Forklifts, also known as powered industrial trucks (PITs), are a common piece of equipment found at most job sites and industrial warehouses. While forklift types and applications can vary (learn more about different forklift types), each type comes with its own set of safety requirements. Understanding these differences is crucial for maintaining a safe working environment.

Although forklifts are generally less dangerous than large rough terrain cranes or excavators, they still pose significant risks that can lead to serious workplace injuries. According to OSHA, forklift overturns are the leading cause of fatalities involving forklifts, accounting for approximately 25% of all forklift-related deaths. In the United States alone, nearly 100 workers are killed and another 20,000 are seriously injured in forklift-related accidents each year (see NOISH report).

Diesel-powered forklifts are designed for outdoor use due to the harmful fumes they emit. Using them indoors without proper ventilation can be extremely dangerous. It's essential to follow safety protocols and ensure that any indoor operation is conducted in well-ventilated areas.

Many factories use colored tape to mark forklift zones, helping workers stay aware of their surroundings. Additionally, mirrors placed near corners allow operators and pedestrians to see each other even when visibility is limited by shelves or other obstacles.

Handling the Forklift Load Preparation

Before lifting any load, it’s important to ensure it is centered and balanced. An off-center load can easily cause the forklift to tip over. Here are some key steps to follow:

• Secure the load to ensure it is stable and properly arranged.
• Inspect the load for damage. If damaged, secure it with wrapping or banding before moving.
• Center the load on the forks to maintain balance.
• If the load cannot be centered, move slowly and take extra care.
• Place the heaviest part of the load closest to the front wheels to help balance the forklift.
• Never overload the forklift. Always check the rated capacity and factor in any attachments used.
• A forklift's capacity is based on a specific load center. If the load is off-center, oversized, or improperly distributed, it may exceed the capacity and cause instability.
• Use the load extension backrest to improve stability.

Takeaway: The top image shows a properly balanced forklift load. The bottom image shows an imbalanced and dangerous load. Improperly balanced loads can lead to tipping and serious accidents.

Approaching the Forklift Load

When approaching a load, always do so slowly and carefully. Follow these guidelines:

• Approach the load slowly and stop 8–12 inches in front of it.
• Position the truck perpendicular to the load with the forks at the correct height.
• Set the direction control to neutral.
• Do not move the forks until the forklift has fully stopped and the brakes are engaged.
• Use the inching pedal to carefully maneuver the forks into position.

Notes: Always stop 8–12 inches in front of the load to give yourself enough space to maneuver the forks safely.

Mast Position

The mast plays a critical role in maintaining load stability. Here are some key tips:

• Monitor the load while adjusting the mast. Loads can become unbalanced during movement.
• Be cautious when tilting the mast forward, especially when the forks are raised. Only tilt forward when picking up or placing a load.
• When stacking or tiering, tilt the mast back just enough to stabilize the load.
• Travel with the mast tilted back to keep the load steady.
• Tilt the mast forward carefully when positioning the load onto the stack.
• Never travel with the load tilted forward. This increases the load's distance from the forklift's center of gravity and makes it unstable.

Notes: The mast should be vertical when approaching a load.

Notes: Tilting the mast forward increases the load's distance from the center of gravity, making it more unstable.

Notes: Tilting the mast back helps reduce the load's distance from the center of gravity, improving stability.

Positioning Forklift Forks

• Ensure the forks are level before inserting them into the pallet.
• Place the forks under the load as far as possible to help balance the weight.
• Slide the forks into the pallet until they are fully under the load. They should be at least two-thirds of the way under the load for safe lifting.
• Be careful not to extend the forks beyond the pallet, which could hit objects on the other side.
• Distribute the load evenly between the forks.
• Tilt the mast back slightly to stabilize the load after insertion.

Notes: Make sure the forks are fully under the load and at least two-thirds of the way in. Avoid extending them too far to prevent hitting nearby objects.

Lifting the Load

• Check for overhead clearance before raising the load. Look for pipes, lights, or other obstructions.
• Lift the load slowly, about 4 inches above the lower stack, and make sure it is stable.
• Once lifted, tilt the mast back slightly to rest the load against the backrest extension.
• Ensure the load is not caught on anything or being moved unintentionally.
• Slowly return the lift control lever to the neutral position.

Notes: Lift the load slowly and carefully, ensuring it remains balanced throughout the process.

Lowering the Load

• Be cautious of falling objects and potential collisions when lowering the load.
• Return the mast to a vertical position before lowering the load.
• Lower the load so that its lowest point is 6 to 8 inches above the floor.

Notes: Tilting the mast back helps stabilize the load before lowering.

Group Discussion Topics

• Is your forklift in good condition? (e.g., tires, hydraulic lines, signage, etc.) Perform a daily visual inspection.
• What are some forklift hazards specific to your workplace?
• Is the forklift designed for indoor or outdoor use?
• Are bystanders and other workers aware of forklift activity in the area?
• What factors could lead to a forklift rollover?

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