Draft 7 27 2011

Forklift Safety
 July 13, 2011
One person died Wednesday after a forklift
accident in Fluvanna County. The incident
happened shortly after 5 p.m. in front of the
Tapscott Brothers Lumber Company. (NC)

The Will County Coroner's line reports that a 35

year old Aurora man was pronounced deceased
at Silver Cross Hospital at 7:22 AM Wednesday
morning, after a forklift accident in Mokena. The
Coroner's line stated that Jose R Barrera-Ruiz
died of multiple injuries.
 These Deaths Were Preventable
These were not isolated Workers have a right to a
incidents. safe workplace.

There were 1000+ deaths In the operation of forklifts

these are the FIVE largest
in 10 Years 2000-2010.
risks among many:
Falls
Hit by Falling or moving
Load
Hit by Forklift
Equipment overturning
Amputation

All of these are preventable

 2010 Injury Causation Statistics
32 falls: includes 12 pallet, platform or forks, 10 forklift went off dock, 1 ejected
from forklift, 5 fall from load lifted, 1 fall through hole, 1 order picker platform, 2
mezzanine

46 struck by falling/moving object or load

36 struck by forklift

15 forklift overturned

29 crushed or caught in forklift/load and an object

10 caught in amputation

5 burns / fire

3 CO, 1 Ammonia

Type of forklift not included - many not identifying the type

 Injury Prevention Basics
Management Leadership These principles are
adopted and
Employee Participation
recognized by
Hazard Prevention and 2100 VPP Companies
Control 1600 SHARPs
Education and Training 1926.20, 1926.21
1910.119
Program Evaluation and
Improvement ANSI Z9.10
OHSAS 18001
Communication and States AR, CA, LA,
coordination on multi- HI, MN, MT NV, NH,
employer sites
NY, OR, WA
 Falls

Pallets used as
elevating platforms
has lead to many
deaths and is not
acceptable
Employees use what
is available
Use proper
platforms designed
per ANSI/ITSDF
B56.1-2005
 Elevating/Order Picker Truck

Fall protection is
required when the
operator rides up with
the load
Use ANSI Z359 fall
arrest equipment
 Struck-by

What should be
done?
Many a foot have
been crushed by
people getting too
close.
How close is too
close?
 Struck By

Leaving forklift trucks

without brakes or
chocks
Truck Moves
 Struck By

Falling Loads KILL

Loads improperly
stored kill people.
What can be done?
 Struck-by

What should
be done
when
backing out?
 Accidents Forklift Leaves Dock
November 1, 2000
An employee was driving
a forklift truck in reverse
She backed off of the
receiving dock and was
pinned under the forklift
Operator was not wearing
seatbelt and the forklift
didn't have a overhead
guard
 Overturned
Uneven surfaces
Curbs
Potholes
Change in grade
Low tire pressure
Seat belts
Excessive weight
lifted
 Is a Forklift a Crane?
Qualified rigger?
OSHAs Construction
Crane standard may
apply in construction.
Many injuries result
from dropped loads
when using slings for
rigging.
 Caught In-Between
SHIB
http://www.osha.gov/dts/s
hib/shib072709.html
There have been
fatalities where standup
type fork trucks crush the
operator under cross bar
of a rack system.
Body part outside frame
of forklift is dangerous!

Guarding Needed!
 Lifting/Moving the Forklift

Is there a procedure
to get forklift off?

What is the procedure

to free a stuck forklift?
 Truck Unloading
Is material palletized?
Will the load stay stable
as straps are loosened?
Many times a person
adjacent to the load
being removed is hit.
Where do people stand?
 Lockout or Guarding?
The person who works on
the forklift must know the
OSHA lockout standards.
Any body part can be cut or
crushed if caught in a
scissor point.
Forklift maintenance
fatalities employees were
crushed after jack failure, or
crushed between mast and
frame of truck because they
didnt block it.
 Forklift Amputation Hazard
Maintenance hazards:
Scissor point between
lifting carriage and
mast.
Pinch point between
overhead guard and
mast
Chain and sprocket
can amputate fingers.

