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 hazards. Workers can be struck, crushed, electrocuted, or injured due to operator errors. These incidents can cause severe injuries and fatalities if we don’t follow proper safety practices. 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 Power Lines
- Hitching a Ride on Forklifts
- Unqualified Operator Error
Safety Practices and Preventative Measures
- Struck by the Forklift
- Hazard: Forklifts are heavy and cannot stop quickly, even without a load.
- Solution: Always be aware of forklift traffic, keep a safe distance, and never assume the operator sees you. Pedestrians have the right-of-way, but alertness is key.
- Caught Between the Forklift and Stationary Objects
- Hazard: Being pinned between a forklift and a wall, trailer, or bench can cause crushing injuries.
- Solution: Never position yourself between a forklift and stationary objects. Always stand to the side to avoid being caught in its path.
- Poor Visibility
- Hazard: Operators have limited visibility, especially when carrying large loads or maneuvering through tight spaces.
- Solution: Communicate with the operator if you think they cannot see you. Step aside, maintain eye contact when possible, and stay in clear, visible areas.
- Standing Under Elevated Forks
- Hazard: Elevated forks or loads can fall unexpectedly, causing fatal injuries.
- Solution: Never stand beneath elevated forks or loads. Keep hands and body parts away from the mast to avoid pinch points.
- Electrocution from Power Lines
- Hazard: Forklifts can accidentally contact overhead power lines, energizing the machine and creating electrocution hazards.
- Solution: Stay alert to overhead power lines. If a forklift contacts power lines, do not approach the equipment. Notify the operator and supervisor immediately.
- Hitching a Ride on Forklifts
- Hazard: Riding on forklifts or standing on forks creates fall and crush hazards.
- Solution: Never ride on forklifts or stand on elevated forks or loads. Only operators in designated seats should be on the equipment.
- Unqualified Operator Error
- Hazard: Untrained or unauthorized personnel operating forklifts may make dangerous mistakes.
- Solution: Only trained and certified operators are allowed to use forklifts. If you’re untrained, stay off the equipment and follow all company protocols.
Real-Life Case or Scenario
In a recent incident, an employee was pinned between a moving forklift and a workbench. The operator’s visibility was blocked by a large load, and the worker didn’t see the forklift approaching. This led to a severe leg injury. Situational awareness, clear communication, and maintaining safe distances could have prevented this accident.
Employee Responsibilities
- Stay alert and aware of forklift movements in your area.
- Maintain a safe distance and never stand under elevated loads or forks.
- Communicate clearly with operators when working near forklifts.
- Never operate a forklift without proper training and certification.
Employer Responsibilities
- Ensure that only trained and authorized personnel operate forklifts.
- Maintain forklifts in safe working condition.
- Establish clear traffic routes and safety protocols for pedestrians and operators.
- Provide training and refreshers on forklift safety.
Discussion & Questions
- Ask Employees:
- "What hazards have you encountered while working around forklifts?"
- "What steps do you take to stay safe around forklifts?"
- Encourage Participation: Share experiences or near misses to reinforce the importance of these safety measures.
Commitment/Action Plan
Starting today, let’s commit to staying alert, communicating with forklift operators, and keeping a safe distance from forklifts and their loads. If you see any unsafe behavior or equipment, report it immediately.
Wrap-Up
Forklifts are essential, but they can also be dangerous if we’re not careful. By identifying hazards, following safety procedures, and staying aware, we can prevent injuries and accidents. Thank you for your attention and for making safety a priority.
Standards Overview
- According to OSHA Standard 1910.178, only trained and certified personnel are allowed to operate forklifts and PITs.
- Employers and workers must identify hazards like pedestrian traffic, poor visibility, and power lines, and implement measures to control these risks.
Disclaimer
“The information provided in this toolbox talk is provided for informational and educational purposes only. It is not intended to be a substitute for professional legal, safety, or regulatory advice. The information presented is based on best practices and general industry standards but may not apply to all workplace situations.
It is the responsibility of the employer, supervisors, and workers to ensure compliance with applicable federal, state, and local laws, regulations, and standards, including but not limited those of the Occupational Safety and Health Administration (OSHA). 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 encouraged to consult appropriate legal, safety, or regulatory professionals to address specific concerns or questions. Always follow your organization's policies and procedures for workplace safety and hazard mitigation.”
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