1. Forklift Safety
Anna Fretheim
ENV H 462, Winter 2012

2. Presentation overview
Forklift Safety Statistics
Forklift Definition and Types
How Forklifts Work
Forklift Safety Regulations (WAC)

3. Forklift safety matters
Fatal Accident Type %
Crushed by vehicle tipping over
42%
Crushed between vehicle and a surface
25%
Crushed between two vehicles
11%
Struck or run over by a forklift
10%
Struck by falling material 8%
Fall from platform on the forks 4%
Forklifts are widely used
Every year in U.S.: 35,000 serious injuries, 62,000 non-serious injuries, 85 fatalities
OSHA estimate: 11% of all forklifts are involved in accidents every year
90% of forklifts will be involved in some type of accident during their career

4. Forklift safety matters
most common citations by L & I safety inspectors involving forklifts:
Lack of training
No seatbelt or not using seatbelt
No inspection of the forklift for defects
Modification of forklift without manufacturer’s approval
No nameplate or unreadable nameplate

5. What is a forklift?

6. What is a forklift?
Forklifts fall under the definition of Powered Industrial Trucks (PITs)
PIT: Mobile, power-driven vehicle used to carry, push, pull, lift, stack, or tier material
Powered industrial trucks include:
Platform lift trucks
Motorized hand trucks

7. What isn’t a pit?
Farm Vehicles
Earth Moving Vehicles

8. Types of forklifts Diesel powered Electrically powered
Gasoline powered
Liquid Petroleum powered
(most common)

9. Types of forklifts
Can have additional safeguards to the exhaust, fuel, and electrical systems
Prevent emission of hazardous sparks
Limit surface temperatures
Allow them to be used in hazardous conditions (i.e. flammable dusts/vapors)
Consider location’s hazard level to decide which to use

10. How do forklifts work? Forks in front of trucks lift loads
Triangle of stability
Formed by front wheels and rear axel
As long as the center of gravity remains within the stability triangle, the truck will not tip over

11. How do forklifts work? Balances its load with counterweight
Front wheels act as fulcrum
When forklift lifts load, center of gravity shifts forward and moves upward
If it shifts outside of the triangle, the forklift will fall

12. Forklift safety
Codes: WAC

13. What can make a forklift dangerous?
Steers from the rear, making it swing wide
Carries heavy loads
Can have reduced visibility
Masts and loads
Can have a high center of gravity (turning
over)
Very heavy
Complicated controls

14. 863-200: Design, construction, and equipment

15. DESIGN AND CONSTRUCTION
: DESIGN, CONSTRUCTION, AND EQUIPMENT
If you own a forklift, it must meet ANSI design and construction requirements
If you want to modify the forklift, get written approval from manufacturer
Forklift must be labeled clearly to indicate type, weight, load capacity, modifications, and if it’s approved for hazardous conditions i

16. OVERHEAD GUARD 863-200: DESIGN, CONSTRUCTION, AND EQUIPMENT
Must have overhead guards
It isn’t intended to withstand the impact of the forklift’s maximum capacity load though

17. 863-300: inspection, repair, maintenance and servicing

18. Safe working condition
: INSPECTION, REPAIR, MAINTENANCE, SERVICING
Must be kept in safe working condition
Do not use forklifts with following conditions
Leak in fuel system
Exhaust system emitting sparks/flames
Abnormally hot part
Keep them
Clean
Free of excess lint, oil, and grease

19. Daily inspections 863-300: INSPECTION, REPAIR, MAINTENANCE, SERVICING
Inspect the forklift daily or after each shift if used continuously
Fluid levels
Defects
Tire pressure & quality
Forks condition
Nameplates in place and legible
Safety devices working properly
Report and correct any deficiencies noticed
Repairs must be made by authorized persons

20. Fueling 863-300: INSPECTION, REPAIR, MAINTENANCE, SERVICING
Turn off engine
Avoid spilling fuel
No open flames!

21. Battery charging 863-300: INSPECTION, REPAIR, MAINTENANCE, SERVICING
Specific areas for battery charging installations (NO SMOKING)
There must be facilities for :
Water for flushing and neutralizing spilled electrolyte from area and from eyes (eyewash)
Fire protection
Adequate ventilation (for hydrogen gas)
Dangers: burns from battery acid, fire from hydrogen gas
If handling battery acid, wear PPE

22. : Operations

23. 18+ TO OPERATE

24. Safe driving 863-400: TRUCK OPERATIONS Use seatbelts
Never let people pass under raised forks
No unauthorized persons can ride
No stunt driving or horseplay
Don’t drive the truck up to anyone in
front of a fixed object!
Make sure there’s enough room to operate forklift

25. Safe driving 863-400: TRUCK OPERATIONS Obey all traffic regulations
Keep a distance of 3 truck lengths from truck ahead
Keep a safe distance from the edge of ramps, platforms, and docks
Drive slowly on wet floors
Slow turning speed
Watch for pedestrians!

26. Handle loads safely 863-400: TRUCK OPERATIONS
Make sure loads are within rated capacity
Put forks under load as far as possible
Tilt forks forwards to pick up or put down load
When carrying load, tilt forks backwards
If the load obstructs your view, travel backwards and with a spotter

27. Handle loads safely 863-400: TRUCK OPERATIONS
Do not travel with a raised load

28. Slopes 863-400: TRUCK OPERATIONS
When on a slope (>10%), the load always faces upwards (so you drive backwards going down)
If no load, forks face downwards

29. Unattended 863-400: TRUCK OPERATIONS
Unattended = 25 or more feet away (or when not in view)
Unattended trucks:
Fork lowered
Controls neutralized
Power off
Brakes set

30. Elevators 863-400: TRUCK OPERATIONS If using an elevator:
Approach it slowly
Enter it squarely
Turn off power
Neutralize controls
Set the brakes

31. Dockboards 863-400: TRUCK OPERATIONS
Do not overload them (check their capacity)
Secure them first
Drive over them very slowly

32. Loading truck trailers and railroad cars
: TRUCK OPERATIONS
Make sure flooring can handle load, check for weaknesses
Set breaks, use wheel stops
Use horn or warning lights when entering or exiting
OSHA

33. Carbon monoxide 863-400: TRUCK OPERATIONS
Propane, gasoline, and diesel powered forklifts produce carbon monoxide
Without enough fresh air ventilation, CO poisoning can occur
Vey common
Severe nausea, headache
If forklifts are used indoors, they must be tested for CO emission periodically and get tune-ups

34. Tipping 863-400: TRUCK OPERATIONS How can a forklift tip over?
Load’s too heavy
Driving too fast around a corner
Driving off edge of platform/ramp
Driving indoor forklift outdoors
Driving on an incline

35. What to do if forklift tips
: TRUCK OPERATIONS
If forklift tips over
Keep arms and legs inside
Hold on to steering wheel
Lean away from direction of fall
Don’t jump!

36. Lifting people 863-400: TRUCK OPERATIONS Lifting people
Only lift workers if you have the proper installations to do so
Must have guardrails & toeboards
Do not move with workers on platform

37. OR PAY THE CONSEQUENCES
Remember: be safe

38. Thank you!