Forklift aisle width calculator
Work out how wide a forklift route must be, from the vehicle or load width and the traffic. The calculation follows the German workplace rule ASR A1.8. The Polish standard PN-M-78010 and US OSHA guidance are shown for comparison.
Result (ASR A1.8)
For comparison: PN-M-78010, two-way without pedestrians: . OSHA guidance (USA), one-way: .
How the width is calculated
- ASR A1.8 adds a safety margin on each side of the vehicle or load: 0.50 m where only vehicles use the route, 0.75 m where pedestrians use it too.
- A two-way route needs room for two vehicles side by side, the margins on both outer sides and 0.40 m between the vehicles.
- PN-M-78010 asks for at least 1.20 m, and for two-way traffic without pedestrians twice the width of the loaded vehicle plus 0.90 m.
- OSHA does not give a number. A long-used guideline is the widest vehicle or load plus 3 ft (0.91 m), and at least 4 ft (1.22 m).
What the calculator does not cover
- Extra width at bends and crossings, which depends on the turning radius of your vehicle.
- The 1 m clearance that vehicle routes must keep from doors, gates and stair exits.
- Hand-moved trucks, where the margins come from your own risk assessment.
- Local rules in your country. Always check the final layout with a qualified person.
Planning a whole hall?
Hallroute places every machine in your hall for the shortest real forklift routes, with these aisle widths, operator areas, pallet space and escape routes built in. Import a DXF from AutoCAD or paste from Excel.
Open the free optimizerFrequently asked questions
How wide must a one-way forklift aisle be?
Under ASR A1.8 it is the width of the vehicle or load plus 0.50 m on each side, so a 1.2 m forklift needs 2.2 m. Where pedestrians use the same route, the margin is 0.75 m on each side, so 2.7 m.
How wide must a two-way forklift aisle be?
Two vehicle or load widths, the side margins and 0.40 m between the vehicles. For two 1.2 m forklifts without pedestrians that is 3.8 m.
Does this replace a risk assessment?
No. The calculator gives the minimum width from the rule. Bends, crossings, doors, visibility and local rules still have to be checked for your hall.