Forklift load testing is one of those legal requirements that operations know they need to comply with but don’t always understand in detail. What exactly does the test involve? Who can perform it? What happens if a forklift fails? And what are the real consequences of running an uncertified machine?
This guide covers the legal framework, the testing process, the certification requirements, and the practical steps to stay compliant for South African businesses operating forklifts in Johannesburg, Gauteng, and beyond.
The legal basis: OHS Act and Driven Machinery Regulation 18
Forklift load testing is a statutory requirement under the Occupational Health and Safety Act, 1993 (Act 85 of 1993). The specific regulation governing forklifts and lift trucks is Driven Machinery Regulation 18 — often referred to as DMR 18 or Regulation 18.6.
The Act requires that all lift trucks (forklifts) be subjected to an independent load performance test annually and inspected by a competent person every six months. The test must be conducted by a registered Lifting Machinery Inspector (LMI) who is accredited with the Department of Employment and Labour.
The relevant technical standard underpinning the test process is SANS 10388:2019, which sets out the scope of components to be examined and the method for conducting the performance test.
What is actually tested and inspected?
The annual load test is not just a weight test. It is a combined inspection and performance assessment that covers the machine’s structural integrity, safety systems, and lifting capability under load.
The inspection component
Before any load is applied, the LMI conducts a visual and mechanical inspection of the forklift. Items typically examined include:
- Mast integrity: chains, rails, rollers, and weld condition.
- Fork condition: wear, cracks, camber, and attachment security.
- Hydraulic system: cylinder seals, hose condition, and oil level.
- Braking and steering systems.
- Tyre condition: tread, wear, inflation (pneumatic), and separation (solid).
- Safety systems: horn, lights, seatbelt, overhead guard.
- Data plate legibility and accuracy.
Any component found to be defective or outside the acceptable tolerance is recorded in the inspection report. Depending on the severity, this may prevent the performance test from being completed until the defect is repaired.
The performance (load) test
The performance test must be conducted at 110% of the forklift’s rated lifting capacity. So a 2,500 kg rated forklift must be tested at 2,750 kg. The test can be conducted as either a static test (load held stationary at rated height) or a dynamic test (load raised and lowered through the full working range). In practice, most South African service providers use calibrated test weights that are documented with current calibration certificates.
The test weight must match the machine’s load centre specification, not just the weight figure, because how a load is distributed on the forks affects the stability calculation.
Who can legally perform a forklift load test in South Africa?
Only a registered Lifting Machinery Inspector (LMI) accredited with the Department of Employment and Labour may conduct forklift load tests and issue valid certificates. The LMI must hold a current registration under the Engineering Professions Act 46 of 2000.
This means the person carrying out the test cannot be an in-house technician, a forklift operator, or an unregistered contractor, regardless of how experienced they are. A load test conducted by anyone other than a registered LMI is not legally valid and cannot be used to issue a certificate that satisfies the OHS Act requirement.
When booking a load test, ask the service provider to confirm the LMI’s registration number and current accreditation status. GP Forklifts coordinates load testing through accredited inspectors and can provide certification details on request.
How often must load testing be done?
Requirement | Frequency | Trigger |
Load performance test | Annually (every 12 months) | Calendar-based or hours-based, whichever is more frequent in your risk assessment |
Inspection by competent person | Every 6 months | As above |
Load test after major repair | After any structural or hydraulic repair that could affect lifting capacity | Event-based |
Load test after modification | After any modification to the mast, forks, or load-handling attachment | Event-based |
Load test before first use | For new or newly acquired forklifts being placed into service | One-off at commissioning |
Some industries and high-risk environments (mining, ports, high-throughput logistics) conduct load tests more frequently than the statutory minimum as part of their internal risk management protocols. The OHS Act sets the floor, not the ceiling.
What happens if a forklift fails its load test?
If a defect is found during the inspection phase, the LMI will document it in a defect report. Whether the performance test can proceed depends on the severity of the defect. Safety-critical defects, typically structural issues with the mast, fork cracks, hydraulic failure, or a compromised overhead guard, will result in the test being suspended until repairs are completed.
