When temperatures rise, so do the challenges on the worksite floor. Summer heat can put extra strain on your forklifts—and your team. From overheating engines to worn-down tires, even the most reliable machines can feel the pressure. Add in a seasonal surge of new operators and trainees, and suddenly forklift safety and efficiency become more important than ever. In this blog, we’ll explore how to maintain safe forklift operation through the summer, including how to spot signs of heat stress in your equipment, why routine maintenance is more critical than ever, and how to support seasonal staff with proper training. A little preparation—and timely attention—goes a long way in keeping your operations productive and accident-free all summer long.
The heat impacts more than just operator comfort—it can turn into a serious forklift hazard. Heatwaves intensify wear and tear on every component of your forklift fleet, especially when it comes to cooling systems, tires. Hydraulics may behave unpredictably, and high ambient temperatures can increase the likelihood of engines overheating. Even worse, warehouses and outdoor facility layouts may shift due to seasonal demand, increasing the risk of forklift and pedestrian safety issues. Combine that with an influx of temporary or new staff, and you’ve got the perfect storm for safety risks unless you're proactive.
Forklifts are built to perform under pressure, but that doesn’t mean they’re immune to the stifling heat of summer. High temperatures can significantly increase the risk of equipment malfunctions, particularly if routine maintenance is neglected. This often results from a combination of factors, including:
1. Clogged Radiators – Dust, debris, or grime buildup can block airflow and reduce the radiator’s ability to cool the engine effectively.
2. Low Coolant Levels – Frequently seen in older forklifts or units used outdoors, insufficient coolant can’t properly regulate engine temperature.
3. Overworked Engines – Long shifts, especially on inclines or rough terrain, placed added strain on internal components. In hot weather, that strain intensifies and can push engines past their safe operating limits.
Staying ahead of these issues with proactive maintenance is essential for safe forklift operation in the summer.
Pro tip: During mid-shift breaks, give operators time to visually inspect key components. A few minutes spent checking coolant or clearing debris can prevent hours of downtime.
Batteries for forklifts are sensitive to temperature extremes. Excess heat accelerates chemical activity inside the battery, shortening its lifespan and increasing the risk of leakage or corrosion. Ensure that the battery is checked daily for signs of heat stress, such as swelling, leaks, or unusual odours. Below are some additional tips:
Even sealed batteries benefit from visual inspections and occasional testing during hot weather. A battery failure can halt operations and, in extreme cases, cause operator injury.
By July, summer is well underway—and so is the strain on your equipment and team. That’s why mid-season check-ins are just as important as pre-summer planning. The hottest months are still ahead, and taking time to reassess can help you avoid costly downtime, equipment failure, and safety incidents.
Taking a few hours to reassess now can save you days of downtime later. Use July as a strategic checkpoint to keep your equipment running strong and your people operating safely through the rest of the season.
With higher summer traffic and more people on the warehouse floor, forklift and pedestrian safety should be a key focus. Employee fatigue from heat stress can lead to slower reaction times and decreased awareness.
Even simple layout and traffic flow adjustments can significantly lower the risk of collisions during peak summer activity.
The influx of seasonal staff often means new or less-experienced operators. According to Canada Safety Training, comprehensive operator training is the number one way to reduce forklift hazards and workplace injuries.
Consider offering quick but focused refresher sessions weekly during peak months. Even veteran operators benefit from a timely reminder of safe practices, especially when dealing with summer-specific conditions like slippery outdoor surfaces or hot metal components.
Outdoor Forklift Safety: Tire Wear, Surface Hazards, and More
Summer means more forklifts operating outside—and that comes with its own set of challenges. Tailift Canada’s guide to maximizing outdoor forklift efficiency in summer highlights several critical concerns:
Outdoor operations also demand attention to proper hydration and sun protection for operators. Heat stress isn't just uncomfortable—it can lead to dizziness, confusion, or even fainting while behind the wheel. Encourage regular hydration breaks, especially in facilities without climate control, and provide cool zones with fans or chilled water stations.
Encouraging a culture where operators feel empowered to take breaks, speak up about discomfort, or report unsafe conditions is essential.
Despite preparation, things can go wrong. Train your team to spot and respond quickly to emerging hazards:
Empowering your team to act without fear of “slowing production” is one of the most effective ways to prevent injury and damage.
Summer is no time to set your safety protocols on cruise control. With hotter conditions, more operators, and increased workloads, maintaining forklift safety requires daily attention and team-wide involvement. From proper maintenance of batteries to strategic mid-season check-ins, your proactive efforts can dramatically reduce forklift hazards and support safe forklift operation all summer long. At Tailift Canada, we’re committed to helping you get the most out of your equipment–season after season. If you’re looking to upgrade your fleet or need assistance with forklift performance, find your nearest Tailift Canada dealer for expert support and solutions.