OSHA Forklift Safety – Powered Industrial Trucks

Powered industrial trucks, commonly called forklifts or lift trucks, are used throughout construction, manufacturing, warehousing, distribution, retail, and other industries to move, lift, stack, and position materials.

Although forklifts make material handling faster and more efficient, they can create serious hazards for operators and employees working nearby. Accidents may involve tipovers, pedestrian strikes, crushing injuries, falling loads, loading-dock incidents, collisions, or employees becoming caught between a forklift and another object.

OSHA forklift safety requirements are primarily found in 29 CFR 1910.178 – Powered Industrial Trucks, which addresses equipment, operation, maintenance, and operator training.

Different Types of Forklifts

forklift-powered-industrial-trucks Not all forklifts operate the same way. Powered industrial trucks can vary significantly in their design, capacity, stability, visibility, controls, and intended use.

Common types include:

Sit-down counterbalanced forklifts.
Stand-up rider trucks.
Reach trucks.
Order pickers.
Motorized pallet trucks.
Walkie and walkie-rider trucks.
Rough-terrain forklifts.
High-lift and low-lift trucks.

The type of truck used should be appropriate for the load, workplace, surface conditions, operating environment, and work being performed. Operators must be trained for the type of powered industrial truck they are authorized to operate.

Common Forklift Hazards

Many forklift accidents result from a combination of equipment, operator actions, workplace layout, loads, and surrounding activity.

Common hazards include:

Tipovers – Excessive speed, sharp turns, elevated loads, uneven surfaces, overloading, slopes, and unstable loads can affect forklift stability.
Pedestrian accidents – Employees can be struck, pinned, or crushed when pedestrians and forklifts share the same work area.
Falling loads – Unstable or improperly positioned materials may shift or fall during lifting or travel.
Loading docks – Forklifts can travel over dock edges or become caught between a dock and a trailer that moves unexpectedly.
Limited visibility – Loads, racks, trailers, doorways, intersections, and other obstructions can prevent operators from seeing pedestrians or hazards.
Overhead hazards – Elevated forks or loads can contact doors, racks, pipes, sprinklers, structures, or electrical hazards.
Equipment problems – Defective brakes, steering, tires, forks, hydraulics, or other components can contribute to accidents.
Fueling and charging hazards – Battery charging and fuel handling can introduce electrical, chemical, fire, and explosion hazards.
Exhaust exposure – Internal-combustion forklifts may create carbon monoxide and other exhaust hazards when operated indoors or in poorly ventilated areas.

Forklift Stability

Forklifts are designed to lift substantial loads while remaining relatively compact and maneuverable. This makes stability one of the most important aspects of forklift operation.

Stability can be affected by:

Weight and position of the load.
Load center.
Lift height.
Attachments.
Speed and turning.
Braking and acceleration.
Ramps and slopes.
Uneven or damaged surfaces.

A load that is within the forklift’s rated capacity can still create a hazard if it is improperly positioned or handled.

Loads should be stable and properly positioned, and operators should travel with the load only as high as necessary to clear the operating surface. Sudden turns, stops, or other movements that could affect stability should be avoided.

Pedestrians and Forklifts

Forklift safety is not limited to the operator. Employees working on foot may be exposed whenever forklifts and pedestrians occupy the same area.

Workplaces can reduce pedestrian hazards through measures such as:

Designated pedestrian walkways.
Barriers or guardrails.
Marked forklift travel lanes.
Warning signs.
Mirrors at blind intersections.
Adequate lighting.
Restricted areas.
Established traffic procedures.

Operators should slow down and sound the horn at cross aisles and other locations where vision is obstructed.

Pedestrians should remain alert around operating forklifts and never assume the operator can see them.

No person may stand or pass beneath the elevated portion of a powered industrial truck, whether it is loaded or empty.

Loads and Material Handling

Forklift capacity is affected by more than the total weight of a load. The size, shape, position, stability, and load center can all influence how safely the truck handles material.

Operators should know the forklift’s rated capacity and consider:

Load weight and load center.
Condition of pallets and containers.
Fork positioning.
Load stability.
Overhead clearance.
Visibility.
Travel path.
Surface conditions.
Final placement of the load.

Unusually long, tall, wide, off-center, or irregular loads may require additional precautions.

Loads should be stable or safely arranged before they are moved, and caution should be used when handling loads that cannot be centered.

Traveling Safely

Operators should maintain control of the forklift and operate at a speed that allows the truck to be stopped safely.

The direction of travel and speed should account for pedestrians, intersections, visibility, surface conditions, loads, ramps, and other workplace hazards.

