A forklift striking a chemical IBC is not a rare event—it is a predictable failure mode. Under COMAH, predictable failures demand engineered controls. In UK chemical manufacturing facilities, where large volumes of hazardous substances are handled daily, even a minor collision can escalate into a major accident scenario. Forklifts are central to these operations, yet their visibility limitations are often underestimated in safety cases. For COMAH operators, this is no longer acceptable. Visibility systems on forklifts are increasingly scrutinised as part of the evidence base for major accident prevention, particularly where loss of containment risks are involved.
Forklift Blind Spots as a COMAH Risk Factor
The Control of Major Accident Hazards Regulations 2015 require you to identify and control scenarios that could lead to significant harm. In chemical manufacturing, this includes loss of containment events involving drums, IBCs, and process materials.
Forklift operations intersect directly with these risks. Common scenarios include:
- Impact with IBCs during transport or stacking
- Contact with drum storage areas during manoeuvring
- Collisions in congested loading or decanting zones
These are not edge cases. They are foreseeable events in busy facilities.
A 360 degree camera for forklift becomes relevant not just as a safety aid, but as a control measure within your COMAH risk assessment. It addresses the root cause of many of these incidents: limited operator visibility.
From a regulatory perspective, if a control can reasonably reduce the likelihood of a major accident, it must be considered. Visibility technology now falls into that category.