http://www.cdc.gov/niosh/face/stateface/ca/04ca012.html
 Electrical
When working around electrical wires be aware
of any potential contact (electrocution).
20ft. safe distance from overhead lines is required by
OSHAs crane standard (1926.1400).
If you must use the lift closer, this must be
preplanned and elements of the crane standard
must be addressed in the planning.
Triple Fatality in Illinois when a forklift contacted
overhead lines in a yard. ~2003
 Fire / Burns
Forklift strikes overhead pipe containing Toluene.
The employee and the forklift were dowsed
in toluene.
The toluene ignited from an unknown
source prior to the employee leaving the lift
seat.
The employee was severely burned.
The truck was a destroyed.
What could be done to prevent this?
Many people trust these machines
 Sample Safety Rules
Follow Manufacturers instructions and OSHA
regulations. Use ANSI/ITSDF B56 standards on
forklifts if you cannot get the manufacturers
rules.
Follow CAUTION WARNING DANGER Labels.
Prohibit untrained personnel from operating all
forklifts.
A trained person must inspect each forklift at
least daily before use.
And many more!
 Training
Hands on training is
necessary. A forklift is
not a car.
The worker must be able
to demonstrate
safe operation in their
workplace
follow each forklift
manufacturers usage
instructions.
BEFORE CERTIFICATION
Certification and
Re-certification
Initially
Every 3 years
Near Miss
 Evaluation
Date of
Certification
Operators name
Trainers Name
 Inspections
Per manufacturers guidelines.
At least daily before use.
Check all working components and safety
device.
Address all leakage of fluids.
Search for defective hydraulic/pneumatic
hoses.
Look for quickfix signs (not acceptable)
i.e. electrical tape, rags tied on hoses
 Inspections

Why is this inspection form weak?

 Manufactured Attachment

NOTE: Use of
such an
attachment
changes the
load capacity
of the PIV

DANGER: Manufacturers Written Approval Required

 Manufactured Attachment
Barrel lifter
(liquid = inertia)
Capacity plate
update required?
Dont forget
unapproved
attachments can
overload the trucks.

DANGER: Manufacturers Written Approval Required

 Lifting Slabs
Many injuries have
occurred while lifting
large flat objects
Use lifting
attachments designed
and approved for
each specific job.
ANSI B30.20
 Seatbelts

Must be worn when

equipped.
Prevent the operator from
being pinned by the truck
or overhead guard.

Click for rollover video

 Inspection
Labels
Ensure that
capacities for
attachments
are listed
 Inspection

Load Backrest
Extension is damaged
 Inspection
How much wear is
acceptable?
 Forklift Inspections
Overhead guard
improperly welded
 Forklift Inspection
Broken Fiberglass
Housing is a
Laceration Hazard
 Inspection
Leaking Hydraulic
Fluid
Can lead to:
Low pressure
Air bubbles
Erratic operation
Slippery surfaces
 Personnel Elevating Platforms
Good Platform must
include guardrails
Secure the platform to
the forklift.
Screen at forklift side
 Personnel Elevating Platforms
OSHA 5(a)(1) Violations
ANSI/ITSDF B56.1-2005:
No screen (scissor point)
Cannot be secured to
forks or backrest
 Emergency Response
What is the response
if the drum contains
flammable or toxic
liquid?
 Fire

Cylinder gases ignited by

forklift.
What can be done?
 Carbon Monoxide

Perfect World:

CxHx O2 CO2 H 20

Real World:

CxHx O2 N 2 CO2 H 2O CO NOx CxHx

 Acute Exposure

Headache
Nausea
Weakness
Irritability
Chest Pain
Unconsciousness
 Chronic Exposure

Headache
Dizziness
Anorexia
Ataxia
Confusion
 Best Practice and Required in MN
General industry: Minnesota Rules 5205.0116 Carbon Monoxide
Monitoring

Subpart 1. Internal combustion engine powered industrial trucks.