If a load obstructs the operator’s forward view, the forklift should generally travel with the load trailing when conditions permit.

Operators should avoid stunt driving, horseplay, unsafe passing, and sudden movements that could affect stability.

Unauthorized riders are prohibited. Where riding is authorized, a safe place to ride must be provided.

Loading Docks and Trailers

Loading docks deserve particular attention because they combine forklifts, elevated edges, trailers, pedestrians, and changing conditions.

Potential accidents include:

Driving over an open dock edge.
Trailer movement while a forklift is inside.
Dockboard or bridge-plate failure.
Trailer floor failure.
Insufficient trailer support.
Pedestrian and forklift conflicts.

Dockboards and bridge plates must be properly secured and capable of supporting the expected load.

Before forklifts enter trailers, trucks, or railroad cars, appropriate precautions must be taken to prevent unintended movement and verify that the floor can support the truck and load.

Forklift Inspections

Forklifts must be maintained in safe operating condition.

OSHA requires powered industrial trucks to be examined before being placed in service, at least daily. When forklifts are used continuously around the clock, they must be examined after each shift.

Depending on the truck, an inspection may include:

Forks and mast.
Tires and wheels.
Brakes.
Steering.
Hydraulic systems.
Controls.
Warning devices.
Lights and alarms.
Operator restraint system.
Attachments.
Fuel or battery system.
Fluid leaks.
Other safety-related components.

A powered industrial truck that is not in safe operating condition must be removed from service until it has been restored to safe operating condition.

Forklift Operator Training

OSHA requires employers to ensure that powered industrial truck operators are competent to operate the equipment safely.

Training must consist of a combination of:

Formal instruction such as lectures, discussions, videos, written materials, or interactive learning.
Practical training including demonstrations and exercises performed by the trainee.
Evaluation of the operator’s performance in the workplace.

Training must address both the truck and the workplace in which it will be operated.

Truck-related topics may include controls and instrumentation, steering and maneuvering, visibility, attachments, capacity, stability, inspections, fueling or charging, and operating limitations.

Workplace-related topics may include surface conditions, load composition and stability, pedestrian traffic, narrow aisles, hazardous locations, ramps and slopes, ventilation, and other environmental conditions.

Training and evaluation must be conducted by a person with the knowledge, training, and experience necessary to train operators and evaluate their competence.

Refresher Training

OSHA does not require forklift operators simply to repeat the entire training course every three years.

Refresher training is required when:

An operator is observed operating a forklift unsafely.
An operator is involved in an accident or near-miss incident.
An evaluation indicates that an operator is not operating safely.
An operator is assigned to a different type of powered industrial truck.
Workplace conditions change in a way that could affect safe operation.

Refresher training must address the relevant topics necessary to restore safe operating knowledge and skills.

Three-Year Operator Evaluation

Separate from refresher training, OSHA requires employers to evaluate each powered industrial truck operator’s performance at least once every three years.

The evaluation is intended to verify that the operator continues to have the knowledge and skills necessary to operate the truck safely in the actual workplace.

Employers must certify that each operator has been trained and evaluated as required. The certification must include the operator’s name, training date, evaluation date, and identity of the person or persons performing the training or evaluation.

Parking and Unattended Forklifts

When a powered industrial truck is left unattended, OSHA requires the load-engaging means to be fully lowered, controls neutralized, power shut off, and brakes set. Wheels must be blocked when the truck is parked on an incline.

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

When an operator dismounts but remains within 25 feet and keeps the truck in view, the load-engaging means must still be fully lowered, controls neutralized, and brakes set.

Fueling and Battery Charging

Forklift fueling and battery charging can introduce additional hazards involving flammable fuels, electrical energy, corrosive battery electrolyte, and hydrogen gas.

Designated areas should be used for charging or changing batteries and for fuel handling as required. Ignition sources must be controlled, appropriate ventilation provided where necessary, and employees must follow the requirements applicable to the type of truck and energy source.

Preventing Forklift Accidents

Forklift safety depends on more than the actions of the operator.

Safe operation requires attention to the interaction between the forklift, operator, pedestrians, loads, workplace layout, docks, trailers, traffic patterns, surface conditions, and surrounding environment.

Properly selected and maintained equipment, trained and evaluated operators, effective pedestrian controls, appropriate load handling, routine inspections, and good workplace traffic management can significantly reduce the potential for serious forklift accidents.

For additional regulatory information, see OSHA 29 CFR 1910.178 – Powered Industrial Trucks.

For company-specific procedures, responsibilities, inspections, operator training, evaluations, maintenance, and documentation, refer to the company’s Forklift/Powered Industrial Truck Program.