South African OHS Act regulations require that defects identified in a load test report be rectified and the forklift retested before it returns to service. The commonly observed window for completing repairs and arranging a retest is 14 calendar days, though the Act does not specify a fixed timeframe: the machine simply cannot legally operate until it passes.
GP Forklifts can coordinate the repair work directly for defects within our scope (hydraulic components, tyre condition, mast wear, fork assessment) and then arrange the retest through the accredited LMI.
What are the consequences of operating without a valid certificate?
Running a forklift with an expired or missing load test certificate is illegal under the OHS Act. The consequences can include:
- Enforcement action by a Department of Employment and Labour inspector, including prohibition notices that stop the machine from operating.
- Personal liability for the employer and for the health and safety representative if an accident occurs involving an uncertified forklift.
- Invalidation of COID (Compensation for Occupational Injuries and Diseases) claims in the event of an operator injury, if the uncertified machine was a contributing factor.
- Insurance complications: most industrial insurance policies include compliance with statutory safety requirements as a condition of cover.
The legal risk is not theoretical. Department of Labour inspection campaigns in Gauteng’s logistics and manufacturing sectors have resulted in stop-work notices on sites where forklift certificates were found to be expired.
How much does a forklift load test cost in South Africa?
Load test costs in Johannesburg and Gauteng generally range from R800 to R2,500 per forklift, depending on machine size, site location, and whether the visit covers multiple units. Fleet bookings, where several forklifts are tested in one visit, are typically more cost-effective per unit because the LMI’s travel and setup time is shared across the group.
For a site-specific quote covering your Johannesburg or Gauteng operation, contact GP Forklifts on 010 110 1819 or email sales@gpforklifts.co.za. We can schedule the test, coordinate the LMI visit, and issue the certificate on the same day the test is completed.
Frequently asked questions
What is Driven Machinery Regulation 18 (DMR 18)?
Driven Machinery Regulation 18 is the specific regulation under the Occupational Health and Safety Act 85 of 1993 that governs the inspection and testing of driven machinery, including forklifts and lift trucks. Regulation 18.6 specifically requires that all lift trucks be subjected to a load performance test annually and inspected by a competent person every six months. Non-compliance is a criminal offence under the OHS Act.
Can I conduct a forklift load test using my own in-house technician?
No. The OHS Act requires that load tests be conducted by a registered Lifting Machinery Inspector (LMI) who is accredited with the Department of Employment and Labour. In-house technicians, regardless of experience or qualifications, cannot issue a legally valid load test certificate. The LMI must also use calibrated test weights with current calibration documentation.
Does a new forklift still need a load test before being used?
Yes. New forklifts being placed into service for the first time in South Africa require a load test and inspection before operations begin, even if the manufacturer has conducted factory testing. The factory test is not a substitute for a test conducted by a South African-registered LMI under the OHS Act framework.
What documents should I keep after a forklift load test?
You should retain the load test certificate itself, the inspection report documenting all components examined, and the test weight calibration certificates used during the test. These records should be kept on site and available for inspection by a Department of Labour inspector at any time. Records must be retained for at least 12 months, but most compliance consultants advise keeping the full history for the life of the machine.
How long does a forklift load test take?
A standard load test for a single counterbalance forklift typically takes one to two hours, covering the pre-test inspection, the performance test, and the documentation. For fleet testing, scheduling multiple machines in one visit allows the inspection and test phases to overlap, reducing the total time per machine. GP Forklifts issues the certificate on the same day the test is completed.
How do I book a forklift load test in Johannesburg or Gauteng?
Contact GP Forklifts on 010 110 1819 or email sales@gpforklifts.co.za to arrange a load test at your Johannesburg or Gauteng site. We coordinate the accredited LMI visit, assist with any pre-test repairs to improve the chances of passing first time, and issue the OHS-compliant certificate on completion.
