Forklift safety

1. Forklift Safety
Draft 7 27 2011

2. July 13, 2011
•One person died Wednesday after a forklift
accident in Fluvanna County. The incident
happened shortly after 5 p.m. in front of the
Tapscott Brothers Lumber Company. (NC)
•The Will County Coroner's line reports that a 35
year old Aurora man was pronounced deceased
at Silver Cross Hospital at 7:22 AM Wednesday
morning, after a forklift accident in Mokena. The
Coroner's line stated that Jose R Barrera-Ruiz
died of multiple injuries.

3. These Deaths Were Preventable
•These were not isolated
incidents.
•There were 1000+ deaths
in 10 Years 2000-2010.
•Workers have a right to a
safe workplace.
•In the operation of forklifts
these are the FIVE largest
risks among many:
–Falls
–Hit by Falling or moving
Load
–Hit by Forklift
–Equipment overturning
–Amputation
•All of these are preventable

4. 2010 Injury Causation Statistics
•32 falls: includes 12 pallet, platform or forks, 10 forklift went off dock, 1 ejected
from forklift, 5 fall from load lifted, 1 fall through hole, 1 order picker platform, 2
mezzanine
•46 struck by falling/moving object or load
•36 struck by forklift
•15 forklift overturned
•29 crushed or caught in forklift/load and an object
•10 caught in amputation
•5 burns / fire
•3 CO, 1 Ammonia
•Type of forklift not included - many not identifying the type

5. Injury Prevention Basics
•Management Leadership
•Employee Participation
•Hazard Prevention and
Control
•Education and Training
•Program Evaluation and
Improvement
•Communication and
coordination on multi-
employer sites
•These principles are
adopted and
recognized by…
–2100 VPP Companies
–1600 SHARPs
–1926.20, 1926.21
–1910.119
–ANSI Z9.10
–OHSAS 18001
–States AR, CA, LA,
HI, MN, MT NV, NH,
NY, OR, WA

6. Falls
•Pallets used as
elevating platforms
has lead to many
deaths and is not
acceptable
•Employees use what
is available
•Use proper
platforms designed
per ANSI/ITSDF
B56.1-2005

7. Elevating/Order Picker Truck

•Fall protection is
required when the
operator rides up with
the load
•Use ANSI Z359 fall
arrest equipment

8. Struck-by
•What should be
done?
•Many a foot have
been crushed by
people getting too
close.
•How close is too
close?

9. Struck By
•Leaving forklift trucks
without brakes or
chocks
•Truck Moves

10. Struck By
•Falling Loads KILL
•Loads improperly
stored kill people.
•What can be done?

11. Struck-by
What should
be done
when
backing out?

12. Accidents – Forklift Leaves Dock
•November 1, 2000
•An employee was driving
a forklift truck in reverse
•She backed off of the
receiving dock and was
pinned under the forklift
•Operator was not wearing
seatbelt and the forklift
didn't have a overhead
guard

13. Overturned
•Uneven surfaces
–Curbs
–Potholes
–Change in grade
–Low tire pressure
•Seat belts
•Excessive weight
lifted

14. Is a Forklift a Crane?
Qualified rigger?
•OSHA’s Construction
Crane standard may
apply in construction.
•Many injuries result
from dropped loads
when using slings for
rigging.

15. Caught In-Between
Guarding Needed!
SHIB
http://www.osha.gov/dts/shib/shib072709.html
There have been
fatalities where standup
type fork trucks crush the
operator under cross bar
of a rack system.
Body part outside frame
of forklift is dangerous!

16. Lifting/Moving the Forklift
•Is there a procedure
to get forklift off?
•What is the procedure
to free a stuck forklift?

17. Truck Unloading
•Is material palletized?
•Will the load stay stable
as straps are loosened?
•Many times a person
adjacent to the load
being removed is hit.
•Where do people stand?

18. Lockout or Guarding?
•The person who works on
the forklift must know the
OSHA lockout standards.
•Any body part can be cut or
crushed if caught in a
scissor point.
•Forklift maintenance
fatalities – employees were
crushed after jack failure, or
crushed between mast and
frame of truck because they
didn’t block it.

