there is also a broad range of optional features and equipment, and even special engineering, that creates a spectrum of lift trucks that ranges from ready-made to tailored. 

Every construction operation faces its own unique challenges, and many applications and conditions call for more customised configurations. Configuration needs vary widely depending on the type of lift truck and application. Although every operation should consider their unique needs - whether choosing options from a standardised list or custom-configuring a forklift for a specific task - it is important to strike a balance between “too much” and “not enough.”  

Over-equipping a lift truck with features that aren’t needed, first and foremost, makes for a higher upfront cost than necessary. Sometimes, those features are subtle ones that are included in the basic design that most buyers don’t think twice about. For example, some lift trucks incorporate features like a full lights package as standard equipment. While seemingly minor, if the lift truck is always going to be used in well-lit areas indoors, or only during the day outdoors, the lights are unnecessary for that business. But their cost is folded into the price of the truck.  

More obvious features that might exceed what operations need are performance related - and they’re easy to spot by comparing the features to the requirements of the application and environment. For instance, if the lift truck is being operated in speed-limited areas and doesn’t need to travel uphill with heavy loads, it is unlikely it requires an engine or motor that is more powerful than that of the standard model. If the lift truck is only operating for a few hours a day or performing light duty tasks, an investment in an upgraded transmission or an advanced braking system is probably unwarranted.  

Apart from cost considerations, over-equipping lift trucks presents a number of practical concerns. Each feature - even if it does not get used - is a potential “opportunity” for additional maintenance or replacement over the life of the lift truck. If a feature is not justified by an application, its presence can also introduce unnecessary complexity, making the lift truck more difficult for operators to understand without additional training.  

There are also definite disadvantages to under-equipping lift trucks. Lower-cost models that are equipped for occasional or light duty cycles tend not to stand up well to hard or intense operations. If the lift truck is struggling to perform the job at hand it slows down the operation, impacting productivity and key performance indicators (KPIs). An imbalance between the forklift and the requirements of the job can also make breakdowns more likely, further undercutting productivity and increasing maintenance and repair costs. 

A lower upfront cost is the biggest motivator when it comes to under-specifying lift trucks. But, if the lift truck will not survive the job it is expected to perform, it will need to be replaced sooner than a properly configured solution, leading to higher overall costs. Avoid under-equipping lift trucks by making sure that the features and performance are up to the task at hand. 

The environment in which the lift truck operates also figures heavily in the configuration process. Initially, the physical dimensions of the work area – the amount of distance the forklift will regularly traverse, aisle widths, turning areas, doors, and overhead obstructions must be considered.  

One of the most obvious environmental factors is whether the lift truck is being used indoors or outdoors. Most of today’s counterbalanced forklifts can operate inside or outside, but the exact configuration could change substantially. For example, options like enclosed cabins, heating, and air conditioning are often desirable for outdoor operation.  

Ambient temperature is a factor that is often overlooked. Consistently high or consistently low temperatures impact lift truck performance. This is a factor that is particularly important for operations used to internal combustion engine (ICE) powered trucks that are thinking of moving to electric.  

Low temperatures can significantly reduce battery capacity, so battery configuration may have to be upgraded even if the operating environment sees reduced temperatures for only a few days per year. Another overlooked factor is altitude. At extreme altitudes, thin air affects the engine performance of ICE lift trucks, reducing their power. This means that electric forklifts could be a better fit for operations at high elevations. 

Terrain is also a consideration. Indoors, surfaces are typically smooth, but expansion joints, ramps between areas, and wet surfaces can all dictate changes to the specification to improve control. Outside surfaces are often variable, comprising everything from smooth tarmac, asphalt, and concrete to dirt surfaces with potholes, gravel, and railway tracks. These rougher surfaces are often drivers for additional features. Work on grades and slopes can also influence configuration decisions, especially if loading is required on a grade. Features like hill hold can help operators improve productivity by reducing the need to ride the foot brake or balance the forklift on the throttle.  

Decisions around power source are not only limited to the lift truck itself, especially when considering changing to a different power source. Questions arise about the need to add or change infrastructure and how to manage the switch across an entire fleet. This is particularly true for operations transitioning from ICE to electric. In situations where multiple forklifts are used, electrical infrastructure must be carefully considered to determine if it can handle the load of charging multiple forklifts. Often, with some minor changes to working pattens, no infrastructure changes are required. An electrification expert from a forklift dealer or manufacturer can perform an evaluation to determine whether electric lift trucks are a good fit. 

Generally speaking, forklift configurations range from a ready-made lift truck that can be configured at the factory - with options chosen from a standardised list or custom-engineered for the customer — to options that are added after the forklift is built and sold. Some manufacturers offer customisation options across most if not all of their product line. 

The breadth of available configuration options varies widely by manufacturer. Regardless of the level of customisation, it is advantageous to choose a manufacturer that has both a wide range of options and the ability to tailor options to meet operational needs if required.  

Operations seeking reliable and affordable alternatives to internal combustion engine (ICE) forklifts might consider Hyster^® J2.0-7.0XTLG electric lift trucks, which deliver a robust, zero-emission solution. They are well suited to both indoor and outdoor handling challenges. Operations moving or storing bricks, blocks, metals, and construction materials can expect to enhance productivity, reduce Total Cost of Ownership, and eliminate tailpipe emissions. The XTLG models provide a practical and powerful alternative to ICE forklifts.

Alternatively, the Hyster A Series forklift range includes both ICE and electric options, each with customisable configurations to suit a wide range of material types. Each forklift can be specified with the mix of features, performance and operator-focused options needed for the application, helping operations avoid paying for capabilities they don’t require.  

Hyster counterbalance lift trucks are ideally suited to frequent load handling in high throughout environments. These may include distribution centres for residential and commercial construction projects or retail like builders’ merchants. These lift trucks are an ideal fit for operations handling: 

• Mixed or varied materials
• Palletised goods
• Finished wood and trusses
• Plasterboard sheets
• Slates, shingle, bricks, and blocks

The electric Hyster A Series may be a good choice for those operations with indoor production environments and inventory handling, or where a mixture of indoor and outdoor tasks are taking place. These forklifts produce zero exhaust emissions and offer quiet, efficient operations inside.  

The Hyster A Series with LPG or diesel fuel may be a particularly effective match for outdoor yards, or high frequency loading and unloading operations. They are built to provide power and durability under frequent use. 

Every Hyster lift truck is backed by a global network of local Hyster dealers, providing the expertise, service and support needed to help keep demanding construction operations moving.

For information and assistance with finding the right equipment for your building and construction handling needs, contact a Hyster expert.