Forklifts play an essential role in warehouses and construction sites. Their ability to quickly and safely transport heavy loads makes them instrumental to many modern workplaces. They’re also vital to the supply chain – there’s no faster way to move products in and out of a warehouse. Forklifts even allow for more efficient storage. When OSHA forklift regulations are followed, these incredible machines are a common sense addition to any workplace. Too often, though, safety best practices are ignored, leading to dangerous forklift accidents on the job.
It is estimated that forklifts cause about one percent of all factory or warehouse accidents. While this might seem low at first glance, it’s important to know that forklifts account for about 10 percent of injuries in the workplace. Forklifts are involved in more than 90,000 accidents throughout the United States annually. Among these incidents, 61,000 cause minor injuries, nearly 35,00 result in serious injuries, and about 85 lead to the death of an employee.
OSHA Forklift Rules
The Occupational Health and Safety Administration has crafted a number of rules and regulations to help keep forklift operators and their colleagues safe on the job. These rules aren’t mere suggestions – violations can result in expensive fines and penalties. Of course, even if workers manage to skirt official consequences, the impact of rule violations may be felt in other ways. Accidents and injuries are more likely among workers who ignore safety recommendations. If you’re hoping to avoid workplace injuries, keep OSHA rules close to mind at all times.
Official OSHA forklift safety regulations are detailed in OSHA Forklift Standards, Part 1910, Subpart N, titled “Powered Industrial Trucks.” The subtitle is “Materials Handling and Storage.” To read these guidelines, visit the official OSHA website. While all the OSHA forklift rules are important, here are a few highlights to keep in mind:
Locations for Forklift Use
OSHA has specific regulations surrounding where forklifts may be used. They are broken into three main classes:
Class 1: Areas where flammable gases or vapors might produce explosive mixtures
Class 2: Areas where combustible dust may present hazards
Class 3: Areas with ignitable mixtures in amounts unlikely to ignite
These designations can help prevent forklift accidents, no matter where you might be using these vehicles. Pay close attention to OSHA regulations for forklift settings, especially when using your forklift in a new application. With a keen eye on the rules, you can sidestep many of the most common types of forklift hazards and accidents.
Forklift Safety Guards
Overhead guards can do wonders to keep operators safe. They’re designed to protect workers from falling objects. OSHA requires high lift rider trucks to have overhead guards that comply with ANSI guidelines for powered forklifts. If there are any hazards associated with their load, operators must use a truck with a vertical load backrest extension.
It’s important to note that overhead guards can be used as protection against small falling objects like bagged material, packages, and boxes. They cannot, however, withstand the impact of a falling capacity load. For additional protection, workers should wear a hard hat and keep hands and feet within the forklift. As part of the daily forklift inspection, workers should take time to check the overhead guard for missing bolts, broken welds, or other types of damage.
Handling and Storing Fuel
Forklifts are powered by internal combustion engines. These run on a range of different fuels, including diesel, gasoline, compressed natural gas, and liquid petroleum gas (LPG). Lifts with internal combustion engines can be quickly and easily refueled but need regular maintenance inspections to ensure systems are working as they should. Forklifts powered by internal combustion engines are also used indoors, though they increase worker exposure to both exhaust and noise.
Diesel, gas, and LPG are to be handled and stored in accordance with the NFPA Flammable Combustible Liquids Code guidelines. Keep fuel in a well-ventilated area. Should fuel spill, carefully wash it away or make sure it evaporates completely. Pre-operation inspections should include a check of all fuel levels, as well as a check for leaks from the fuel system.
Charging and Changing Batteries
There are a lot of benefits associated with electric forklifts. They produce no emissions, more or less eliminate the risk of carbon monoxide poisoning, and run more quietly than traditional internal combustion forklifts. Electric forklifts can present serious hazards that must be taken seriously, though.
OSHA has a lot to say about the the charging and changing of forklift batteries. They require designated battery charging stations to be set up and used at all times. An overhead hoist or conveyer must be used to handle batteries. Once recharged, truck batteries must be properly maintained and stored. In order to fully charge a battery, a forklift must be complete deactivated. Defective battery vent caps must be complete deactivated, and employees are forbidden from smoking in the area where batteries are charged.
Safe Forklift Operation
OSHA has outlined best practices for safe forklift operation, too. Forklifts must not be driven up to someone who is sitting or standing. Untrained workers are not permitted to ride of forklifts, either. Workers may not pass or stand under the elevated portion of the truck, whether it is loaded or not. Forklifts in need of repair must be taken out of service until fixed. Fuel tanks cannot be filled as the lift is still actively running.
Forklift operators must maintain a safe distance from other vehicles. They should travel slowly as they move up and down grades. Safe stopping is a priority, so speed must be kept to a minimum. Stunt driving is strictly forbidden. Only safely arranged loads within the rated weight limit should be handled.
The Importance of Forklift Training
OSHA places a lot of significance around forklift training. There are specific requirements for the training program, the topics covered, and renewal training. The training must include formal written instruction, practical training, and a skills evaluation. Forklift training classes should be led by an experienced, qualified instructor in a safe environment.
Forklift training classes must cover operating precautions and instructions. Trainees must learn about the truck controls and instrument panel. They need to know about the differences between a forklift and an automobile. The course should cover engine or motor operation, steering, maneuvering, as well as vehicle capacity and stability.
Learners must master the use of fork attachments, the fueling and recharging process, and know how to perform regular maintenance and inspections. The course should also cover how to drive on different surface conditions, best practices for load composition, manipulation, and stacking. Trainees should also learn how to avoid pedestrians, how to drive in hazardous settings, how to maneuver slopes and ramps, and how to navigate tight spaces.
Renewal training is required for forklift operators, too. Every three years, operators must take a refresher course to familiarize themselves with industry best practices. Renewal training is also required in the wake of a workplace accident or injury.
The High Price of OSHA Violations
Fail to abide by OSHA regulations and your organization will be penalized. OSHA routinely levies fines totalling $100,000 or more. While the aforementioned standards seem relatively easy to comply with, many operators cut corners to save time. Save yourself money and stress by following OSHA regulations to the letter. With an eye on safety, you’ll foster a work environment that’s safer for everyone on site.
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