Fork guides are one of the most important features on any stillage, cage or pallet that will be lifted or moved by a forklift, telehandler or side loader. They locate the forks in a controlled position, stop the load shifting on the tines and make handling faster and safer. On our engineered steel stillages and wider product range, fork guides are a standard design consideration rather than an afterthought.
This guide explains what fork guides do, the two main types we manufacture, how we decide which to use, and how to choose the right option for your application.
What are fork guides and why use them?
Fork guides are steel channels or pockets fitted to the base of a stillage or pallet. Each guide constrains one fork of the lifting equipment within an area slightly larger than the fork itself, so the load stays located correctly throughout the lift and the journey.
The benefits all come down to safety and risk reduction:
- They stop the load slipping. Without guides, a load can shift on the forks during lifting or while travelling between locations, which risks the load falling, near misses, damage or injury.
- They speed up handling. A driver can locate the forks quickly and consistently, with less repositioning.
- They support compliance. Well-designed handling points help operators use equipment safely and are part of meeting your duties under the relevant regulations.
Fork guides sit within a broader safety picture. Lifting a stillage is a lifting operation, so the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) apply to the lift itself, while the day-to-day use of the equipment falls under the Provision and Use of Work Equipment Regulations 1998 (PUWER). For general handling practice, our stillage safety guide covers training, reporting and safe handling in more detail.
How we decide which fork guide to use
Choosing a fork guide is a design decision, not a fixed catalogue option. When we specify a product we look at three things:
- Application. Where and how the product is handled, stored and transported, and what lifting equipment is available on site.
- Design of the load and the product. The overall size and shape of the product, and the size, shape and packaging of what it will carry.
- Magnitude of the load. The safe working load (SWL) the product must carry, which drives the section size and steel thickness.
We also position the guides so the forks sit evenly about the combined centre of gravity of the product and its load. Where possible we design the product so its centre of mass is close to its centre of gravity, which keeps everything balanced during lifting and travel. Getting this right up front is far cheaper than reworking a design later, which is why we ask for accurate weights and dimensions early. Our guide to giving us the right technical information explains exactly what helps.
If you are working through a new specification from scratch, our buyer’s and design guide walks through the wider decisions alongside the fork guide choice.
The two main types of fork guide
We primarily manufacture two types of fork guide. Most products use one of these, but we regularly adapt the design where an application calls for something different.
Formed fork guides
Formed fork guides are steel plate bent and formed to suit the required fork dimensions, in a width equal to or less than the section they are welded to, and in a thickness chosen to suit the load and application. They are fitted to either side of the base of the product.
- Best for: products with a lower SWL, typically up to around 2 tonnes.
- Product size: works well where the product width is shorter than the length of the forks being used.
- Typical uses: warehousing and storage, and light-to-medium production and industrial applications.
Formed guides are common across our metal stillages and mesh stillages, where loads are moderate and the priority is efficient day-to-day handling.
Box fork guides
Box fork guides are made from cut lengths of rectangular hollow section (RHS) that span the full length of the product. The RHS is sized slightly larger than the forks used to lift it, with the wall thickness chosen to suit the size and weight of the load.
- Best for: products needing a higher SWL, typically 2 tonnes and above.
- Product size: suits products whose length is equal to, or slightly longer than, the forks being used. Any overhang should be kept to a minimum, or fork extensions used.
- Typical uses: medium-to-heavy industrial applications and specialist products.
Box guides are a natural fit for heavier equipment such as post pallets and collapsible metal pallets used for demanding site and factory loads.
Two-way and four-way fork guides
Both formed and box fork guides can be arranged for two-way or four-way access:
- Two-way: the forks enter from one axis only. This is the most common arrangement and suits products handled in a consistent orientation.
- Four-way: guides are fitted along both the length and the width of the product, so it can be lifted from either side. This adds flexibility for handling in tight spaces and extra security when a product needs to be picked up from the side.
Four-way access is straightforward with formed guides and can also be achieved with box guides by cutting out a section where the runs cross each other.
Other fork guide options
Formed and box guides cover most requirements, but we regularly design alternatives to suit a specific application, including:
- Integrated skid and fork guide combinations
- Half fork guides
- Pallet truck guides for hand-operated pallet trucks
Because everything is designed and fabricated in-house, we can adapt the handling arrangement to fit your equipment, your load and your site rather than forcing your process to fit a standard product. Custom work is available across our bespoke stillage solutions.
Quick decision checklist
Not sure which type you need? Use this as a starting point:
- Load up to ~2 tonnes, product narrower than the forks, general warehouse or light-industrial use? Formed fork guides are usually the right choice.
- Load 2 tonnes or more, longer product, heavier industrial or specialist use? Box fork guides give the strength and length you need.
- Need to lift from more than one side? Specify four-way guides.
- Using a hand pallet truck as well as a forklift? Ask about pallet truck guides or a combination arrangement.
If your application does not fit neatly into these, that is exactly the point at which a quick conversation with our team saves time and money.
Talk to us about the right fork guides
Whatever you need to move, we can design and manufacture a stillage, cage or pallet with the correct fork guides for the job. Tell us the load, the dimensions and how it will be handled, and we will recommend the best option.
Request a quote or contact our team to discuss your requirements. You can also call us on 01889 563244.