Forklift Safety - Understanding Stability , SWL & Safe Use

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Chapter : Forklift Safety

Situations That Can Tip a Forklift—And How to Control Them

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Chapter : Forklift Safety

Situations That Can Tip a Forklift—And How to Control Them

Forklifts are designed to lift and move heavy loads. The forklifts themselves must be heavy to prevent them from falling forward when the load is lifted. Forklifts also tend to be small and narrow to navigate tight workspaces.

Being small, narrow, and heavier than they look can be a recipe for
tipping if workers are not careful.

Tip over accidents are more likely in certain situations and circumstances. Make sure your workers know their specific truck, terrain, and load, and take precautions to prevent tipovers.

(Eg. A Driver/Worker was preparing to move large bundles of steel at a construction project. As he positioned his forklift, it tipped, pinning him. By the time emergency responders reached him, he was dead.)

1. Inadequately Secured Loads

A load that is not secured can shift, tipping the lift. Workers must know:

• Not to move the truck until the load is secure. The load-engaging device must be placed in a manner that securely holds or supports the load.
• Not to tilt the load-engaging means forward while the forks are elevated, unless they are picking up a load. An elevated load also must not be tilted forward unless it’s being deposited.
• How to use attachments. If the truck is equipped with attachments, special precautions may be required for securing loads and for operating the truck after the load has been removed.

2. Overloaded Forklifts

Loading a forklift beyond its rated capacity can cause the lift to tip. Make sure workers never exceed the forklift’s rated capacity. The rated capacity of all industrial forklifts must be prominently displayed on the vehicle at all times, in a location where the operator can easily see it.
Besides observing the forklift’s rated capacity, operators should heed the rated capacity of the work surface (floor, ramp, dockplate, or other operating surface).

3. Poorly Selected Forklifts

Using the wrong truck for the terrain can cause a lift to tip. Make sure workers know not to use a forklift designed for use on smooth concrete in areas with rough terrain.

4. Traveling or Parking on a Grade

A forklift is more likely to tip on a grade than on a flat surface. Make sure workers know that:

• On grades greater than 10 percent, loaded trucks must be driven with the load upgrade, except for motorized hand and hand/rider trucks, which should be operated on all grades with the load downgrade.
• On all grades, they should raise the load only as far as necessary to clear the road surface and should tilt the load-engaging means back if possible.
• They should avoid turning on a grade.

5. Alterations to the Forklift

Alterations to a forklift can change the lift’s capacity and handling characteristics, including its susceptibility to tipover. Make sure workers know that no alterations may be made to a truck that will:

• Change the relative positions of the various parts from the manufacturer’s original positions;
• Add parts not provided by the manufacturer;
• Eliminate parts provided by the manufacturer; or
• Add counter weighting, unless approved by the manufacturer.

6. Poorly Marked Aisles

Forklifts often tip or roll over the side of a ramp, dock plate, or loading dock. Make sure markings are present and clearly visible at edges of loading docks and other areas where forklifts could roll off, along with other precautions such as guardrails and chains.

Operators must also take special care when moving from bright to dim light, which can blind them just long enough for them to miss visual cues.

Forklist Check Point For Operater Safety:-

1. You must only operate machines of a type on which you have been trained, authorised and certified to use.
2. See that your machine is serviceable and properly maintained at all times. Make sure tyre pressure is correct. Check water ballasting where necessary.
3. Never allow passengers to ride on the fork lift the forks or use a pallet as a makeshift work platform – it is illegal.
4. Understand the limits of your machine, both loaded and unloaded. Never exceed the maximum weight shown.
5. Always load with the mast vertical or tilted back slightly.
6. Have the forks as widely spaced as practicable to give maximum stability to the load.
7. Ensure that the load does not obscure your view of the way ahead. If your view is restricted, travel in reverse. If necessary work with a banksman.
8. Beware of other personnel and plant in your working area. Sound horn whenever to warn others of your approach.
9. Avoid sharp obstacles and excessively uneven surfaces as far as possible.
10. Always travel with the load in the lowest practicable position. Do not raise the load while travelling. Wait until the off-loading position has been reached.
11. Deposit all loads gently on to storage areas or loading platforms.
12. Always travel at a steady speed consistent with the site and load conditions. Do not accelerate, brake or turn violently.
13. When driving on inclines, when load is carried the load should always face uphill. When no load is carried the forks should always face downhill. Adjust tilt to suit gradient and raise just enough to clear the road.
14. Ensure that there is always sufficient overhead clearance for the mast. Particular care is required in the vicinity of overhead power lines unless within the confines of “goal posts”.
15. When the machine is parked, the forks should be lowered to the ground, the ignition key removed and the handbrake applied.
16. Report all defects immediately.
17. Ensure forward protection is provided to the front of the driver to prevent access to the forks e.g. mesh grill.
18. Ensure that no unauthorised persons can use fork lift when left unattended.

