Forklifts & Powered Industrial Trucks

Using forklifts to safely move material is a significant safety concern. During the movement of products and materials there are numerous opportunities for personal injury and property damage caused by improper forklift operations or safety procedures.  Safety programs for forklifts, powered industrial tucks, hoists & lifting gear are essential.

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A Forklift Safety or Powered Industrial Truck program is required by OSHA if your company has any mechanized-wheeled equipment for moving material or employees.  OSHA's standard also covers motorized pallet jacks.

Ensure that the type motor or engine for each type forklift in service is compatible with the environment in which it will be used.

Refueling or recharging stations for forklifts must be designed with proper ventilation - petroleum or LP gas refueling areas must be outside - battery charging areas require a well ventilated area with eye-wash/showers and material for battery acid spill cleanup.  Forklift Battery charging creates hydrogen gas which is highly explosive.

OPERATIONS

Look at the forklift operational environment for both the forklift and the operator. Select the type of forklift motor  and classification that is compatible with potential and existing hazards. 

Check paths of travel to ensure they are not restrictive and are well lit.  Forklift traffic paths should be marked on the floor areas to warn pedestrians.  Protect unguarded drop-offs and utility areas.  Look at areas where forklifts must make corners - ensure stair landings or doorways do not exit blindly into forklift traffic paths.

Place signs and mirrors along traffic paths.  Set and enforce a safe forklift speed limit both inside and outside.

Establish routine daily forklift operator inspections and documentation.  Establish procedures for identification, removal from service, replacement and control of unsafe forklifts and equipment.

Install seatbelts on all seats and attachments for lanyards & harnesses for any equipment used to elevate a worker above floor level.  All attachments must be authorized for the specific fork truck by the manufacturer.  Label attachments to show with what equipment they can be used.

Shipping Docks - check all areas for forklift clearance.  Conduct routine inspections of dock & bridge plates.  Set up a key control system to prevent trailers from being pulled away from docks while loading with a forklift is in progress.

Forklift Safety Training

Step 1  Review Information
Review OSHA Standard 1910.178
Review equipment manufacturer's operator manuals

Step 2 Identify Operators & Equipment
Operators- Anyone who is expected to ever operate a forklift or other "Powered Industrial Truck" such as manlifts, pallett jacks, etc., must be training and certified as an operator.

Equipment - There are many different types of powered industrial trucks. Typically, these types of vehicles are known as forklifts or lift trucks.  If your employees will be expected to operate several different types of powered industrial trucks, then training is required on the unique handling characteristics of the vehicles.

Step 3 - Define Training Methods

OSHA required that forklift training be conducted by a competent person.  Your company decides the level of competency.  The trainer must know the equipment, be able to conduct training and evaluate trainee performance.  Training must consist of a combination of formal instruction and practical training.

Formal instruction may include lectures, conferences, classroom discussions, demonstrations, and written or oral tests. To make the training  more understandable to the employee, consider using movies, slides, computers, video tapes and other visual presentations.