Many businesses operate material handling equipment (MHE) in areas where pedestrians, both employees and customers, are present, often in close proximity. For this reason, it is essential that effective safety measures are in place to protect everyone onsite.

During busy periods, there is often an increase in both activity and footfall on site. At such times, it’s especially important to ensure that everyone onsite understands the dangers and how to stay safe. 

Crucially, that includes keeping pedestrians and MHE a safe distance apart, wherever possible.

Why segregation matters

The latest provisional RIDDOR figures indicate that being struck by a moving vehicle led to over 1,300 non-fatal injuries to employees in Great Britain in the last reported year alone.

Pedestrians and lift trucks in the same environment results in heightened risk, so it’s vital that appropriate safety measures are in place to keep people out of harm’s way.

Busy periods may introduce additional factors such as new staff, who will be unfamiliar with the site and working practices. Public-facing companies can also see increased volumes of customers onsite who may have no awareness of MHE safety whatsoever.

Segregation is key to keep everyone safe, and failing to incorporate this can have consequences - not only serious accidents, but prosecutions and fines - so non-compliance isn’t a risk worth taking.

Effective segregation methods

So with pedestrian segregation identified as a vital safety measure, how do you ensure it is effectively implemented on your site?

It’s essential that, wherever possible, pedestrians are kept out of forklift operating areas. Using separate working zones, accompanied by physical barriers, clearly marked pedestrian routes/crossings and relevant signage as reminders, is the best way to do this.

Clearly designate any operator-only areas and ensure pedestrians are aware of them and understand not to enter. 

In areas where pedestrian access is necessary, provide clearly marked walkways to allow safe passage and establish who has right of way.

Identify routes around site including potential crossing points and consider all areas where pedestrians and forklifts may interact, including access points, the sides and ends of aisles, areas with reduced visibility, and battery charging stations. These are high-risk areas where caution is essential.

Avoid crossing paths where possible and wherever forklifts and pedestrians will be operating in close proximity, implement effective measures to maintain a safe distance.

Supplementing physical segregation measures

Additional measures can be utilised to support safe working, such as:

• Audible warning devices (for example, reversing alarms)
• Flashing warning beacons
• Visibility aids, such as CCTV cameras or convex mirrors
• High-visibility clothing for pedestrians
• Presence-sensing equipment that alerts operators to pedestrians or obstacles.
• Combining these methods helps to ensure the safety of both employees and customers alike.
• Communicating safe practice

With the right measures in place, it’s then vital to ensure that anyone who steps on to site understands how to navigate it safely. 

Employees should be suitably trained. Carry out the relevant onboarding for new starters so you can confirm that they are trained to the required standard, and be sure to include temporary/agency workers; don’t forget, employers have the same responsibility to provide adequate training regardless of how long someone is part of the team.

With regard to customers, remember, they are unlikely to have the same safety awareness as trained operators (nor are they guaranteed to be wearing PPE, such as hi-vis vests, for visibility). 

Safety measures must therefore be unambiguous, clearly indicating restricted zones and preventing interaction with moving equipment. Proper segregation should eliminate any room for confusion and is vital for maintaining a safe working environment.

Preparation is key to safety

Ensure that segregation measures are implemented, and everyone understands their role in upholding site safety, then regularly monitor operations to confirm all is working as it should. With these plans in place, you will be best prepared for busier times.