Forklifts, or powered industrial trucks, are essential tools in many workplaces. These machines
can lift, carry, and maneuver heavy loads with ease, making jobs faster and safer—if operated
correctly. However, improper use can lead to accidents, injuries, or even fatalities. In this
comprehensive guide, we’ll dive into OSHA’s Powered Industrial Truck Standard, 29 CFR
1910.178, and share actionable forklift safety tips for operators.
Forklifts are essential tools, but without proper training and safety measures, they can lead to preventable injuries.
Forklifts are powerful, versatile, and invaluable in industries such as construction, warehousing,
and retail. But without proper safety measures, they can become dangerous. According to
OSHA, forklift-related incidents account for thousands of injuries annually, many of which are
preventable through training, inspections, and adherence to safety protocols.
Forklift operators must complete OSHA-required training, hands-on practice, and regular evaluations to stay certified and safe.
To operate a forklift, you must be trained, evaluated, and certified by a qualified instructor. This
three-step certification process ensures that operators are equipped with the knowledge and
skills necessary for safe operation:
- Formal Instruction: Classroom-style learning about safe operating procedures.
- Practical Training: Hands-on experience with the specific forklift model.
- Performance Evaluation: An on-the-job assessment of the operator’s ability to safely use the forklift.
OSHA mandates refresher training in scenarios such as:
- Unsafe operation observation.
- Involvement in an accident or near miss.
- Use of a new type of forklift.
- Significant changes in workplace conditions.
Every three years, operators must undergo a comprehensive evaluation to maintain certification.
Different forklifts are built for different jobs, so knowing your machine’s capabilities and limits is key to staying safe.
Not all forklifts are created equal. Each type serves specific purposes based on its design and
capabilities.
- Counterbalance Forklifts: Heavy-duty forklifts used in construction sites, shipyards, and large warehouses.
- Narrow-Aisle Forklifts: Compact forklifts designed for indoor use in confined spaces, like retail stores and smaller warehouses.
Understanding your forklift’s capabilities, including its load capacity and limitations, is crucial to
operating safely.
Always start with a thorough pre-operation inspection to spot hazards, check equipment, and report any issues before using the forklift.
Before using a forklift, conduct a thorough pre-operation inspection to identify potential hazards.
This inspection should be documented and include:
- General Equipment Check:
- Inspect the mast, forks, and hydraulic components for damage.
- Ensure roller tracks are greased, and tires are in good condition.
- Power Source Check:
- For battery-powered forklifts: Check for leaks, cracks, and secure connections.
- For propane-powered forklifts: Inspect tanks, valves, and hoses for damage.
- For gasoline or diesel forklifts: Confirm fuel type and refuel safely.
If any issues arise during inspection, report them immediately to your supervisor and avoid
using the forklift until repairs are completed.
After inspection, lift carefully, drive cautiously, and adjust for ramps, tight spaces, and slippery surfaces.
Once your forklift passes inspection, you’re ready to work. Follow these best practices for safe
operation:
- Lifting: Approach the load straight on, position the forks evenly, and lift slowly.
- Transporting: Keep the load low and tilted slightly back for stability.
- Unloading: Level the forks, lower the load gently, and back out cautiously.
Steering and Driving
- Always adhere to posted speed limits.
- Use the horn at intersections and blind spots to alert others.
- Avoid sharp turns, especially when carrying a load, to prevent tipping.
- When visibility is obstructed, drive in reverse or use a spotter.
Working in Challenging Conditions
- On ramps: Travel forward uphill with a load and reverse downhill.
- In tight spaces: Move slowly and adjust the forks to maximize turning angles.
- On slippery surfaces: Reduce speed, make wide turns, and avoid sudden braking.
Don’t Skip Forklift Safety—Take the Next Step.
If you’re unsure about proper forklift operation, maintenance, or OSHA compliance, now is the time to learn. Understanding your forklift’s capabilities, potential hazards, and safety protocols is essential for protecting yourself and your coworkers. OSHA and the National Institute for Occupational Safety and Health (NIOSH) provide valuable resources to help operators stay informed and compliant. By prioritizing safety and taking action, you contribute to a safer, more efficient workplace. Forklift safety matters. Master OSHA standards, daily practices, and operator responsibilities with our Forklift Safety Training Course!
References
Occupational Safety and Health Administration (OSHA), Powered Industrial Trucks Standard, Subpart N – 29 CFR 1910.178
https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.178
Occupational Safety and Health Administration (OSHA), Forklift Safety – QuickCard
https://www.osha.gov/publications/bytopic/forklift-safety
National Institute for Occupational Safety and Health (NIOSH), Preventing Injuries and Deaths of Workers Who Operate or Work Near Forklifts
https://www.cdc.gov/niosh/docs/2001-109/
