Forklift and Powered Industrial Truck (PIT) Safety
The Problem
Forklifts and powered industrial trucks (PITs) are essential in many workplaces, but they also present serious risks. Workers can be struck, crushed, electrocuted, or injured due to operator errors. These incidents can result in serious harm or fatalities if proper safety practices aren’t followed. Today, we’ll identify common hazards associated with forklifts and discuss how we can eliminate these risks to keep ourselves and others safe.
Identify the Hazards
Safety Practices and Preventative Measures
Struck by the Forklift
- Hazard: Forklifts are heavy and cannot stop quickly, even when unloaded.
- Solution: Always stay alert to forklift activity, maintain a safe distance, and never assume the operator can see you. Pedestrians have right-of-way, but awareness is vital.
Caught Between the Forklift and Stationary Objects
- Hazard: Workers can be crushed between forklifts and solid objects like racking or walls.
- Solution: Never position yourself between a forklift and any structure. Stay clear of the operating area.
Poor Visibility
- Hazard: Operators may have limited sightlines, especially with large loads.
- Solution: Make yourself visible to the operator. Use eye contact, hi-vis clothing, and stay in designated pedestrian zones.
Standing Under Elevated Forks
- Hazard: Loads or forks may fall unexpectedly.
- Solution: Never stand under raised forks or loads. Keep hands and body clear of the mast to avoid pinch points.
Electrocution from Overhead Lines
- Hazard: Forklifts contacting overhead power lines can cause electrocution.
- Solution: Be aware of electrical lines overhead. If contact occurs, stay away from the forklift and notify site management immediately.
Riding on Forklifts
- Hazard: Standing or riding on forklifts is unsafe and can lead to falls or being crushed.
- Solution: Only trained operators in the driver’s seat may ride. Never ride on forks or sit on the vehicle.
Untrained Operator Error
- Hazard: Forklifts operated by unqualified workers can result in serious incidents.
- Solution: Only trained and authorized operators are permitted to drive forklifts. Untrained personnel must not operate this equipment.
Real-Life Case or Scenario
A recent incident involved a worker being pinned between a forklift and a bench. The operator’s view was blocked by a large load, and the worker failed to see the forklift approaching. The worker suffered serious leg injuries. This could have been prevented with improved communication and spatial awareness.
Employee Responsibilities
- Be alert and aware of forklift activity.
- Maintain a safe distance — never stand under raised loads.
- Communicate clearly with operators and ensure eye contact.
- Do not operate a forklift unless trained and authorized.
Employer Responsibilities
Discussion & Questions
- What forklift hazards have you observed at our worksite?
- What actions do you take to stay safe around forklifts?
- Have you ever reported unsafe forklift use or a near-miss?
Encourage everyone to share stories or lessons from previous experiences.
Commitment/Action Plan
Let’s commit to being more aware of forklifts on site. From today forward, always maintain safe distances, communicate with operators, and report unsafe conditions or behaviours immediately.
Wrap-Up
Forklifts are important tools, but they can be extremely dangerous when safety practices are not followed. With good communication, awareness, and proper training, we can prevent serious injuries. Thank you for putting safety first.
Standards Overview
Under applicable provincial and territorial health and safety legislation, employers must ensure workers are trained and competent to operate forklifts safely. Canadian workplace safety regulations require:
- Forklifts must be operated only by trained and competent workers.
- Workplaces must manage risks associated with mobile plant and pedestrian interaction.
- Employers must provide information, training, and supervision to keep workers safe.
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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