Forklifts

A forklift, or lift truck, is a powered industrial vehicle that lifts and carries loads on two forks mounted on a vertical mast. The forks slide under a pallet, a crate or a bundle, the mast raises the load, and the truck carries it to where it is needed, whether that is a rack in a warehouse, the bed of a lorry or a storage area on a building site. Forklifts are among the most common machines in the world: they are found in factories, ports, distribution centres, builders’ merchants, precast yards and on the smoother parts of construction sites.

Most forklifts are built for firm, level surfaces such as concrete floors and asphalt yards. Machines designed for unpaved ground are treated as a separate family, rough-terrain forklifts, and telescopic handlers are a different machine again. This entry covers the industrial forklift in its main forms, from compact electric trucks to heavy diesel machines able to lift steel coils and containers.

Brief History of Forklifts

Powered platform trucks for moving goods in factories and railway stations appeared in the early twentieth century. In the years around the First World War, the American company Clark began building powered load carriers for its own plant, and in the following years companies such as Yale & Towne and Towmotor developed trucks that could raise a load as well as carry it. These early machines established the basic layout that is still in use: a driver’s position, a drive axle at the front, steering at the rear and a lifting device at the front.

The key step came in the late 1930s and during the Second World War, when hydraulic lifting spread and the wooden pallet became a standard way of moving goods. The combination of pallets and forklifts transformed warehousing and military logistics. After the war, the industry grew quickly in North America, Europe and Japan. Narrow-aisle reach trucks appeared in the 1950s, electric trucks took over much indoor work, and later decades brought better ergonomics, electronic controls, lithium-ion batteries and automated models. Today the market is served by large groups from Japan, Europe, the United States and China.

How a Forklift Works

A conventional counterbalance forklift has a simple principle: the weight of the truck at the rear balances the load on the forks at the front, with the front axle acting as the pivot point.

Chassis and counterweight. The frame carries the drive train, the operator’s compartment and a heavy counterweight at the rear. On electric trucks the battery contributes much of this weight.
Mast. Two or more nested steel channels, raised by hydraulic cylinders and chains. Two-stage masts are common for general work, three-stage and four-stage masts for high stacking. A free-lift mast lets the forks rise before the mast extends, which helps in low doorways and containers.
Carriage and forks. The forks hang on a carriage that runs up and down the mast. The mast tilts forward and back so the operator can pick up a load and secure it against the backrest.
Drive and steering. Most counterbalance trucks drive through the front wheels and steer with the rear wheels, which gives a tight turning circle. Three-wheel electric trucks turn even more tightly.
Hydraulics. A pump supplies the lift, tilt and attachment functions through control valves operated by levers or a joystick.
Load centre and capacity. Every truck has a rated capacity at a stated load centre, the distance from the fork face to the load’s centre of gravity. If the load is longer, higher or further out, the safe capacity falls.

Types of Forklifts

Counterbalance Forklifts

The most widespread type, with forks at the front and no outriggers. Available with electric, diesel, LPG or petrol power, from about 1 t to well over 40 t.

Reach Trucks

Electric warehouse trucks whose mast or forks move forward to pick a pallet, then retract so the load sits between stabilising legs. They work in narrower aisles and lift high, often above 10 m.

Pallet Stackers and Pallet Trucks

Pedestrian or ride-on machines for short moves and low to medium stacking. Powered pallet trucks only lift enough to clear the floor.

Very Narrow Aisle and Order Picking Trucks

Turret and man-up trucks that work in very narrow, guided aisles, where the forks or the operator cab rise with the load.

Sideloaders and Multidirectional Trucks

Trucks that carry long loads such as timber, pipes and steel sections along their side, and multidirectional models that can travel sideways.

Heavy Forklifts

Large diesel machines for steel, precast concrete, heavy machinery and container handling, often fitted with long forks, positioners or container spreaders.

Truck-Mounted and Rough-Terrain Models

Portable forklifts carried on the back of a lorry and forklifts with big tyres and four-wheel drive for building sites are covered in the entry on rough-terrain forklifts.

Size Classes

Class	Typical rated capacity	Typical use
Light	about 1 to 2.5 t	Warehousing, retail, light manufacturing
Medium	about 2.5 to 5 t	Factories, builders’ merchants, yards
Large	about 5 to 16 t	Steel, timber, precast, heavy manufacturing
Heavy	about 16 to 50 t and more	Steel coils, heavy machinery, containers

Figures are indicative.

