Nothing is more important than worker and pedestrian safety — especially when using or being around heavy machinery. The bustling nature of warehouses and construction sites, where forklifts are a common sight, demands a heightened awareness and commitment to safety protocols. The interaction between heavy machinery and humans, if not managed with care, can lead to serious accidents, making it imperative to prioritize safety above all else.
Providing comprehensive safety training for team members is a cornerstone of maintaining a secure workplace. This training should not only cover the basics of operating heavy machinery but also emphasize the critical importance of situational awareness. By ensuring that all team members are well-versed in safety practices, businesses can create a culture of safety that permeates every aspect of their operations.
Understanding the dangers associated with forklift trucks and other powered industrial truck types is crucial for anyone involved in their operation. These vehicles, while indispensable for moving heavy loads, come with their own set of risks, including the potential for tipping over or causing injury to pedestrians. A thorough knowledge of these dangers is the first step towards mitigating them.
Understanding Forklift Hazards
Forklifts and industrial counterbalance lift trucks, while invaluable for their lifting and transporting capabilities, present several hazards that can lead to accidents if not properly managed. One of the most common dangers is the risk of the forklift tipping over, which can occur due to improper loading or handling. Similarly, falling loads pose a significant threat to both operators and bystanders, emphasizing the need for secure load management and adherence to weight limits.
The workplace dynamic between forklifts and pedestrians is fraught with the risk of collisions, which can result in serious injuries or even fatalities. Adding to the complexity is the danger of the lift truck overturning, a scenario that can be triggered by excessive speed, sharp turns or uneven surfaces. These risks underscore the importance of spatial awareness and the implementation of traffic management plans in areas where forklifts operate.
Mechanical failures represent another critical hazard, highlighting the importance of regular maintenance and inspections to ensure forklifts are in safe working condition. The danger of being struck by a forklift is a constant concern, particularly in environments where visibility is limited or where forklift traffic is heavy. Additionally, operators must be wary of falls from elevated platforms and the risks associated with improper lifting techniques, which can lead to both personal injury and damage to materials.
Forklift operation also involves potential fuel and fire hazards, especially in models that run on gasoline, diesel or propane. Proper material handling and storage of fuel, along with adherence to refueling protocols, are vital to prevent fires and explosions. Moreover, operating forklifts in confined spaces introduces unique challenges, including limited maneuverability and reduced ventilation, which can exacerbate the risks associated with exhaust fumes and fire hazards.
15 Tips for Safe Forklift Operation Practices
OSHA found that between 35,000 and 62,000 injuries occur every year involving forklifts and industrial trucks. Keep your workforce safe and prioritize safety by implementing the following tips and best practices to reduce forklift accidents:
Complete Proper Training
Ensuring that all forklift operators complete proper training is the foundation of safe forklift truck use. This training should cover not only the basics of operation but also the specific safety protocols of the workplace. This education must be seen not as a one-time event but as an ongoing process, with regular refreshers and updates to address new challenges or equipment.
Perform Pre-Operation Inspections
Regular pre-operation inspections are a critical step in preventing accidents and mechanical failures. Operators should be trained to perform these inspections systematically, checking for issues such as tire condition, brake functionality and the integrity of lifting mechanisms. This proactive approach can identify potential problems before they lead to accidents.
Understand Load Capacity
Understanding and adhering to load capacity limits is essential for the safe operation of forklifts. Overloading a forklift can lead to tipping, falling loads and structural damage. Operators should be familiar with the capacity of their forklifts and the weight of the materials they are handling to ensure they stay within safe limits.
Ensure Proper Load Stabilization
Stabilizing loads correctly before moving is crucial to prevent shifting or falling materials. This involves not only proper stacking and securing of the load but also an understanding of how movements and turns can affect stability. Training should include techniques for load stabilization and the importance of smooth, controlled movements.
Wear Appropriate PPE
Wearing appropriate personal protective equipment (PPE) can significantly reduce the risk of injury in the event of an accident. This includes helmets, safety shoes and high-visibility vests. Ensuring that all operators and nearby workers are properly equipped is a simple yet effective measure to enhance safety.
Use Seat Belts
The use of seat belts while operating forklifts is a basic safety rule that can prevent serious injuries in the event of a tip-over. Despite this, compliance can sometimes be overlooked. Emphasizing the importance of seat belts and making their use a non-negotiable part of forklift operation is key.
Keep Forks Low to the Ground
Keeping forks low to the ground during travel improves stability and reduces the risk of tipping. It also lowers the chance of accidentally striking objects or individuals. Training should stress the importance of adjusting fork height according to the situation and always erring on the side of caution.
Operate at a Safe Speed
Maintaining a safe speed during forklift operation is vital to prevent accidents. High speeds can lead to loss of control, especially when carrying loads or navigating turns. Speed limits should be established based on the environment and type of load and adherence to these limits should be strictly enforced.
Watch for Pedestrians
Staying vigilant for pedestrians in the work area is a shared responsibility between forklift operators and all other employees. Measures such as designated walkways, clear signage and mutual awareness training can help minimize the risk of collisions.
Use Forklifts on Stable, Even Ground
Operating forklifts only on stable and even ground is essential to prevent accidents. Uneven surfaces, slopes and slippery conditions can lead to loss of control and tipping. Operators should be trained to recognize unsafe conditions and to adjust their routes or seek assistance as needed.
Avoid Sharp Turns
Avoiding sharp turns with the forklift truck helps maintain stability and prevent loads from shifting or falling. Operators should be encouraged to plan their movements in advance, allowing for wide, gradual turns whenever possible.
Don’t Lift People
The prohibition of lifting people with forklifts is a fundamental safety rule. Despite this, incidents of an operating forklift being used inappropriately for lifting workers occur. Reinforcing the dangers and establishing strict policies against such practices are crucial steps in preventing accidents.
Maintain Visibility
Ensuring proper visibility while operating the forklift is critical for safety. This includes not only keeping the load at a height that allows for clear sight but also using mirrors and cameras to enhance visibility. Operators should be trained to adjust their approach if their view is obstructed.
Refuel or Recharge in Protected Areas
Refueling or recharging forklifts in designated safe areas helps prevent fuel-related hazards. These areas should be well-ventilated, away from ignition sources and equipped with appropriate fire safety equipment. Training should cover the correct procedures for refueling or recharging, emphasizing the importance of doing so safely.
Park Safely
Adhering to parking safety protocols for forklifts, such as engaging the parking brake, lowering the forks to the ground and turning off the engine, is the final step in a safe operation cycle. These practices prevent accidental movement of the forklift when not in use and should be ingrained in every operator’s routine.
Forklift Safety Training Requirements
While you might already have forklift training, you must stay up to date on the latest requirements and implement new resources when available. Video Training Power offers an all-access pass to modern video-based training you can easily integrate into your current training program. Our courses make training more engaging, ensuring everyone on your team learns how to protect themselves and the people around them. We offer forklift safety training for operators and pedestrians, so everyone involved is as safe as possible.
Not only will Video Training Power help educate your employees but our resources can ensure they meet the necessary standards to achieve certification as a forklift operator. Please note, to be a certified forklift operator a driver must also have practical training. This includes hands-on instruction, live demonstrations, and practice exercises on the forklift, and cannot be done online. Evaluation of the operator’s performance must be done in the workplace, and cannot be done online.
By adhering to these forklift safety training requirements and continuously seeking out innovative training solutions, businesses can create a safer work environment. This not only protects employees from harm but also contributes to more efficient and productive operations. Safety training is an investment in both the well-being of workers and the success of the business.