3 Risk factors to control for safe forklift operation

Forklifts are widely used in many industrial settings and on construction sites to move materials from one place to another and to raise, lower, or remove large objects or smaller objects on pallets or in boxes, crates, or other containers. These actions expose forklift operators and those working in the vicinity to hazards that can result in injury or death. As a result, the Occupational Safety and Health Administration (OSHA) provides regulations for the safe operation of powered industrial trucks, including forklifts, under 29 CFR 1910.178.

Violations of OSHA’s forklift regulations are one of the most cited standards in materials handling industry. Overturns are the leading cause of fatalities involving forklifts, representing approximately 25% of all forklift-related deaths. Case studies examined by the National Institute for Occupational Safety and Health (NIOSH) indicate that the forklift, the work environment, and actions of the operator can all contribute to fatal incidents involving forklifts. Safely operating a forklift requires preparation, anticipation, and careful attention to maintain control of the vehicle at all times.

1. The forklift

Forklifts are essential in warehouses, construction sites, and other workplaces, so they must be properly operated and maintained via regular inspections and maintenance. OSHA requires that all forklifts be examined at least daily before being placed in service. Forklifts used on a round-the-clock basis must be examined prior to use on each shift.

There should be a pre-loading visual check with the key in the off position to confirm the forklift is in good operating condition, and a subsequent operational check with the engine running to verify the forklift and all appropriate safety equipment are functioning properly. Any problems should be recorded, reported to a supervisor, and the forklift must not be placed in service if the examinations show that the vehicle may not be safe to operate.

2. The work environment

Safely operating a forklift requires awareness of the conditions at your workplace. Consider the following to avoid hazards.

Know why you are using the forklift

Forklifts are specifically designed for transporting and lifting loads and should not be used for any other purpose. Operators should always confirm that a forklift is the right tool for the job and follow the manufacturer’s instructions and workplace safety policies.

Be aware of the surroundings

Knowledge of the floor plan and areas of travel is essential. Be aware of heights, clearances, and aisle widths. Know the stops, turns, and curves within the work environment. Slow down, stop, and sound the horn at intersections, corners, and wherever your vision is obstructed. Always be aware of pedestrian travel, maintain a safe distance, and yield the right-of-way when necessary.

Check the surface

The surface where the forklift will operate should be clean and level. Operating a forklift on an incline or a slippery floor, especially when loaded, can be very dangerous. Confirm that the flooring or surface can support the combined weight of the forklift and the load it is carrying.

3. The forklift operator

All forklift operators must be certified, documenting that they have been trained and properly evaluated on the equipment they will be using. Operators must take the necessary precautions, including the following, to ensure safe forklift operation:

• Be aware of the forklift load capacity and center of gravity. Never overload the forklift and always inspect the load to ensure it is stable, undamaged, and packed properly.
• Always wear a seat belt, keep all parts of the body within the vehicle, and be aware of the procedure to follow in the event of a tip-over. Never carry a passenger.
• Operate the forklift by looking in the direction of travel, drive at a safe speed, observe all traffic regulations and signs, and keep the load at a safe height.
• Beware of any potential hazards; even a small bump can cause a load to fall.
• Verify the unloading location is ready to safely receive the load and is free from any obstructions.

Staying proactive about forklift safety

Forklifts are essential pieces of equipment in many workplaces, but they present numerous hazards that can impact the safety of the operator and other employees. Paying proper attention to each of the three factors of forklift safety – the forklift, the workspace, and the actions of the operator – can mitigate risks and create a safer working environment. Making forklift safety an ongoing priority not only protects workers but also helps maintain efficient and compliant operations.