Attachments

Forklift attachments change what the truck can handle. Side shifters move the forks left and right without moving the truck, and fork positioners change the fork spacing hydraulically. Other common tools include clamps for paper rolls, cartons and bales, rotators, push-pull devices for slip sheets, carpet poles, jibs and crane arms, drum handlers, block and brick clamps for building materials and multi-pallet handlers. Any attachment adds weight and moves the load centre forward, so it reduces the truck’s net capacity, and the manufacturer’s capacity plate should reflect the combination.

Main Manufacturers

Toyota Industries, with the Toyota Material Handling and Raymond brands.
KION Group, with Linde and STILL.
Jungheinrich, a German specialist in electric and warehouse trucks.
Crown Equipment, based in the United States.
Mitsubishi Logisnext and Hyster-Yale, with the Hyster and Yale brands.
Anhui Heli and Hangcha, the largest Chinese manufacturers.
Clark, one of the pioneers of the industry.
Doosan Bobcat, Komatsu and Kalmar in parts of the range, with Kalmar known for heavy trucks.

Main Uses of Forklifts

Loading and unloading lorries, containers and railway wagons.
Storing and retrieving pallets in warehouses and distribution centres.
Moving raw materials and finished goods in factories.
Handling bricks, blocks, timber, cement and steel at builders’ merchants.
Handling precast elements, reinforcement and formwork in yards.
Moving steel coils, heavy castings and machinery in heavy industry.

Choosing a Forklift

Start with the load. Weight, dimensions and load centre determine the capacity class. A heavy load carried far from the mast needs a larger truck than its weight suggests.
Check the lift height. The highest rack or stack, plus clearance, sets the mast. Capacity usually falls at the top of a tall mast.
Match the surface. Cushion or solid tyres suit smooth indoor floors, pneumatic tyres suit outdoor yards. Unpaved sites call for a rough-terrain machine.
Choose the power source. Electric trucks suit indoor work and are quiet and clean at the point of use. Diesel and LPG trucks remain common outdoors and for heavy duty, although large electric models are becoming more widespread.
Consider the aisle width. Warehouse layout often decides between counterbalance, reach and very narrow aisle trucks.
Plan for attachments. A side shifter is almost standard, and other attachments should be specified with the truck so the capacity is rated correctly.

Safety

Forklifts are involved in a significant share of workplace transport accidents. The main risks are overturning, especially when turning with a raised load or on a slope, pedestrians being struck, loads falling from the forks and people crushed between the truck and fixed objects. Operators should be trained and authorised for the type of truck they use, respect the capacity plate, travel with the load low and tilted back, and never lift people on the forks except in a purpose-built, approved platform where rules allow it. Overhead guards and seat belts or operator restraint systems protect the driver in a tip-over. Separating pedestrian and vehicle routes, speed limits, blue spot or zone lights, cameras and proximity detection systems help reduce collisions. Daily pre-use checks and regular thorough examinations of the mast, chains and forks are required in many countries.

Trends and Technology

Electrification is the strongest trend. Lithium-ion batteries allow opportunity charging and longer shifts, and electric trucks are moving into capacity classes that were once the domain of diesel machines. Hydrogen fuel cells are used in some large warehouses. Automation is spreading through automated guided and autonomous mobile forklifts that follow routes without a driver. Telematics records impacts, usage and battery status and controls access to the truck. Operator assistance systems limit speed when a load is raised, warn of pedestrians and help the driver stay within the stability limits of the truck.

Key Terms

Load centre: the distance from the fork face to the centre of gravity of the load, used to rate capacity.
Counterbalance: a truck that balances the load with weight at the rear, with no outriggers.
Mast: the upright assembly of channels that raises the carriage and forks.
Free lift: the height the forks can rise before the mast starts to extend.
Side shifter: an attachment that moves the forks sideways.
Capacity plate: the plate on the truck stating its rated capacity for each configuration.

Frequently Asked Questions

What is the difference between a forklift and a telehandler? A forklift lifts vertically on a mast, while a telehandler uses a telescopic boom that can reach forward and upward. Forklifts are more precise for stacking at height in a small footprint, telehandlers are better at reaching over obstacles.

Can an ordinary forklift be used on a building site? Only on firm, level and paved areas. On soft or uneven ground, a rough-terrain forklift or telehandler is the right choice.

Why does a forklift’s capacity drop at height? As the mast extends, the combined centre of gravity rises and mast deflection increases, so manufacturers reduce the rated capacity at the top of the lift.

Are electric forklifts suitable for outdoor work? Many are, provided they have the right protection and tyres. Large electric counterbalance trucks are now used in yards and ports.