One of the responsibilities of a trained operator is to carry out workplace hazard identification prior to operating. The goal is not only to avoid these hazards but also to eliminate them with corrective actions.
In order to manage workplace health and safety at all times, it is essential to identify and control and reduce the threat-associated hazards involved in the operation of the forklift. The operators must be taught to identify these threats and report them to their superiors.
The best way to protect the company assets and employees is by knowing these hazards and taking reasonable actions to prevent their potential harm.
If you haven’t known them yet, in this article we made them available for you. If you become aware of these 13 most common forklift hazards and their solution, you will be off to a safer work environment and motivated workers.
- Read related article:(7) Effective Ways to Make Forklift Operation in the Warehouse Safe
1. Transporting of Over Capacity Loads
The size and weight of the load to be transported have always a great impact on the stability of the forklift - it makes the truck unstable.
Transporting heavy loads more than the forklift’s maximum load capacity is a definite way to make the truck unstable during travel. The situation could become more dangerous when the road surface where the truck is to be driven is wet or on an incline or in rough terrain.
Always keep in mind that the load is less stable when doing a turn and when the load is in a raised position. It affects the load center and could make the forklift to tip over.
Always be aware of the forklift’s maximum load capacity prior to operation by checking its data plate. It indicates there that information and other relevant details about the truck. You could find in the data plate the load center, maximum fork height, weight of the truck, and other pertinent information.
2. Traveling at Excessive Speed
The forklift operator, if improperly trained, has a habit of driving the forklift at high speed especially when the operation is in outdoors.
To mitigate accidents due to overspeeding, the workplace should maintain a maximum speed limit by posting visible signs in different places warning operators and other vehicles of the allowable speed at the vehicles can be driven.
Speed-limiting devices are also available in the market today. It is fitted on the forklift to reduce the maximum speed of a truck depending on the turning radius and load weight. Fitting the forklift with a speedometer is also a good way to warn the operators that the speed is exceeding to make them aware.
3. The forklift is Traveling with Elevated Load
This happens much too frequently. This is a common mistake we always see committed by the operator. The forklift should not be driven or repositioned when its load is elevated.
When traveling, the forks should be just below the front axle height or at a minimum distance from the floor surface, the height of the forks should clear the ramp and bump of the operating surface even because even a small bump on the floor can cause the load to fall off.
If the load is too bulky and is blocking the forward view, travel in reverse instead and make sure that the mast is tilted back against the backrest to make the load more stabilized to transport.
When the forklift is traveling up or down a ramp with a load, keep the load pointed uphill. When going up an incline, the load should face uphill, and when going down, travel in reverse instead.
4. Improper Turning
Regardless the forklift is loaded or not, it can tip over when turning. The forklift turns with the rear wheels which causes the rear end to swing outward, it raises the probability of the truck tipping over when doing tight turns.
To prevent such an accident, maintain a gradual speed during travel and slow down before making the turn. It makes the truck more stable during any turn.
5. The Load is Blocking the Forward View of the Operator
It is very common to see operators travel backward when the load being carried is too bulky because it obstructs the forward view. Traveling in reverse is the best way possible to make transport safe and secure.
It was a standard practice to travel in reverse when transporting a vision-blocking load. By doing so, the operator has a better and clear path of travel ahead avoiding the pedestrian and other vehicles around the operating area.
6. Improperly Balanced or Unsecured Load
This is just another cause of forklift tip over. The heavy load being carried can make the forklift go sideways when the load is not properly balanced or unsecured.
Always make sure the load is properly placed on the pallet and that they’re evenly distributed, and cross-tied if possible, before transport so that it won’t rock or tilt.
If the load is heavy, see first the destination of travel it if is flat or rough so that you can know how the truck is driven on the surface.
- Read the related article: 11 VITAL Steps You Should Take When Transporting a Load
7. Equipping the Truck with an Attachment
Attachments such as clamps, rotators, lifters, baskets and other kinds of such attachments can significantly reduce the load the capacity the truck can carry.
The attachment can affect the stability and center of gravity, with an attachment being used, the load is moved away from the load center affecting the capacity and road grip and reducing the maximum load it can lift or carry.
Always check the user’s manual about attachments, if it is not there, consult the truck’s manufacturer by calling them for help and guidance when you are intending to put an attachment.
