Safe Use of Forklifts
Overview
Forklifts are essential material handling equipment but are involved in numerous serious accidents annually. These powerful machines require specialized training, proper operation techniques, and constant awareness to prevent tip-overs, struck-by incidents, and falls from elevated platforms.
Why This Is Important
Forklift accidents cause approximately 85 fatalities and 34,900 serious injuries each year, according to OSHA statistics. These incidents often involve tip-overs, workers being struck by forklifts, falls from elevated platforms, and workers being caught between the forklift and other objects.
Both operators and pedestrians must understand forklift hazards and safety requirements. Many forklift accidents involve workers on foot who are struck by moving equipment or caught in blind spots.
Best Practices & Safety Tips
Operator Certification
Only trained, certified, and authorized operators may drive forklifts. Certification must be specific to equipment type and renewed regularly.
Pre-Operation Inspection
Inspect forklifts before each shift for mechanical problems, damaged components, and proper fluid levels.
Safe Operating Practices
Drive at safe speeds, use seat belts, maintain clear visibility, and follow all traffic rules and site procedures.
Load Handling
Keep loads stable, within capacity limits, and properly positioned on forks before moving.
Operating Safety
For Operators
- Always use seat belts and maintain three points of contact when mounting/dismounting
- Drive at safe speeds appropriate for conditions, loads, and pedestrian traffic
- Sound horn at intersections, corners, and when approaching pedestrians
- Keep forks low during travel and tilt load slightly backward for stability
- Never exceed rated load capacity and ensure loads are stable before moving
- Maintain clear visibility and use spotters when view is obstructed
Load Management
- Center loads on forks and ensure they are stable before lifting
- Keep forks as low as possible during travel (4-6 inches off ground)
- Tilt loads slightly backward when traveling to prevent sliding
- Approach loading/unloading areas slowly and carefully
- Never lift people on forks or use forklifts as elevating platforms
Pedestrian Safety
For Workers on Foot
- Maintain safe distances from operating forklifts and stay out of blind spots
- Use designated walkways and avoid taking shortcuts through forklift operating areas
- Make eye contact with operators before entering their work areas
- Never walk under elevated loads or between a forklift and fixed object
- Stay alert and avoid distractions when working near forklift operations
Site Management
- Establish separate traffic areas for forklifts and pedestrians where possible
- Install mirrors at blind corners and intersections
- Use warning signs and lights to alert workers to forklift operations
- Maintain adequate lighting in all forklift operating areas
Discussion Questions
- What forklift hazards do you encounter in your work area, and how are they controlled?
- How do you ensure clear communication between forklift operators and pedestrians?
- What inspection items should be checked before operating a forklift?
- How can we improve separation between forklift traffic and pedestrian areas?
- What would you do if you witnessed unsafe forklift operation?
Action Items
- Verify all forklift operators have current certification and training
- Establish clear traffic control measures for forklift and pedestrian separation
- Review daily inspection procedures and documentation requirements
- Ensure adequate lighting and visibility in all forklift operating areas
Related Safety Topics
- Preventing Struck-By Incidents - Protection from moving equipment
- Safe Material Handling - Comprehensive material handling safety
Forklift Safety Priority: Safe forklift operation protects both operators and pedestrians from serious injuries and fatalities. Follow all certification requirements, maintain constant awareness, and communicate effectively. Remember - forklift accidents happen quickly and can be prevented through proper training and procedures.