Avoiding Struck-By Hazards When Operating Forklifts
The Problem
Forklifts are an essential part of many workplaces, but they also present significant struck-by hazards. Each year, workers are seriously injured or killed in forklift-related incidents. Most of these accidents occur due to poor visibility, unsafe operation, or failure to follow site safety protocols. Today, we’ll focus on identifying these hazards and discuss how to operate forklifts safely to prevent struck-by incidents.
Identify the Hazards
Safety Practices and Preventative Measures
Maintain Clear Visibility
- Always ensure the area ahead and around the forklift is free from obstructions.
- Use mirrors and spotters in areas with blind spots.
- Avoid carrying loads that block your line of sight; reverse if necessary.
Secure and Balance Loads
- Ensure loads are stable and evenly distributed before moving.
- Do not exceed the forklift’s rated lifting capacity.
- Use straps or load restraints where appropriate for loose or irregular loads.
Control Speed
- Drive at safe speeds, especially in shared or confined areas.
- Slow down when cornering, and avoid sudden stops to prevent load displacement.
Warn and Communicate
- Use horns, flashing lights, and alarms to alert others of your presence.
- Make eye contact with pedestrians before proceeding.
Create Safe Pedestrian Zones
- Where possible, separate forklift routes from pedestrian paths.
- Use cones, barriers, painted walkways, or signage to clearly define exclusion zones.
- Restrict forklift use in high foot-traffic areas when possible.
Safe Reversing Procedures
- Always check surroundings before reversing.
- Use a spotter in tight or blind spots.
- Never assume the area behind you is clear—always confirm visually.
Training and Certification
- Only certified operators should use forklifts.
- Operators must be trained in accordance with CCOHS requirements and site-specific procedures.
Real-Life Case or Scenario
A worker was seriously injured when struck by a forklift carrying a high load that blocked the operator’s view. The pedestrian did not see the forklift, and the operator did not have a spotter. This incident could have been prevented by using a spotter and ensuring clear communication.
Employee Responsibilities
- Follow forklift safety procedures including speed limits and load checks.
- Remain alert and aware of forklift activity around you.
- Communicate with operators before crossing or working in their area.
- Report any damaged forklifts or unclear pedestrian areas to your supervisor.
Employer Responsibilities
- Ensure operators are properly trained and certified.
- Maintain forklifts to ensure all safety systems are working (e.g., alarms, mirrors, lights).
- Create and maintain clear pedestrian and vehicle zones.
- Conduct routine site safety checks to identify and address risks.
Discussion & Questions
- What struck-by hazards have you observed with forklifts on our site?
- How can we improve operator-pedestrian communication here?
Encourage workers to share experiences or suggestions.
Commitment/Action Plan
Let’s commit to improving forklift safety starting today. All operators should inspect their forklifts before use, drive safely, and ensure good communication with others. Pedestrians should stay alert, stay in marked walkways, and avoid cutting across active forklift zones.
Wrap-Up
Struck-by incidents involving forklifts are preventable. By remaining vigilant, using proper communication, and following safety protocols, we can protect ourselves and our workmates. Thank you for your commitment to site safety.
Standards Overview
CCOHS requires all forklift operators to hold a current operator certificate and be trained according to applicable provincial regulations and standards. Employers must:
- Maintain forklifts in safe working condition.
- Implement traffic management plans separating pedestrians and mobile plant.
- Ensure forklifts are only operated by trained, competent workers.
- Provide high-visibility PPE and ensure signage and warnings are clearly displayed.
Disclaimer
“The information provided in this toolbox talk is intended for informational and educational purposes only. It is not a substitute for professional legal, safety, or regulatory advice. The content reflects general best practices and industry standards but may not be applicable to all workplace environments or jurisdictions.
It is the responsibility of employers, supervisors, and workers to ensure compliance with applicable federal, provincial, and territorial laws, regulations, and standards, including but not limited to those set by the Canadian Centre for Occupational Health and Safety (CCOHS) and relevant provincial occupational health and safety authorities. Site App Pro, its affiliates, agents, or representatives—as well as the authors, presenters, and distributors of this toolbox talk—assume no liability for the use or application of the information provided.
Participants are strongly encouraged to consult appropriate legal, safety, or regulatory professionals regarding specific workplace concerns or questions. Always adhere to your organisation’s policies and procedures for health and safety and hazard management.
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