Forklifts on Rough Terrain

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Chapter : Forklift Safety

Forklifts on Rough Terrain

Rough terrain forklifts require the right operators to handle them and misuse can lead to serious accidents. The workhorses are designed to handle heavy loads and operate on challenging terrain.
Most rough terrain forklift accidents are caused by operator error. The right training procedures can help your employees understand how to carefully operate the equipment to prevent serious accidents.
The three most common types of accidents on rough terrain are:

1. Rollovers
2. Tipovers
3. Collisions

And what causes the accidents? The culprits are:

• Slopes
• Dips, holes, and trenches
• Narrow aisles
• Ground and overhead obstructions

Discuss Hazards Beforehand

One of the most important things to do is to hold a training session with your employees before they drive on the rough terrain. Discuss the hazards so they know what can occur if they do not practice the right safety habits when driving their forklifts. While the vehicles do move slowly, you can end up with serious problems if you do not load them correctly, and you can end up driving too quickly with the load.
1. Improve Visibility. It is important to keep the windows clean and to make sure people can see when they are driving the forklift. Do they need to wear glasses? Vision testing can help ensure you have people who can see accurately when they drive the forklift. Not having a clear line of sight when driving can easily cause an accident.

2. Failure to Pay Attention. How often do you find yourself dozing off when you are working? Employees often end up failing to pay attention when they work long hours or they do the same job several times. A routine can end up causing people to get careless on their job, which can lead to wrecks. Inattention while driving is something that you need to address as it costs the company thousands of dollars if an accident occurs.

3. Failure to Yield to Other Vehicles. Some wrecks occur when people fail to yield to other vehicles. If you hit something with a rough terrain forklift, it can end up causing major damage to the forklift and the other vehicle, not to mention the drivers. Not only do drivers need to yield to other vehicles, they need to be aware of the pedestrians who cross their paths.

4. Overloading. If your forklift is overloaded, it can cause it to tip to the side when you turn or when you are near a steep edge. Overloading the machine can be hazardous when you are trying to drive the machine forward as it is easy for the machine to be pushed to the side.

5. Misjudging Terrain. People often drive the machine on rough terrain and assume the forklift will be able to handle anything. While the machine is designed to work on rough terrain, it isn’t always set to work on all types of terrain. Misjudging terrain is something that can end up leading to serious accidents.

6. Failure to Inspect the Forklift. If a forklift is not inspected and serviced properly, it could end up with major problems. It is important to have the machine correctly maintained and inspected so it operates at its highest capability.

7. Improper Loading or Unloading. Another major reason accidents occur is because of improper loading and unloading of the forklift. A rough terrain forklift is set up to deal with a number of weights and loads, but the operator is the key component who focuses on keeping everyone safe and the machine safe and reliable.

Workplace That Can Lead to Forklift Accidents

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Chapter : Forklift Safety

Workplace That Can Lead to Forklift Accidents

Surface or ground conditions are an important part of safe powered industrial truck operation. In today's Advisor we focus on hazardous conditions in your workplace that can lead to forklift accidents.

Physical conditions in the workplace that can lead to forklift accidents include slippery conditions, obstructions and uneven surfaces, flooring and load limits, overhead clearances, and ramps and grades.

Slippery Conditions

Hazards

• Danger of skidding when traveling on oil, grease, water or other spills
• Danger of tip over when traveling on ice, snow, mud, gravel and uneven areas

Safe Practices

• Avoid the hazardous surface when feasible.
• Spread absorbent material on slick areas that you cannot avoid.
• Cross the slippery area slowly and cautiously.
• Report the area to prevent others from slipping.
• Post a sign or warning cones until the area can be cleaned.
• Drive slowly!
• Maintain contact with the ground by crossing uneven areas at an angle.
• Clean up the oil or grease spill before proceeding (driving over an oil or grease spot will enlarge the hazardous area).

