Forklifts, commonly referred to as powered industrial trucks (PITs), are a staple at most job sites and industrial warehouses. These versatile machines come in various types and applications, each with unique safety requirements (for more details on different forklift types, click here). While generally less hazardous than large rough terrain cranes or excavators, forklifts still pose significant risks that can lead to serious workplace injuries.
According to the Occupational Safety and Health Administration (OSHA), forklift overturns are the leading cause of fatalities involving these vehicles, accounting for approximately 25% of all forklift-related deaths. In the United States alone, nearly 100 workers die and another 20,000 suffer serious injuries annually due to forklift-related accidents (refer to the NOISH report for further information).
Diesel forklifts are specifically designed for outdoor use due to the harmful fumes they emit. Operating a diesel forklift indoors without proper ventilation poses significant health risks. Many factories address this issue by marking forklift zones with colored tape to keep workers aware of their surroundings. Additionally, mirrors installed near corners help forklift operators and pedestrians spot each other when visibility is obstructed by shelves.
Preparing to Handle the Forklift Load
Before handling any load, ensure it is properly centered and balanced to prevent tipping. Off-center loads significantly increase the risk of accidents. To handle loads safely:
- Secure the load to ensure stability and proper arrangement.
- Inspect the load for damage. Damaged goods should be wrapped or banded to prevent shifting.
- Center the load on the forks.
- Exercise extra caution when dealing with off-center loads that cannot be fully centered. Proceed at a slower pace and exercise heightened vigilance.
- Place the heaviest part of the load close to the front wheels of the forklift to maintain balance.
- Avoid overloading. Always understand the forklift's weight limit and consider any attachments.
- A forklift's capacity is based on a specified load center. Any deviation from this—such as an off-center or oversized load—can exceed capacity and destabilize the forklift.
- Utilize the load extension backrest to enhance stability.
Key Takeaway: The top image demonstrates a correctly balanced forklift load, whereas the bottom image shows an unbalanced and potentially hazardous load. Improperly balanced loads can easily result in a forklift tipping over.
Approaching the Load
Approach the load cautiously, stopping 8 to 12 inches in front of it. Align the truck perpendicularly to the load and adjust the forks to the appropriate height. Neutralize the direction control, and refrain from manipulating the forks until the forklift comes to a complete stop and the brakes are engaged. Use the inching pedal to gently bring the load to the stack.
Note: Stopping 8 to 12 inches in front of the load provides ample space to maneuver the forks effectively.
Mast Positioning
Monitor the load as you move the mast. Unbalanced loads can occur during movement. Exercise care when tilting loads, avoiding forward tilts unless necessary for picking up or placing a load. When stacking or tiering, tilt the mast backward only as much as needed to stabilize the load. Keep the mast tilted back while traveling to maintain load stability. Tilt the mast forward cautiously when positioning the load onto the stack. Never travel with the load tilted forward, as this increases instability.
Note: The mast should be vertical when approaching a load.
Note: Exercise caution when the mast is tilted forward, as this increases load distance and instability.
Note: Tilting the mast back reduces load distance and helps center gravity.
Positioning the Forks
- Level the forks before inserting them into the pallet.
- Insert the forks as far under the load as possible to maintain balance.
- Slide the forks into the pallet until they are fully under the load. They should cover at least two-thirds of the load's length. If you cannot achieve this, consider using a different forklift.
- Avoid damaging items on the opposite side of the pallet while inserting the forks.
- Center the load between the forks and adjust them to distribute weight evenly.
- Tilt the mast back carefully to stabilize the load. This action helps maintain the center of gravity.
Note: Slide the forks under the load until they are fully inserted. Be cautious not to extend beyond the pallet and strike surrounding objects. The forks must cover at least two-thirds of the pallet to lift it safely.
Lifting the Load
- Ensure there is sufficient overhead clearance before raising the load. Look out for overhead installations, lighting, pipes, and similar obstacles.
- Carefully lift the load 4 inches above the lower stack and verify its stability.
- After lifting, tilt the mast back slightly to support the load against the backrest extension.
- Confirm that the load is not obstructed, tied down, or interfering with anything it shouldn't.
- Gradually return the lift control lever to the neutral position.
Note: Lift the load slowly and carefully to a height of 4 inches. Verify that the load is balanced and secure.
Lowering the Load
- Be mindful of falling loads and potential collisions with objects when lowering the load.
- Return the mast to the vertical position before beginning to lower the load.
- Lower the load so that its lowest point is 6 to 8 inches from the floor.
Note: Tilting the mast backward enhances load stability.
Group Discussion Topics
- Is your forklift in good working order? (Check tires, hydraulic lines, signage, etc.) Perform a visual inspection daily.
- What specific forklift hazards exist in your workplace?
- Is the forklift designed for indoor or outdoor operation?
- Are bystanders and other workers aware that a forklift is in operation nearby?
- What situations could lead to a forklift rollover?
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