19. Forklift Amputation Hazard
•Maintenance hazards:
–Scissor point between
lifting carriage and
mast.
–Pinch point between
overhead guard and
mast
•Chain and sprocket
can amputate fingers.
•http://www.cdc.gov/niosh/face/stateface/ca/04ca012.html

20. Electrical
•When working around electrical wires be aware
of any potential contact (electrocution).
–20ft. safe distance from overhead lines is required by
OSHA’s crane standard (1926.1400).
•If you must use the lift closer, this must be
preplanned and elements of the crane standard
must be addressed in the planning.
•Triple Fatality in Illinois when a forklift contacted
overhead lines in a yard. ~2003

21. Fire / Burns
•The employee and the forklift were dowsed
in toluene.
•The toluene ignited from an unknown
source prior to the employee leaving the lift
seat.
•The employee was severely burned.
•The truck was a destroyed.
•What could be done to prevent this?
Forklift strikes overhead pipe containing Toluene.

22. Many people trust these machines

23. Sample Safety Rules
•Follow Manufacturer’s instructions and OSHA
regulations. Use ANSI/ITSDF B56 standards on
forklifts if you cannot get the manufacturer’s
rules.
•Follow CAUTION WARNING DANGER Labels.
•Prohibit untrained personnel from operating all
forklifts.
•A trained person must inspect each forklift at
least daily before use.
•And many more!

24. Training
•Hands on training is
necessary. A forklift is
not a car.
•The worker must be able
to demonstrate
–safe operation in their
workplace
–follow each forklift
manufacturers’ usage
instructions.
BEFORE CERTIFICATION

25. •Initially
•Every 3 years
•Near Miss
Certification and
Re-certification

26. Evaluation
•Date of
Certification
•Operator’s name
•Trainer’s Name

28. Inspections
Per manufacturer’s guidelines.
•At least daily before use.
•Check all working components and safety
device.
•Address all leakage of fluids.
•Search for defective hydraulic/pneumatic
hoses.
•Look for quickfix signs (not acceptable)
i.e. electrical tape, rags tied on hoses…

29. Inspections
Why is this inspection form weak?

30. Manufactured Attachment

NOTE: Use of
such an
attachment
changes the
load capacity
of the PIV
DANGER: Manufacturer’s Written Approval Required

31. •Barrel lifter
(liquid = inertia)
•Capacity plate
update required?
•Don’t forget
unapproved
attachments can
overload the trucks.
DANGER: Manufacturer’s Written Approval Required
Manufactured Attachment

32. Lifting Slabs
•Many injuries have
occurred while lifting
large flat objects
•Use lifting
attachments designed
and approved for
each specific job.
•ANSI B30.20

33. Seatbelts
•Must be worn when
equipped.
•Prevent the operator from
being pinned by the truck
or overhead guard.
Click for rollover video

34. Inspection
Labels
•Ensure that
capacities for
attachments
are listed

35. Inspection
•Load Backrest
Extension is damaged

36. Inspection
•How much wear is
acceptable?

37. Forklift Inspections
•Overhead guard
improperly welded

38. Forklift Inspection
•Broken Fiberglass
Housing is a
Laceration Hazard

39. Inspection
•Leaking Hydraulic
Fluid
•Can lead to:
–Low pressure
–Air bubbles
–Erratic operation
–Slippery surfaces

40. Personnel Elevating Platforms
•Good Platform must
include guardrails
•Secure the platform to
the forklift.
•Screen at forklift side

41. Personnel Elevating Platforms
OSHA 5(a)(1) Violations
–ANSI/ITSDF B56.1-2005:
•No screen (scissor point)
•Cannot be secured to
forks or backrest