Obstructions and Uneven Surfaces

Hazards

• Danger of tip over when traveling over obstructions
• Danger of tip over in holes and bumps

Safe Practices

• Keep all aisles clear.
• Watch out for overhead obstructions.
• Avoid the obstruction or get off the forklift and remove the obstruction.
• Never drive straight across speed bumps or railroad tracks. Cross slowly at a 45-degree angle.
• Maintain steering control by keeping contact with the ground at all times.
• If an area is cluttered, walk the route first to spot problems.

Flooring and Load Limits

Hazard

• Danger of collapsing floor

Safe Practices

• Observe posted floor loading limits.
• Inspect the condition of the floor. Look for holes or weakened flooring, loose objects or obstructions, protruding nails or boards.
• Inform a supervisor immediately if flooring is defective.
• Do not travel over a surface that cannot support the weight of the lift truck, its load, and its operator.
• Do not enter a boxcar or semi-van without inspecting its floor and knowing its load limits.

Overhead Clearances

Hazards

• Danger of tip over
• Damage to lights, stacks, doors, sprinklers, pipes
• Damage to load

Safe Practices

• Be aware of the height of fixtures.
• Don't travel with loads elevated.

Ramps and Grades

Hazards

• Danger of tip over
• Damage to load

Safe Practices

• Always look in the direction of travel.
• Never turn on a ramp or incline. Turn prior to the ramp or incline to place forks in proper direction.
• Keep a safe distance from the edge of a ramp.
• Do not travel on ramps with slopes or other conditions that exceed the manufacturer's recommendation.
• When traveling with a load, make sure the load points up the incline, regardless of the direction of travel.
• When traveling without a load, make sure the load points down the grade, regardless of the direction of travel.

Forklift Safety Training, Who Needs Forklift Training

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Chapter : Forklift Safety

Forklift Safety Training, Who Needs Forklift Training

The forklift safety to be taken very seriously. In fact, they’ve beefed up the standard to include very specific operator training requirements.Standard on Powered Industrial Trucks has specific requirements for operator training that require a combination of formal training (classroom, videos, etc.) with practical instruction, as well as an evaluation and certification process. The standard says that only those who are already competent operators can provide this training, and also specifies a long list of required training topics. Once trained, operators need refresher training and evaluation at least every 3 years or as per Local goverment / Organizational statndards ; more often for operators that have a record of accidents or near-misses. And speaking of near misses: Don’t take them lightly! Use them as an opportunity for formal or informal safety training so the “real thing” doesn't happen at your facility. Trainers should refer to the standard to make sure all the required subject matter is covered. However, make sure all your employees take forklift safety seriously, too. While it’s true that only employees with specific training can operate a forklift, any employees who work around forklifts should know the basics of safe operation and maintenance and how to avoid getting hurt accidentally. So it’s good practice to conduct a “basic forklift safety” session for anyone who might be affected by forklifts. Even experienced, trained operators can benefit from refresher training in basic forklift safety. Forklifts are heavy machines that can seriously injure or kill people; they’re not like mini-cars in an amusement park. Remind employees that forklifts can topple over, collide with objects (and people), and drop heavy loads. As well, they present a possible fire and explosion hazard when being refueled. Also review these basics of forklift safety: Never exceed the rated load capacity. Make sure the load is balanced on the forks. Never ride as a passenger on a forklift. Never stand under the forks when they’re raised. Never smoke when the forklift is being refueled. Finally, encourage all employees to be on the lookout for possible forklift safety hazards, including unsafe operation or maintenance problems, and to report any such hazards to a supervisor as soon as possible.

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Chapter : Forklift Safety 

Forklift Workers & Maintenance Safety

A forklift, also known as fork truck, is a motor-driven industrial truck used for lifting and moving goods on a pallet within the premises of a warehouse, storage facilities and distribution centre. Depending on the design, some Forklifts allow the operators to sit while driving or operating the machine.