8. Horse Playing with the Forklift
Racing with the truck, giving rides on the forklift, standing on the overhead guard while moving, alighting the vehicle while it is moving, and other forms of stunts are a surefire ways to get you in trouble. Those may seem harmless but they’re very dangerous. It is never a good idea to commit any of these stunts.
When the forklift operator has been observed doing horseplay, he should be retrained or cited with a company violation ticket so that he recognizes the mistake he has done.
9. Leaving the Forklift with Its Engine Still Running
Leaving the forklift while it is still running is a big no-no! A forklift is considered unattended when its operator is 25 feet away from the vehicle even it remains in his view or vision. It is considered unattended when the operator leaves it and it is not in his view. Even the operator is just a few meters away from the vehicle but when its view is obstructed, it is still considered unattended.
The forklift should not be left or parked in the proper parking area. When parking, the forks should be lowered, the controls should be neutralized, the engine should be shut off and the brakes should be set. Never park the forklift with its keys still in the ignition.
10. Worn Out Forklift Tires
Whether the forklift tires are cushion or pneumatic, it is destined to be worn out. Chunking and cracking can be problematic. When the truck is operated over debris and uneven surfaces, pieces of tires fall off and leave chunks missing. It creates bouncing and vibration when being driven, the operator now has to adjust to that unintended movement.
Besides being unsafe to the driver, worn-out tires can be a big risk to the load being carried or transported. This makes the base unstable and the load will be too.
The checking of the condition of tires should be included in the daily checklist. Worn-out tires should be reported to the supervisor for immediate replacement.
11. Poor Road or Surface Condition Where the Forklift is being Driven
The physical condition of the surface or ground where the forklift is being driven also contributes to accidents. Condition such as slippery conditions, bumps, and uneven surfaces can spell disaster.
There is a danger of skidding during travel on these surfaces. There is also a danger of tipping over on icy, oily muddy even in uneven road surfaces.
You can mitigate risk in such conditions by traveling slowly and cautiously. If you see oil and other spilled liquid on the road, report it immediately to your supervisor for corrective action. If the road is uneven and impossible to cross with the forklift, find another route to the destination.
12. Pedestrians and Forklifts Moving in the Same Place
Pedestrians and forklifts don’t mix. It is had been stated by OSHA that the pedestrian has the right of way so drivers must be in constant alert when operating around pedestrians. The dangers involved is being crushed by a passing forklift which is too common, falling hazard is the next big threat for pedestrian, and running over the feet of pedestrian is much more common since sometimes forklift is being driven just feet away from people.
To avoid accidents with pedestrians, the company can designate a traffic lane solely for forklifts, mark the walkways with warning signs and postings, and by stressing the danger of pedestrian crossing during training. During travel, slow down and sound the horn in an intersection, blind corners, and in any exits and doorways.
13. Finally, When the Operator is not Properly Trained (Unauthorized Operation)
It is against the law for someone to operate a forklift without proper training. According to OSHA, the operator should be certified first before he can put his hands on the controls. The forklift is much more dangerous to operate when handled by an untrained individual.
Be sure to have prior training before any work commencement. The training is easy to complete, it only takes about a few hours to complete the course. The course consists of classroom and practical training and evaluation at the end.
Individuals who wish to be certified, can contact the training school or ask their employer for training. It is the responsibility of the employer to supply you with such training.
- Read related article: 3 Cost-Effective Ways to Train Group of Forklift Operators
Understanding Forklifts and Their Use
A. Detailed explanation of how forklifts operate
Forklifts, also known as lift trucks or fork trucks, are powered industrial trucks used to lift, move, and stack materials over short distances. They operate by means of two power-operated prongs, or "forks," that slide under a load, lift it, and transport it to its desired location. The operator controls the machine from a cab and can adjust the forks' height and tilt to manage different types of loads.
B. Different types of forklifts and their specific uses
There are several types of forklifts, each designed for specific applications:
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Counterbalance Forklifts: This is the most common type, capable of lifting heavy loads. The 'counterbalance' refers to the weight at the back of the truck that counteracts the weight it lifts at the front.
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Reach Trucks: These are used in warehouses where high stacking is required. They have the ability to 'reach' high shelves that would be inaccessible to other types of forklifts.
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Side Loaders: These forklifts are perfect for handling long, awkward loads that a traditional forklift can't handle effectively. The forks are situated on the side of the truck, allowing the load to be picked up parallel to the vehicle.
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Telescopic Handler Forklifts: These are often used in agriculture and construction, capable of reaching heights that other types can't.
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Pallet Trucks: These are used to move and lift pallets, usually within warehouses.