42. Emergency Response
•What is the response
if the drum contains
flammable or toxic
liquid?

43. Fire
•Cylinder gases ignited by
forklift.
•What can be done?

44. Carbon Monoxide
0222 HCOOHCxx +®+
Perfect World:
Real World:
xxxxx HCNOCOOHCONOHC ++++®++ 2222

45. Acute Exposure
•Headache
•Nausea
•Weakness
•Irritability
•Chest Pain
•Unconsciousness

46. Chronic Exposure
•Headache
•Dizziness
•Anorexia
•Ataxia
•Confusion

47. Best Practice and Required in MN
General industry: Minnesota Rules § 5205.0116 Carbon Monoxide
Monitoring
•Subpart 1. Internal combustion engine powered industrial trucks.
The employer shall monitor environmental exposure of employees to
carbon monoxide whenever internal combustion engine powered
industrial trucks as defined in Code of Federal Regulations, Title 29,
section 1910.178(a)(1) are operated indoors to ensure that carbon
monoxide levels do not exceed those given in Code of Federal
Regulations, Title 29, section 1910.1000, Table Z-1-A.
The air monitoring shall be done at least quarterly and represent
exposures during a day of highest usage in the areas where employee
carbon monoxide exposure is most likely.
•Subpart 2. Tailpipe exhaust gas analysis.
The employer shall ensure that powered industrial truck engine exhaust
gases do not contain more than one percent carbon monoxide for
propane fueled trucks or two percent carbon monoxide for gasoline
fueled measured at idle and at three-fourths throttle during final engine
tuning in a regular maintenance program.

48. Exposure Limits
•OSHA 50 ppm 8-hour
Time Weighted Average
(TWA)
•NIOSH 35 ppm 8-hour
TWA
•200 ppm Ceiling by
NIOSH
•ACGIH Threshold Limit
Value is 25 ppm 8-hour
TWA; 40-hour work week

49. Dizziness, nausea,
convulsions. Death within
1 hour.
20
minutes
1600
Dizziness, nausea,
convulsions. Death after
2-3 hours.
45
minutes
800
Symptoms intensify. Life
threatening after 3 hours.
1-2 hours400
Headache, fatigue,
nausea.
2-3 hours200
SymptomsTimePPM CO

50. ACGIH Recommendations
•Limit CO concentration to 1%
or less for propane fueled
trucks
•Limit CO concentration to 2%
or less for gasoline fueled
trucks.

51. Forklift Exhaust Test
•No Violation
–Forklift emits low
level of CO

52. Prevention of CO Poisoning
•Maintain equipment in good working
order
•Provide periodic tune-ups for forklifts to
ensure that they run “lean”
•Periodic CO analysis of exhaust gases
to determine emission concentrations
•Provide adequate ventilation
•Install CO monitors

53. Storage
•What is the
problem and
solution?

54. Storage
•No Violation
–Material stored
properly in racks

55. Material Handling
•Rack was hit by
forklift and tagged out
and pallets removed.

56. Material Handling
•No Violation
–Aisle properly
marked
–Smooth Clean
lanes

57. Struck By
•No Violation
–Corner marked so
forklift operation can
see around corner

58. Cautions
•Watch for any holes. These will flip some
forklifts. These should be identified in
advance and plans to prevent a forklift
from going into one is necessary.
•Watch for aerial lifts and other mobile
equipment. Barricade the equipment to
prevent contact with each other.

59. Quiz
•How often does a forklift driver have to be re-
evaluated/certified? __________
•Forklifts must be inspected every ________
before use.
•OSHA’s limit for Carbon Monoxide in an 8 hour
shift is ____ ppm.

60. Resources
•www.osha.gov
•Compliance Assistance Specialists in OSHA
offices
•On-site Consultation
•Quick Takes
http://www.osha.gov/as/opa/quicktakes
•www.aiag.org Pedestrian & Vehicle Safety
Guidelines
Comments or Corrections go to John Newquist

61. What is the pending hazard?

62. Summary
Training
Job Hazard Analysis
Written procedures
Manufacturer rules
Inspections

63. Further
•This ppt was prepared by John Newquist as a
preliminary aid for people required to evaluate forklifts.
•Thanks to Misette Kobler, Carlos Gallegos and Janet S.,
for corrections and suggestions.
•Thanks to Joe Schwarz, Marc Snitzer, Walter Visage,
Rick Dvorak, Cynthia Evans, Aaron Priddy, for previous
work on the topic.
•This is not an official OSHA publication. Those will be on
the OSHA.gov website.
•[email protected] is my email if you see any
errors. This is just a draft as of the cover date.
•312-353-5977

64. Wage & Hour Referral
•No one under 18 allowed on a PIT
“Order 7 of Hazardous Occupations” prohibits
employees under 18 years of age from operating
forklifts, employers must make certain that workers
under 18 years of age are not permitted to use PIT’s.