The employer shall monitor environmental exposure of employees to
carbon monoxide whenever internal combustion engine powered
industrial trucks as defined in Code of Federal Regulations, Title 29,
section 1910.178(a)(1) are operated indoors to ensure that carbon
monoxide levels do not exceed those given in Code of Federal
Regulations, Title 29, section 1910.1000, Table Z-1-A.
The air monitoring shall be done at least quarterly and represent
exposures during a day of highest usage in the areas where employee
carbon monoxide exposure is most likely.

Subpart 2. Tailpipe exhaust gas analysis.

The employer shall ensure that powered industrial truck engine exhaust
gases do not contain more than one percent carbon monoxide for
propane fueled trucks or two percent carbon monoxide for gasoline
fueled measured at idle and at three-fourths throttle during final engine
tuning in a regular maintenance program.
 Exposure Limits
OSHA 50 ppm 8-hour
Time Weighted Average
(TWA)
NIOSH 35 ppm 8-hour
TWA
200 ppm Ceiling by
NIOSH
ACGIH Threshold Limit
Value is 25 ppm 8-hour
TWA; 40-hour work week
PPM CO Time Symptoms

200 2-3 hours Headache, fatigue,

nausea.
400 1-2 hours Symptoms intensify. Life
threatening after 3 hours.
800 45 Dizziness, nausea,
minutes convulsions. Death after
2-3 hours.
1600 20 Dizziness, nausea,
minutes convulsions. Death within
1 hour.
 ACGIH Recommendations

Limit CO concentration to 1%
or less for propane fueled
trucks
Limit CO concentration to 2%
or less for gasoline fueled
trucks.
 Forklift Exhaust Test

No Violation
Forklift emits low
level of CO
 Prevention of CO Poisoning
Maintain equipment in good working
order
Provide periodic tune-ups for forklifts to
ensure that they run lean
Periodic CO analysis of exhaust gases
to determine emission concentrations
Provide adequate ventilation
Install CO monitors
 Storage

What is the
problem and
solution?
 Storage

No Violation
Material stored
properly in racks
 Material Handling

Rack was hit by

forklift and tagged out
and pallets removed.
 Material Handling
No Violation
Aisle properly
marked
Smooth Clean
lanes
 Struck By
No Violation
Corner marked so
forklift operation can
see around corner
 Cautions
Watch for any holes. These will flip some
forklifts. These should be identified in
advance and plans to prevent a forklift
from going into one is necessary.
Watch for aerial lifts and other mobile
equipment. Barricade the equipment to
prevent contact with each other.
 Quiz
How often does a forklift driver have to be re-
evaluated/certified? __________

Forklifts must be inspected every ________

before use.

OSHAs limit for Carbon Monoxide in an 8 hour

shift is ____ ppm.
 Resources
www.osha.gov
Compliance Assistance Specialists in OSHA
offices
On-site Consultation
Quick Takes
http://www.osha.gov/as/opa/quicktakes
www.aiag.org Pedestrian & Vehicle Safety
Guidelines
Comments or Corrections go to John Newquist
What is the pending hazard?
 Summary
Training
Job Hazard Analysis
Written procedures
Manufacturer rules
Inspections
 Further
This ppt was prepared by John Newquist as a
preliminary aid for people required to evaluate forklifts.
Thanks to Misette Kobler, Carlos Gallegos and Janet S.,
for corrections and suggestions.
Thanks to Joe Schwarz, Marc Snitzer, Walter Visage,
Rick Dvorak, Cynthia Evans, Aaron Priddy, for previous
work on the topic.
This is not an official OSHA publication. Those will be on
the OSHA.gov website.
Newquist.john@dol.gov is my email if you see any
errors. This is just a draft as of the cover date.
312-353-5977
 Wage & Hour Referral
No one under 18 allowed on a PIT

Order 7 of Hazardous Occupations prohibits

employees under 18 years of age from operating
forklifts, employers must make certain that workers
under 18 years of age are not permitted to use PITs.