Pallet trucks and hand trucks look simple enough to use without much thought, and that apparent simplicity is exactly why injuries involving them are so common — the real hazards are in the details of load stability, foot positioning, and terrain that a genuinely simple-looking task can still get wrong.

Foot positioning and crush risk

A pallet truck’s wheels and the pallet itself can crush a foot positioned underneath or immediately alongside the load path, and this risk is specifically elevated when maneuvering in tight spaces or turning, where the operator’s own feet can end up closer to the load’s path than intended without a deliberate awareness of foot position throughout the movement. Keeping feet clear of the truck’s wheel path and the pallet’s footprint at all times, not just when moving in a straight line, addresses a risk that is easy to underestimate given how slow-moving pallet trucks generally are.

Load stability and pallet condition

An unstable or poorly stacked load on a pallet truck can shift during movement, particularly when turning or on any incline, and checking load stability before moving, not just the truck’s mechanical function, is part of a complete pre-use check. Pallet condition itself matters too — a damaged or split pallet can fail under load during transport in a way that has nothing to do with the truck or the load’s own stacking.

Ramps, inclines and floor transitions

Manual pallet trucks are considerably harder to control on any incline than on a level floor, since the operator has less ability to stop or control a loaded truck’s momentum going downhill, and pushing rather than pulling on a downward incline, keeping the truck between the operator and any hazard below, reduces the consequence if control is lost. Floor transitions, such as the edge of a loading dock leveler or a threshold between different floor surfaces, can also unexpectedly destabilize a load if crossed too quickly or at an angle.

Pushing versus pulling

Pushing a hand truck or pallet truck generally gives better visibility of the path ahead and more control than pulling, though pulling can be appropriate in certain tight or reversing situations, and the choice should reflect which gives better visibility and control for the specific space being navigated, rather than defaulting to whichever feels more natural without considering the actual layout.

Weight limits and hand truck selection

Both pallet trucks and hand trucks have a rated maximum load capacity, and exceeding it strains the equipment’s mechanical components and control in ways that increase both mechanical failure risk and loss-of-control risk during movement. Selecting equipment rated for the actual load, rather than the nearest available truck regardless of its rated capacity, matters directly for both these risks.

For safe stacking practices that affect load stability before transport even begins, see safe stacking and load securing for storage.

Related standards

The standards below set the test methods and performance levels behind the equipment referenced in this note.

• EN ISO 20345 — Safety footwear
• EN 388 — Gloves against mechanical risks

Frequently asked questions