- Read related article: Hazards of Operating Electric Forklifts in Narrow Aisles
C. The role of forklifts in different industries
Forklifts play a crucial role across many industries, including:
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Warehousing and Distribution: They are used for loading and unloading goods, stock movement, and order picking.
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Manufacturing: They aid in moving raw materials, finished products, and supplies within a manufacturing facility.
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Construction: On construction sites, forklifts move building materials, including bricks, steel beams, and other heavy items.
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Retail: Large retail stores use forklifts to manage inventory, particularly in stock rooms or during off-peak hours.
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Shipping and Freight: Forklifts load and unload cargo from ships, trucks, and trains. They are essential to port operations and shipping yards.
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Agriculture: In farming, they are used to handle large quantities of produce, feed, and other materials.
Understanding these aspects of forklifts can help operators and safety professionals mitigate the risks associated with their use.
Regulations and Standards Regarding Forklift Safety
A. Brief overview of Occupational Safety and Health Administration (OSHA) forklift regulations
OSHA, an agency of the United States Department of Labor, sets and enforces standards to ensure safe and healthy working conditions. OSHA's guidelines for forklifts are detailed in the standard 29 CFR 1910.178, "Powered Industrial Trucks."
Some key OSHA regulations include:
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Training Requirements: All forklift operators must undergo initial training and an evaluation. Refresher training is required if the operator is observed operating the truck unsafely, is involved in an accident or near-miss incident, or is assigned to a different type of truck.
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Daily Inspections: Forklifts should be inspected at least daily, or after each shift when used around the clock.
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Specific Standards for Different Types of Trucks: OSHA's regulations include specific requirements for different types of powered industrial trucks, including fire safety guidelines, design and construction rules, and more.
B. Other international standards concerning forklift safety
There are several international standards in place to promote forklift safety:
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ISO 3691: This is a series of standards from the International Organization for Standardization (ISO) that cover safety requirements for powered industrial trucks.
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European Directive 2006/42/EC: This is the European standard that governs the safety of machinery, including forklifts. It requires machinery to be designed and built to certain mandatory safety standards.
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Australian Standard AS 2359: In Australia, this standard series sets the guidelines for powered industrial trucks.
C. Importance of following these standards
Adherence to safety standards is crucial for several reasons:
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Protecting Worker Safety: Standards provide a baseline for safe operations, reducing the risk of accidents that can lead to injury or death.
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Legal Compliance: Non-compliance with OSHA standards or relevant international regulations can lead to heavy fines and legal trouble.
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Efficiency and Productivity: A safe workplace tends to be a more efficient one, as fewer accidents mean less downtime and more consistent operations.
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Reputation: A strong safety record can enhance a company's reputation among clients, partners, and potential employees.
By understanding and implementing these standards, businesses can promote a culture of safety, mitigate risks, and ensure they're meeting their legal obligations.
Importance of Training in Minimizing Forklift Hazards
Proper forklift training is crucial to minimizing the risk of accidents in the workplace. According to OSHA, about 70% of industrial accidents are caused by operator error, which can often be mitigated by proper training. A well-trained operator not only knows how to operate a forklift correctly but also understands the potential hazards and how to avoid them. Training helps ensure that operators know how to handle unexpected situations, reducing the likelihood of accidents and injuries.
Components of effective forklift training programs
An effective forklift training program should include the following components:
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Classroom Instruction: This may involve lectures, written materials, videos, and group discussions covering the principles of safe forklift operation.
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Hands-On Training: Trainees should operate a forklift under direct supervision, learning how to handle different situations they may encounter on the job.
Read related article: How to Pass the Forklift Practical Test? and this: Passing the Training Written Test -
Evaluation: The instructor should assess each trainee's performance in the workplace to ensure they can operate the forklift safely.
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Specific Training for Different Types of Forklifts: Because different forklifts have different operating characteristics, training should be specific to the type of truck an operator will be using.
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Training on Workplace-Specific Topics: Since each workplace has unique conditions and potential hazards, training should cover these specifics.
Importance of refresher courses and continual learning
Just as the initial training is crucial, refresher courses and continual learning are also essential to maintain safety standards. These ongoing training sessions help to reinforce the safety protocols and keep operators up-to-date with any changes in regulations or equipment.
Refresher courses are required by OSHA under certain conditions, such as after an accident or near-miss incident, but they are beneficial even when not mandated. They ensure that operators don't become complacent and continue to operate forklifts with safety as a top priority.
