Forklifts, often referred to as powered industrial trucks (PITs), are a common sight at construction sites and industrial facilities. These machines come in various types and serve different purposes, each with its own set of safety considerations. While forklifts are generally safer than larger machinery like cranes or excavators, they 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. Every year in the United States, nearly 100 workers lose their lives, and around 20,000 others sustain severe injuries due to forklift accidents (as reported by NOISH).
Diesel-powered forklifts are designed for outdoor use due to the harmful fumes they emit. Operating such a machine indoors without proper ventilation can be extremely hazardous. In many factories, colored tape is used to mark out forklift zones, ensuring that workers are mindful of their surroundings. Additionally, mirrors positioned near corners help forklift operators and pedestrians see each other when visibility is obstructed by shelving or other obstacles.
Preparing to Handle the Forklift Load
Always ensure that the forklift load is centered and balanced to prevent tipping. To achieve this:
- Secure the load securely so it remains stable during transport.
- Inspect the load and confirm it is undamaged; if merchandise is damaged, it 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 perfectly aligned. Proceed slowly and cautiously.
- Place the heaviest portion of the load closest to the front wheels of the forklift to maintain balance.
- Avoid overloading. Know the forklift's maximum capacity and never exceed it. Remember to account for any attachments used.
- A forklift’s capacity is specified based on a particular load center. If the load is unevenly distributed, off-center, or too heavy, it could exceed the capacity and destabilize the forklift.
- Utilize the load extension backrest.
Key Takeaway: The top image illustrates a correctly balanced forklift load, whereas the bottom image shows an unbalanced and risky load. An improperly loaded forklift is prone to tipping over.
Approaching the Load with the Forklift
When approaching a load, follow these steps:
- Move toward the load gradually, stopping approximately 8 to 12 inches in front of it.
- Align the forklift perpendicularly to the front of the load with the forks at the appropriate height.
- Set the direction control to neutral.
- Refrain from manipulating the forks until the forklift is completely stationary and the brakes are engaged.
- Use the inching pedal to gently bring the load to the stack.
Note: Stopping 8 to 12 inches away from the load provides ample space to adjust the forks properly.
Managing the Mast Position
While moving the mast, always monitor the load since it can easily become unbalanced.
- Exercise caution when tilting loads. Do not tilt forward with forks elevated unless necessary for loading or unloading.
- When stacking or tiering, tilt backward only enough to stabilize the load.
- Travel with the mast tilted back to keep the load stable.
- Tilt the mast forward cautiously when placing the load onto the stack.
- Never travel with the load tilted forward. Forward tilting increases the load distance and makes the load less stable.
Note: The mast should be vertical when approaching a load.
Note: Be cautious when the mast is tilted forward. Forward tilting increases the load distance and raises the risk of imbalance.
Note: Tilted-back masts reduce the load distance and help center the load's gravity.
Positioning the Forklift Forks
- Confirm the forks are level before inserting them into the pallet.
- Insert the forks as far under the load as possible. This helps center the load’s gravity.
- Slide the forks into the pallet until they are fully underneath the load. The forks should be at least two-thirds the length of the load. If you cannot get two-thirds of the load length under the forks, consider using a different forklift for the task.
- Be cautious not to damage items on the opposite side of the pallet.
- Center the weight of the load between the forks. Adjust the forks to distribute the weight evenly.
- Tilt the mast back carefully to stabilize the load. Tilting the mast helps stabilize the center of gravity.
Note: Slide the forks into the pallet until they are fully under the load. Avoid extending beyond the pallet and hitting other objects. The forks must be at least two-thirds of the way under the pallet to lift it safely.
Lifting the Load
- Verify there is sufficient overhead clearance before raising the load. Look out for overhead installations, lighting fixtures, pipes, etc.
- Carefully raise the load about 4 inches above the lower stack and check that it is stable.
- Once lifted, tilt the mast back slightly to rest the load against the backrest extension.
- Ensure the load is not caught on anything, tied down, or inadvertently moving something it shouldn’t be.
- Slowly return the lift control lever to the neutral position.
Note: Lift the load slowly and carefully 4 inches up. Confirm the load is balanced and secure.
Lowering the Load
- Be aware of falling loads and potential strikes when lowering the load.
- Return the mast to the vertical position before lowering the load.
- Lower the load so that its lowest point is 6 to 8 inches from the floor.
Note: Tilting the mast backward helps stabilize the load.
Group Discussion Topics
- Is your forklift in good working order? (Check tires, hydraulic lines, signs, etc.) Perform a daily visual inspection.
- What are some specific forklift hazards present in your workplace?
- Is the forklift intended for indoor warehouse use or outdoor operations?
- Are bystanders and other workers aware that a forklift is operating nearby?
- What conditions could lead to the forklift rolling over?
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