15 Oct Forklift Safety – Safe Operation and Equipment Hazards

Forklift Safety – Safe Operation and Equipment Hazards

Forklift safety requires trained operators, properly maintained equipment, and constant awareness of pedestrians, loads, travel surfaces, and surrounding hazards. Forklifts are essential material-handling equipment, but their weight, limited visibility, rear-end steering, and ability to carry elevated loads can result in serious injuries, fatalities, and property damage when operated improperly.

Operator Training and Authorization

Only employees who have been properly trained, evaluated, and authorized by the employer may operate a forklift.

Under OSHA’s Powered Industrial Truck standard, operators must receive training that includes formal instruction, practical hands-on training, and an evaluation of their ability to safely operate the specific type of truck used.

Operator performance must be evaluated at least once every three years. Refresher training and an evaluation are required when an operator:

• Operates the forklift unsafely.
• Is involved in an accident or near-miss incident.
• Receives an evaluation indicating unsafe operation.
• Is assigned to operate a different type of forklift.
• Encounters workplace changes that could affect safe forklift operation.

Training must be completed before an employee is permitted to operate a forklift independently.

Operator Responsibilities

Forklift operators are responsible for operating their equipment safely and protecting themselves, coworkers, pedestrians, property, and materials.

Operators shall:

• Operate only forklifts they are trained, evaluated, and authorized to use.
• Follow manufacturer instructions and company procedures.
• Wear required personal protective equipment.
• Use the operator restraint system or seat belt when provided.
• Never engage in horseplay or reckless operation.
• Never permit unauthorized riders.
• Keep arms, legs, hands, and other body parts within the operator compartment.
• Report accidents, near misses, equipment damage, and unsafe conditions immediately.
• Never operate a forklift while impaired by fatigue, medication, alcohol, drugs, or another condition that prevents safe operation.

Pre-Operation Inspection

Forklifts must be examined before being placed in service. At a minimum, inspections are required daily and after each shift when forklifts are used continuously around the clock.

Before operating the forklift, check items such as:

• Forks and attachments.
• Tires and wheels.
• Mast and lift components.
• Hydraulic hoses and cylinders.
• Steering.
• Service and parking brakes.
• Horn.
• Lights and warning devices.
• Controls and gauges.
• Seat belt or operator restraint system.
• Overhead guard and load backrest, when equipped.
• Fuel, battery, or other energy system.
• Fluid leaks and visible damage.

Any forklift found to be unsafe must be removed from service until it has been repaired and determined safe to operate.

Traffic Safety

Operators must follow established traffic rules and remain alert to changing workplace conditions.

• Obey posted speed limits, traffic signs, and workplace traffic rules.
• Maintain a safe speed that allows the forklift to be stopped safely.
• Slow down for wet, slippery, uneven, or hazardous surfaces.
• Slow down and sound the horn at cross aisles and other locations where vision is obstructed.
• Maintain a safe following distance from other vehicles.
• Keep the forklift under control at all times.
• Avoid sudden starts, stops, and turns.
• Allow sufficient clearance beneath overhead installations, doors, pipes, sprinklers, and other obstructions.
• Maintain adequate clearance from edges of loading docks, ramps, excavations, and elevated surfaces.
• Never drive toward a person standing in front of a fixed object.
• Follow established procedures when operating on ramps or grades.

Pedestrian Safety

Pedestrians and forklifts frequently occupy the same work areas, making communication and visibility critical.

Operators shall:

• Yield to pedestrians.
• Watch for employees entering aisles or crossing travel paths.
• Sound the horn where visibility is obstructed.
• Establish eye contact with pedestrians when practical.
• Never assume a pedestrian sees or hears the forklift.
• Maintain sufficient clearance from pedestrians.
• Never allow anyone to walk or stand beneath elevated forks or loads.
• Use designated travel lanes and pedestrian exclusion zones when provided.

Pedestrians should remain alert and stay clear of operating forklifts, especially when the forklift is turning or backing.

Traveling With a Load

Loads can affect a forklift’s steering, stability, braking distance, and visibility.

• Make sure the load is stable and safely arranged before traveling.
• Keep the load within the forklift’s rated capacity.
• Carry forks or loads only as high as necessary to provide safe ground clearance.
• Tilt the load back when appropriate to stabilize it.
• Accelerate, brake, and turn smoothly.
• Never raise or lower a load while traveling except as necessary for safe positioning.
• Never travel with an unstable or inadequately secured load.
• Allow for the forklift’s rear-end swing when turning.

If a load obstructs the operator’s forward view, travel with the load trailing when safe to do so and maintain a clear view in the direction of travel.

Load Handling and Capacity

Never exceed the forklift’s rated capacity.

Before handling a load:

• Know the approximate weight of the load.
• Check the forklift’s capacity/data plate.
• Consider the load center and attachment being used.
• Spread the forks appropriately for the load.
• Insert the forks as far beneath the load as practical.
• Make sure the load is centered and stable.
• Secure unstable loads before moving them.

Attachments can change the forklift’s capacity and operating characteristics. Only approved attachments may be used, and the forklift’s capacity information must reflect modifications when required.

Ramps and Grades

Use additional caution when operating on grades.

• Travel slowly.
• Maintain control of the forklift.
• Keep a safe distance from ramp edges.
• Avoid turning on grades whenever possible.
• Follow manufacturer requirements for the particular forklift and load.

On grades exceeding 10 percent, loaded forklifts must generally be driven with the load upgrade.

Parking and Unattended Forklifts

When parking a forklift:

• Park only in an authorized location.
• Do not block aisles, exits, emergency equipment, fire extinguishers, or access routes.
• Fully lower the forks or other load-engaging means.
• Place the controls in neutral.
• Set the parking brake.
• Shut off the power when the forklift is unattended.
• Prevent movement when parked on an incline.

A forklift is considered unattended under OSHA requirements when the operator is 25 feet or more away while the vehicle remains in view, or whenever the operator leaves the vehicle and it is not in view.

When the operator is within 25 feet and the forklift remains in view, the forks must still be fully lowered, controls neutralized, and brakes set.

Refueling and Battery Charging

Refueling and battery charging introduce fire, explosion, chemical, and electrical hazards.

• Refuel or recharge only in designated areas.
• Shut off the engine during refueling.
• Prohibit smoking and ignition sources.
• Follow manufacturer procedures.
• Clean up fuel spills before restarting the forklift.
• Use appropriate PPE when servicing batteries.
• Provide adequate ventilation in battery-charging areas.
• Keep tools and metallic objects away from exposed battery terminals.
• Follow applicable procedures for propane cylinder replacement.

Remember

Forklifts are powerful industrial vehicles, not passenger vehicles. Operate only equipment you are trained and authorized to use, inspect it before operation, maintain control of the load, watch constantly for pedestrians, and never operate defective equipment.

No production deadline or material-handling task justifies unsafe forklift operation.