Operating A Forklift Outside Safely: A Guide From Jofson

At Jofson, we know that not every material handling operation happens under a warehouse roof. Customers operate across mixed environments, moving goods from inside facilities to yards, loading bays, or more expansive outdoor areas. If that sounds like your business, there are a few extra considerations to take on board when using forklifts outdoors. We’ve put together this practical guide to help you stay safe, efficient, and compliant when working in open-air environments. Below, we talk about operating a forklift outside safely and highlight our own experience of working with forklifts and clients across Manchester and Birmingham.

Weather Protection Matters

Operating forklifts outdoors means dealing with whatever the British weather throws your way. Whether it’s freezing winds or blazing sunshine, you and your drivers need the right gear. Ensure operators are equipped with weather-appropriate PPE – think warm coats, gloves and hats for winter and breathable high-vis clothing for summer.

In colder regions or during winter, you might also consider forklifts with heated cabs, which we can advise you on. On the flip side, hot weather brings its risks. Without suitable protection, heat stress and sun-related illnesses can become a genuine concern, and employers may be held responsible if staff aren’t adequately safeguarded.

Handling Uneven Ground

Unlike the smooth concrete floors of a warehouse, outdoor surfaces can be unpredictable. Operators must be trained to adapt to gravel and slopes, potholes, and loose terrain. All forklift drivers should be confident in their braking, speed control, and manoeuvring skills on rough ground. This will protect your team and reduce the risk of tip-overs and other potentially serious incidents.

Pre-Use Checks Are Crucial

Outdoor conditions put more strain on forklifts. Exposure to the elements can speed up wear and tear, so it’s essential to carry out regular inspections. Daily checks should include:

Tyre pressure (PSI) and condition
Oil and antifreeze levels
Battery charge and terminal condition
Lights and indicators
General wear from mud, dust or debris

These simple checks help prevent unexpected breakdowns, especially in extreme temperatures where overheating or freezing can quickly become an issue.

Know the Hazards

Working outside means dealing with more than just machinery. Forklift operators need to be alert to a range of outdoor hazards, including:

Uneven or unstable ground
Stray branches and debris
Wildlife or domestic animals
Steep inclines or sudden gradient changes
Unpredictable weather – rain, wind, snow, or hail

Keeping a close eye on your environment – and training your team to do the same – is a key part of working safely.

Keep It Clean

Forklifts used outdoors are bound to collect dirt, grime, and mud. Left unchecked, this buildup can affect performance and even become a safety risk – for example, if debris interferes with your tyres’ grip or steering response. Regular cleaning, especially around wheels and undercarriages, helps keep your trucks in good working order and extends their lifespan.

Prioritise Communication

Communication is critical whether you’re working in a yard, on a construction site, or between buildings. Everyone on site should know what’s happening, especially when conditions change or a risk arises. Encourage your team to speak up and share updates – it could prevent an accident or keep things moving smoothly during busy periods.