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
- Struck by the Forklift
- Caught Between the Forklift and Stationary Objects
- Poor Visibility
- Standing Under Elevated Forks
- Electrocution from Overhead Lines
- Riding on Forklifts
- Untrained Operator Error
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 authorised 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 authorised.
Employer Responsibilities
- Ensure only trained, competent operators use forklifts.
- Maintain forklifts in safe working condition.
- Provide clear site traffic plans separating pedestrians and forklifts.
- Offer regular training and refresher courses in forklift safety.
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 the Health and Safety at Work Act 2015 (HSWA), all PCBUs must ensure workers are trained and competent to operate forklifts safely. WorkSafe NZ requires:
- 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
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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