Kevin Lindley, Safety Consultant, FRSA Self Insurer’s Fund
Forklifts are indispensable in warehouses, construction sites and manufacturing facilities but they also pose significant risks if not operated safely. Implementing proper forklift safety protocols can prevent accidents, injuries and fatalities. Understanding key safety principles and best practices is crucial for
all forklift operators and workplace personnel.
Forklifts are powerful industrial vehicles that can cause severe injuries if mishandled. Common forklift-related accidents include tip-overs, collisions and falling loads. By prioritizing safety, businesses can minimize workplace hazards and protect employees from harm.
Proper training and certification – OSHA guidelines require all operators to have training and certification and we recommended that operators carry physical certification cards on them for verification of training and certification at all times.
Pre-operational inspections – Before use, inspect forklifts for mechanical issues, such as malfunctioning brakes, steering problems or hydraulic leaks. All inspections must be documented and available upon request.
Wearing safety gear – Appropriate safety equipment, including high-visibility vests, helmets and steel-toe boots, should be worn by operators. Forklift operators are not required to wear hard hats inside an operating cab, if the cab is covered. However, the operator needs to wear his hard hat when exiting the equipment, especially if materials are above head level.
Load management – Ensure loads are balanced, properly secured and within the forklift’s weight capacity to prevent tip-overs.
Safe speed and maneuvering – Adhere to speed limits, avoid sudden turns and exert caution when navigating through tight spaces, especially when entering blind spots, intersections or corners.
Workplace awareness – Pedestrians should be aware of forklift movements and operators should use horns and lights to signal their presence. Pedestrians always have the right of way; operators are responsible for looking out and stopping for pedestrian traffic.
Proper parking and shutdown procedures – When not in use, forklifts should be parked on level ground, with brakes engaged and keys removed.
Propane safety – Wear proper personal protective equipment when exchanging propane tanks. Propane cylinders must be stored in a location where they are unable to be struck or tipped over and must remain in an upright position. Propane tanks shall be placed on the forklift correctly and secured on the vehicle at all times.
Overloading – Exceeding the forklift’s capacity can lead to instability and tipping.
Blind spots – Limited visibility can result in collisions with pedestrians or obstacles.
Poor floor conditions – Wet, uneven or cluttered floors increase the risk of accidents.
Improper use of attachments – Using incorrect or unapproved attachments can compromise the forklift’s balance and safety.
Forklift safety is a shared responsibility that requires proper training, vigilance and adherence to safety protocols. By fostering a culture of safety, businesses can reduce workplace accidents, enhance productivity and ensure a secure working environment for all employees. Prioritizing forklift safety ultimately leads to a more efficient and hazard-free workplace.
FRSA’s Self Insurers Fund Safety Consultants are able to provide insured members with forklift training and certification. Please contact your safety representative to coordinate the required training for employees who operate equipment in the warehouse or on the jobsite.
Workers’ comp rates are the same no matter which insurance company insures your business. At the FRSA-SIF, discounts are available for a drug-free workplace with the possibility of yearly dividends. Together with discounts, free employee training and assistance with OSHA inspections, you can’t beat the coverage the FRSA-SIF can offer. For more information, please contact Alexis Ayala at 800-767-3772 ext. 206 or by email at alexis@frsasif.com.
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