Forklift Safety - Preventing Injuries & Deaths

By
Larry Z. Sherman, CSP, CPCU, ALCM
There are over a million forklifts in use in the United States. They are the primary means of
movement and handling of materials and goods in most industries. Every year approximately
95,000 workers are injured in forklift accidents, with 20,000 of them being seriously injured, and
100 are killed. (Bureau of Labor Statistics - 1998) In addition to injuring employees, customers,
or visitors, a forklift can cause significant property damage. Forklifts are very heavy and
inherently unstable because they must be designed lift heavy loads and fit into small areas and
narrow aisle spaces.
Because they are so common, it is easy for both management and employees to become
complacent about the use of forklifts and to forget how dangerous and deadly they can be. For
many businesses, a forklift accident is probably the most likely exposure in the workplace to
cause a serious injury or death. It is important that operators of forklifts, also known as powered
industrial trucks, be properly trained to operate the equipment safely. Other workers who may
be exposed to the movement of forklifts should also be trained to work safely around forklifts.
OSHA has had a forklift standard since 1971 and in 1998 the standard was revised to be more
specific as to the training that forklift operators must receive, how often they must be evaluated
and re-certified, and under what circumstances an operator must be retrained. Only operators
who have been specifically trained and authorized may operate a powered industrial truck.
OSHA Training Requirements
An employer must ensure that each of their forklift operators is competent to operate a forklift by
the successful completion of the specific training and evaluation outlined in the OSHA standard.
Employees who have not received the training and evaluation are not permitted to operate a
forklift. During an inspection, OSHA compliance officers may require proof that the training was
conducted and that forklifts are being operated only by trained and authorized employees.
The training and the evaluation must be conducted by a person who has "the knowledge,
training and experience to train powered industrial truck operators and evaluate their
competence." OSHA does not require that the trainer be "certified" or have a specific
educational background or professional designation. If you have someone on staff who has the
required knowledge and experience and is capable of providing the training, that person can
conduct the training. The training must consist of a combination of formal instruction (e.g.,
lecture, discussion, interactive computer learning, video tape, written materials), practical
training (e.g., demonstrations by the trainer, practical exercises performed by the trainee) and
an evaluation of the operator's performance in the workplace. A trainee may operate a forklift
only under the direct supervision of a competent person and only where such operation does
not endanger the trainee or other employees.
The OSHA standard (CFR 1910.178 Powered Industrial Trucks) contains a very specific listing
of the subjects that must be covered in the training. If someone in your company is going to do
the training and is competent to do so, you should review the OSHA standard to be sure that
they include the required information. The standard is available for downloading from OSHA's
web site at www.osha.gov.
Refresher Training & Re-Evaluation:
Refresher training is required by OSHA when:
" The operator has been observed operating a forklift in an unsafe manner
" The operator has been involved in an accident or near-miss incident
" The operator has received an evaluation that reveals that the operator is not operating the
forklift safely
" The operator is assigned to drive a different type of powered industrial truck
" A condition in the workplace changes in a way that could affect safe operation of the forklift
Once an operator has been trained and evaluated, they must be re-evaluated at least once
every three years according to the OSHA standard. Although the standard allows this time
period without re-evaluation, prudent employers will chose to conduct a re-evaluation and
refresher training annually.
The OSHA standard attempts to avoid the need for duplicative training if a forklift operator is
hired who has operated the same type of powered industrial trucks at their prior place of

employment. If the operator has proof that they received the training from their prior employer,
and the training was appropriate for the type of truck and same type of working conditions,
additional training by the new employer is not required if the operator is evaluated and found to
be competent to operate the forklift safely. Again, it is probably better to provide the training
anyway to be sure that the driver has been trained properly in all of the required subjects.
Basic Forklift Operation Safety Practices:
The following are some of the basic safe operating practices that you should teach all forklift
operators should follow:
Inspect the forklift before each use or at the beginning of each shift. Check horn, lights,
brakes, warning devices/flashing lights, mast tilt & raise/lower mechanism, tires & wheels, oil
leaks, hydraulic lines, chains, forks (level, not bent, no cracks)
Don't operate a forklift that has any mechanical deficiencies
Buckle your seat belt if forklift has one
Keep hands, arms and legs inside the cage
Know the capacity of the forklift and know the weight of the load to be lifted. Don't exceed
the load capacity of the forklift. If the weight of the load is close to the capacity of the forklift,
proceed with extreme caution or find a way to reduce the weight.
Drive, turn and stop SLOWLY and smoothly
If the view forward is blocked by materials being carried, drive backwards
Before backing, LOOK BACK OVER BOTH SHOULDERS!
Slow down and sound the horn at all intersections, doorways, blind corners, etc.
Don't drive a forklift up to anyone standing in front of a wall, rack or other fixed object
No riders!!! No one should be on a forklift except the operator
Don't lift people unless an approved safety platform is used and it is secured to the forks
Travel with the load uphill when going up or down a hill, incline, ramp, etc.
Don't move unstable loads
Be cautious around holes in floors, uneven surfaces, ramps, slopes or grades, etc.
Yield the right-of-way to pedestrians; assume they don't see or hear you
Don't let anyone walk under elevated loads. Keep everyone clear of the area when moving
or lifting a load
Plan your route for best surface, overhead clearances, visibility, etc.
Before getting off a forklift, lower the forks to the ground, set controls in neutral, turn off
engine, set parking brake.
Never push or pull things with your forks; they are designed to lift and can be damaged or
weakened by sideward pressure
Never turn on a slope or incline
Don't raise, lower or tilt a load while moving
Before entering a truck or trailer, be sure the wheels of the truck or trailer are chocked &
dock plate is set
Don't attempt to jump from an overturning, sit-down type forklift. Stay with the truck, holding
on firmly, and press your back against the seat back
Summary:
Forklifts are complex material handling vehicles which are capable of seriously injuring or killing
the operator, co-workers, customers, or visitors. They are very heavy vehicles and are
inherently unstable and prone to tip-over if not used properly. They can cause significant
physical damage such as knocking down walls, causing racks to topple or collapse or knock out
a building column causing the roof to collapse.
Limiting the number of operators and ensuring that those operators are trained in accordance
with OSHA requirements is important to control the hazards presented by forklifts. If a forklift
operator is observed operating in an unsafe manner, immediate action should be taken to reinstruct and re-evaluate that operator. Repeated violations of safe operating procedures should
result in removal of that operator from further operation of forklifts.

The use and misuse of forklifts and other similar equipment should be taken very seriously.
Failure to strictly control the hazards and exposures can result in very serious and costly
accidents.