When it comes to forklift safety, a lot of emphasis is placed on operators and their training. But maintenance is also critical to forklift safety—and workers who perform forklift repairs and maintenance face hazards that must be addressed with worker training and attention to the work environment.

Only “authorized” persons may make repairs to and perform maintenance on forklifts. A worker’s authorization may be only for a specific task, such as refueling or battery replacement. Training requirements for workers who perform forklift maintenance are found in the Powered Industrial Trucks. 

Training for Forklift Maintenance Workers

• Fuel handling and storage. Workers must know how to properly handle and store fuels. Specifically:
• Liquid fuels (gasoline and diesel fuel) must be stored and handled in accordance with NFPA Flammable and Combustible Liquids Code.
• Liquefied petroleum gas (LPG) fuel must be stored and handled in accordance with NFPA Storage and Handling of Liquefied Petroleum Gases.
• Changing and charging storage batteries. Workers who change and charge storage batteries must know:
• To properly position trucks and apply brakes, before attempting to change or charge batteries;
• Not to pour water into acid;
• To assure that vent caps are functioning and that battery (or compartment) cover(s) are open to dissipate heat;
• Not to smoke in the charging area;
• To take precautions against open flames, sparks, or electric arcs in battery charging areas; and
• To keep tools and other metallic objects away from the top of uncovered batteries.
• Maintenance of Industrial Trucks. Forklift maintenance workers should know, at a minimum:
• To repair the fuel and ignition systems of industrial trucks only in locations designated for such repairs;
• To disconnect the batteries of trucks before repairing electrical systems;
• To only use replacement parts that are equivalent with respect to safety to the truck’s original parts;
• Not to alter industrial trucks so that the relative positions of the various parts are different from what they were originally;
• Not to add extra parts not provided by the manufacturer without the manufacturer’s approval; and
• Not to eliminate parts without manufacturer’s approval.

Identifying Maintenance Issues

There are two ways to identify a forklift that is in need of maintenance.

• Daily inspections. Forklift operators are required to inspect forklifts before each shift, for forklifts that are in continuous use. These daily inspections are supposed to identify issues that require attention.
• Malfunctions during use. Sometimes an issue arises while the forklift is in use—the forklift may overheat or dramatically malfunction (sparks or flames coming from the exhaust are one possible example).

Make sure that operators who have identified a potential safety issue with a forklift know to take it out of service immediately until it is repaired.

Additional Training for Forklift Maintenance Workers

Some topics are specific to forklifts, but other forklift maintenance hazards are covered by different standards. Employees who are exposed to these hazards while working on forklifts may require additional training for following hazards:

• Exhaust hazards. Workers should know how to use adequate ventilation to protect themselves against gasoline, diesel, or LPG exhaust.
• Hazardous energy. Maintenance workers should keep control of the forklift’s ignition key while they work. Also, they should disconnect the battery before working on the electrical system. Blocking raised parts and elevated equipment are another topic they may need training.
• Wheel hazards. Workers who service forklift wheels may need training Servicing Single-Piece and Multi-Piece Rim Wheels.
• Asbestos. During brake and clutch repairs, workers may be exposed to asbestos.
• Compressed gases. LPG is a compressed gas. Compressed gas hazards are Hazardous Materials.
• Eye, face, hand, and body hazards. To protect against some chemical exposures, cut and abrasion hazards, and falling object hazards, workers may need PPE 
• Fire hazards. Because maintenance work may involve fire hazards, workers should know how to use a fire extinguisher.
• Welding hazards. If repairs involve welding operations, workers will need training and certified for Welding, Cutting and Brazing work.

Work Locations

Forklift repairs must take place in locations that are specifically designed to perform the necessary tasks safely. Make sure that workers have:

• A location free of fire hazards. Repairing forklifts in hazardous (Class I, II, or III) locations. In particular, repairs to the fuel or ignition system of a forklift may only be made in an area with no uncontrolled fire hazards.
• Emergency equipment. Because forklift repairs can involve fire hazards, fire extinguishers must be provided. Because liquid chemical hazards may be present, emergency eyewashes and showers must also be located in the work area.

Forklift training requirements are extensive, and it can be confusing to try to figure out exactly which requirements apply to which workers.

Forklift An Extremely Useful Workplace Vehicles

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Chapter : Forklift Safety