5 Forklift Safety Tips to Prevent Injuries

Forklifts are among the most commonly used equipment in workplaces.  These powered industrial trucks are employed for agile and precise lifting and transporting of loads.  Despite their powerful functionality, operating any industrial machinery entails risks.  With over a million forklifts estimated to be in operation, ensuring personnel receive adequate training on proper safety measures is crucial.

The Occupational Safety and Health Administration (OSHA) estimates that forklift accidents cause approximately 34,900 serious injuries and 85 fatalities annually.  More alarmingly, 25% of these accidents result from inadequate training, underscoring the critical importance of educating every worker on key safety rules for forklift operations.

By bolstering forklift training, you and your team can confidently prioritize safety in production.  Here are some fundamental forklift safety tips:

Obtain Forklift Certification

As many accidents stem from insufficient training, it's recommended that only those trained and certified according to OSHA standards should operate forklifts.  Employers should assess employee performance at least every three years, supplementing it with lectures, videos, software training, and demonstrations.

Wear Appropriate Attire

Forklift operators should don proper safety gear, including safety shoes, helmets, and high-visibility jackets.  Ensure loose clothing is tucked in to prevent entanglement with the forklift.

Familiarize with Forklift Types

OSHA recognizes various forklift types and classifications.  Understanding your equipment's structure, weight limits, travel speeds, turning radii, and usage, as each type has distinct characteristics, is crucial to adhering to best safety practices.

Daily Equipment Inspection

Thoroughly inspect the forklift before each use.  Daily checks with shift supervisors are advisable to identify and record any issues or defects.  Some recommended checks include:

• Testing operational controls like brakes, lights, horns, and steering

• Inspecting the mast and overhead guard for damage

• Checking tire and fluid levels (hydraulic, brakes, engine, fuel, and coolant)

• Examining for water, oil, or radiator leaks

• Ensuring forks are in good condition (straight, no cracks, no distortion)

• Identifying potential hazards

When using a forklift, it's crucial to comply with all site rules, signage, and regulations.  Here are some best practices to help you observe your operating environment and protect yourself and others on site:

Maintain 360° Visibility

Keep the forks low to provide clear forward visibility.  If the load restricts your visibility, operate the equipment in the opposite manner.  Always ensure you have a good view of the mast when positioning loads.  Other OSHA-defined best practices include:

• Always make eye contact with pedestrians and other workers

• Always face the direction of travel

• Use rear-view mirrors for enhanced visibility

• Use headlights when working at night, outdoors, or in areas requiring additional illumination

Implement Floor Marking Systems

Floor marking systems aid in enhancing worker safety. Use yellow markers to indicate physical hazards, such as areas prone to falling or tripping, and use red markers for fire hazards, firefighting equipment, and emergency switches. Placing barriers and signs throughout the site keeps pedestrians away from forklift paths, guiding the forklift along safe routes and improving overall traffic flow.

Avoid Overloading

Be mindful of the forklift's capacity and any attachments used. Avoid transporting weights exceeding the forklift's counterbalance. Overloading a forklift can cause the rear wheels to lift off the ground, leading to machine tipping, resulting in injuries to personnel and damage to equipment and materials.

Never Carry Extra People

Unless the forklift is equipped with a second seat, it's prohibited for other workers to ride along on the equipment. Do not use a forklift to lift people, as it's designed for transporting goods. If you need to elevate a person, use a secure work platform and cage.

Pay Attention to Forklift Stability

Before using a forklift, ensure hands and shoes are completely dry and sit in a comfortable position with all controls within reach. Apart from securely seated positions, take the following steps before operating a forklift to enhance your safety:

Every forklift has a center of gravity—where weight is equally concentrated—as the load it carries. Forklifts are based on a three-point suspension system called the "stability triangle," and operators must remain within this system to prevent tipping. The heavier the load, the further the center of gravity is from the load center, decreasing the forklift's lifting capacity.

Ensure Load Stability and Safety

When placing loads at loading docks, ensure they are balanced. Tilt the load backward and keep the forks low to enhance equipment stability, especially while navigating on inclines. If necessary, use ropes or secure stacks and heavy loads, ensuring any pallets or skids used are of the appropriate weight for the load.

Move at Appropriate Speeds

Drive the forklift within designated speed limits. It's crucial to avoid abrupt stops, turns, sudden changes in direction, or making sharp turns while moving rapidly, as these actions can lead to forklift tipping. If your forklift begins to tip, do not attempt to jump out of the machine. Experts advise staying inside, gripping the steering wheel, and bracing your feet.

Maintain a Safe Operating Distance

Always be mindful of surrounding equipment in the work environment. Avoid operating the forklift near other machinery unless absolutely necessary, maintaining a safe distance to allow for secure parking, preventing other machines from moving unpredictably.

Avoid Hazard Zones around Equipment

Avoid standing or walking under loads, lifting mechanisms, or forklift attachments, as a load could fall on anyone underneath. Keep hands and feet away from the forklift mast, as moving masts can cause severe injuries.

Refueling and Charging the Forklift

Keeping the equipment fully charged and fueled is crucial. Always refuel and charge at specifically designated locations, typically well-ventilated and flame-free areas. Ensure the equipment is switched off each time you refuel.

Parking the Forklift at Shift's End

At the end of a shift, always park the equipment in designated and authorized areas. Construction companies should ensure parking areas do not block roads or obstruct any exits or entrances. Lower the forks completely until they fit the floor, engage the parking brake, turn off the engine, and remove the key from the ignition.