14 Apr Forklift Fatalities

Forklift Fatalities

Forklifts are powerful material-handling equipment, but their weight, limited visibility, changing center of gravity, and interaction with pedestrians can make an accident extremely serious. Tip-overs, struck-by incidents, crushing hazards, falling loads, and falls from elevated forks or platforms can result in severe injury or death.

Older forklift accident statistics are frequently repeated in safety materials, but employees should focus on the causes of serious incidents and the actions that prevent them rather than relying on outdated percentages.

Guide for Discussion

Common Causes of Serious and Fatal Forklift Accidents

Serious forklift incidents commonly involve:

• Forklift tip-overs.
• Operators being crushed between the forklift and another surface or object.
• Pedestrians being struck or run over.
• Collisions between forklifts, vehicles, structures, or equipment.
• Workers being struck by falling or unstable loads.
• Falls from elevated forks or improperly used work platforms.
• Driving from loading docks, ramps, or other elevated surfaces.
• Operating with obstructed visibility.
• Excessive speed or unsafe turning.
• Improper loading or exceeding the forklift’s rated capacity.

Training and Authorization

Under OSHA’s Powered Industrial Truck requirements, employees must be trained and authorized before operating a forklift.

Operator training must include formal instruction, practical training, and evaluation of the operator’s performance in the workplace. Operators must understand both the specific forklift they operate and the conditions present in their work environment.

Refresher training and evaluation are required when an operator:

• Operates the forklift unsafely.
• Is involved in an accident or near miss.
• Is observed operating the truck unsafely.
• Is assigned to operate a different type of truck.
• Encounters workplace changes that could affect safe operation.

Each operator’s performance must also be evaluated at least once every three years.

Preventing Tip-Overs

A forklift’s stability changes as loads are raised, lowered, tilted, and moved. To reduce the possibility of a tip-over:

• Never exceed the forklift’s rated capacity.
• Ensure loads are stable, centered, and properly positioned.
• Keep forks and loads as low as practical while traveling.
• Tilt the load appropriately according to the manufacturer’s instructions.
• Slow down before turning.
• Avoid sudden starts, stops, and directional changes.
• Use extreme caution on ramps, grades, docks, and uneven surfaces.
• Never turn a forklift on a ramp or grade unless specifically permitted by the manufacturer’s operating instructions.
• Maintain a safe distance from dock and platform edges.
• Never use a forklift on a surface that cannot safely support its weight and load.

If a Sit-Down Counterbalanced Forklift Tips Over

One of the most dangerous reactions during a tip-over is attempting to jump from the forklift. An operator who jumps may be caught or crushed by the overhead guard or truck.

For a typical sit-down counterbalanced forklift equipped with an operator-restraint system, follow the manufacturer’s instructions. Generally, the operator should:

• Stay in the forklift.
• Keep the seat belt fastened.
• Hold firmly to the steering wheel or available handholds.
• Brace the feet.
• Lean away from the direction of the tip.
• Do not attempt to jump from the truck.

Tip-over response can differ for other powered industrial trucks, including stand-up and rear-entry designs. Operators must be trained in the emergency procedures specified by the manufacturer for the particular truck they operate.

Pedestrian Safety

Forklift operators and pedestrians share responsibility for preventing struck-by and crushing incidents.

Operators must:

• Maintain a clear view in the direction of travel.
• Travel in reverse when a load obstructs the forward view when appropriate and safe to do so.
• Slow down and sound the horn at cross aisles and locations where vision is obstructed.
• Maintain adequate clearance from pedestrians.
• Never drive toward a person standing in front of a fixed object.
• Never allow anyone to stand or pass underneath elevated forks or loads.
• Keep hands, arms, legs, and other body parts within the operator compartment.

Pedestrians should establish eye contact with operators when possible and stay clear of forklift travel paths, blind corners, loading areas, and operating zones.

Falling Loads

Improperly stacked or unstable loads can fall onto operators or nearby employees.

Before moving a load:

• Verify that it is stable and safely arranged.
• Ensure the load is within the forklift’s rated capacity.
• Spread and position the forks appropriately.
• Insert the forks sufficiently beneath the load.
• Secure unusual or unstable loads when necessary.
• Never allow employees beneath an elevated load.

An overhead guard provides protection from certain falling objects but does not make it safe to travel beneath or remain beneath elevated loads.

Elevating Personnel

Never allow an employee to stand or ride directly on forklift forks or an unsecured pallet.

When a forklift is permitted to elevate personnel, use an approved personnel platform and procedures appropriate for the forklift and applicable OSHA requirements. Employees must never improvise a work platform using pallets, boxes, lumber, or similar materials.

Seat Belts and Operator Restraints

When a forklift is equipped with an operator-restraint system, use it as designed. Seat belts and other restraint systems help keep the operator within the protective area of the operator compartment during a tip-over.

Never disable, remove, or bypass an operator-restraint system.

Remember

Forklift accidents are rarely minor because forklifts are heavy machines operating around employees, structures, vehicles, and materials. Operate only when trained and authorized, wear the seat belt, keep traveling loads low, control your speed, watch for pedestrians, and never take shortcuts with forklift safety.

If a sit-down forklift begins to tip, stay with the truck—brace yourself, lean away from the tip, and do not jump.