In conclusion, forklift safety training is a critical factor in minimizing hazards associated with forklift operation. It leads to safer workplaces, fewer accidents, and compliance with regulatory standards.
Case Studies of Forklift Accidents
Overview of a few real-life cases of forklift accidents
- Case Study 1: Forklift Overturn
In this case, a forklift operator attempted to lift a heavy load beyond the forklift's capacity. As a result, the forklift tipped over, causing serious injuries to the operator.
- Case Study 2: Pedestrian Collision
In this incident, a forklift operator failed to see a pedestrian walking near the forklift while reversing. The pedestrian was struck by the forklift, resulting in severe injuries.
- Case Study 3: Improper Load Handling
A forklift operator attempted to lift a load that was unstable and improperly secured. As a result, the load fell off the forks, damaging nearby equipment and creating a potential hazard for workers.
Analysis of what went wrong in each case
- Case Study 1: Forklift Overturn
The primary factor contributing to this accident was the operator's failure to assess the load weight and determine if it exceeded the forklift's capacity. Additionally, poor load stability and improper distribution of weight further increased the risk of overturning.
- Case Study 2: Pedestrian Collision
The key issue in this incident was the lack of proper communication and awareness. The forklift operator failed to check their surroundings adequately and did not use the appropriate warning signals to alert pedestrians of their presence.
- Case Study 3: Improper Load Handling
This accident resulted from inadequate load inspection and improper load handling techniques. The forklift operator should have checked the load for stability and ensured proper securing methods were in place before attempting to lift it.
Lessons learned and how to avoid similar incidents
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Conduct Proper Load Assessments: Operators must accurately assess load weights and ensure they are within the forklift's capacity. Overloading a forklift can lead to stability issues and potential accidents.
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Maintain Clear Visibility: Forklift operators should maintain a clear line of sight at all times, using mirrors and other aids to check blind spots. Adequate warning systems, such as horns or flashing lights, should be used to alert pedestrians of the forklift's presence.
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Proper Training and Certification: Comprehensive training programs should be implemented to educate operators on safe forklift operation. Operators should be certified and receive regular refresher courses to reinforce best practices and keep up with industry standards.
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Emphasize Load Handling Safety: Proper load handling techniques, including proper securing and stability checks, must be part of the training program. Operators should be encouraged to report any concerns about load stability or handling to their supervisors.
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Promote a Safety Culture: Employers should foster a safety-conscious work environment where all employees, including forklift operators, are encouraged to prioritize safety. This includes reporting hazards, near-miss incidents, and actively participating in safety training and programs.
By analyzing these case studies and implementing the lessons learned, workplaces can strive to prevent similar accidents and create safer environments for forklift operations.
To Conclude This
Forklift hazards pose significant risks in various industries, but by understanding and addressing these risks, we can create safer work environments. Throughout this article, we have explored the common hazards associated with forklift operations and the importance of mitigating them.
Proper training plays a vital role in minimizing forklift accidents. By providing comprehensive training programs, operators gain the knowledge and skills needed to operate forklifts safely, identify potential hazards, and respond appropriately to unexpected situations. Ongoing refresher courses and continual learning are essential to maintain safety standards and prevent complacency.
Adherence to regulations and standards, such as those set by OSHA and international organizations like ISO, is critical. These standards provide guidelines for safe forklift operations and equipment maintenance, ensuring compliance and reducing the risk of accidents. By following these standards, businesses can prioritize worker safety, maintain legal compliance, and enhance their overall reputation.
The case studies discussed in this article highlight the consequences of forklift accidents and the lessons learned from each incident. From load assessments to clear visibility and proper load handling, there are specific actions that can be taken to minimize hazards and prevent accidents. By learning from these case studies, we can implement preventive measures to avoid similar incidents in the future.
Creating a safety culture within the workplace is crucial. It requires the commitment of employers, employees, and supervisors to prioritize safety, report hazards, and actively participate in training programs. By fostering a culture where safety is valued and promoted, we can reduce the frequency of forklift accidents and create a safer working environment for everyone involved.
In conclusion, forklift hazards should not be underestimated. Through proper training, adherence to regulations and standards, continuous learning, and a strong safety culture, we can mitigate these hazards and ensure the well-being of forklift operators, pedestrians, and all those working in industries where forklifts are utilized. By taking these steps, we can work towards a future with fewer forklift accidents and safer workplaces overall.
