FORKLIFT
http://www.cdc.gov/niosh/docs/2001-109/default.html
What is a Forklift
• A forklift (or lift truck, high/low)
is a powered industrial truck
used to lift and transport
materials.
• First developed in 1920s, due to
the labor shortages caused by
the World War I.
• World War II also spurred the
use of forklift trucks that were
with more maneuverability and
could reach greater heights.
http://en.wikipedia.org/wiki/Forklift
Types of Forklifts
• Power Supply
– Electric
– Internal Combustion (diesel / gasoline / LP gas)
• Specialized
Narrow Aisle Rough Terrain Variable Reach
http://www.buyerzone.com/industrial/forklifts/forklift-types.html
Components of a Forklift
The operator sits
in the cab which
is mounted on a
truck frame and
moves the forks
up and down to
lift and transport
pallets or other
materials.
http://en.wikipedia.org/wiki/Forklift
Special Safety Concerns
• A forklift has its LIMITS!
– Which are indicated as the maximum loads
listed on the nameplate visible to the operator
• A forklift is REAR-WHEEL STEERING!
– Which differs from a driver’s traditional
experience with other wheeled vehicles
• A forklift is UNSTABLE!
– Especially when loaded and when turning
http://en.wikipedia.org/wiki/Forklift
Forklift Accidents are REAL!
• Forklifts results in 100 deaths and over
20,000 serious injuries annually in the
United States Alone.
• Each year, an additional 94,750 injuries
related to forklift accidents are reported.
• The costs incurred due to forklift accidents
are estimated to be over a hundred million
dollars.
NIOSH Publication 2001-109 http://www.cdc.gov/niosh/docs/2001-109/default.html http://www.forklift-safety-site.com/
Top Forklift Killers
• #1: Forklift Overturns
• #2: Nearby Workers Struck by Forklift
• #3: Victim Crushed by Forklift
• #4: Fall from Forklifts
• NOTE: This is generous data and not for
construction industry only.
NIOSH Publication 2001-109 http://www.cdc.gov/niosh/docs/2001-109/default.html http://www.blr.com/topic.cfm/topic/67
Top Forklift Killers Distribution
25
22
20
20
16
15
% total victims
10 9
5
0
#1 Tipping #2 Struck #3 Crush #4 Fall
NOTE: This is generous data and not for construction industry only.
NIOSH Publication 2001-109 http://www.cdc.gov/niosh/docs/2001-109/default.html http://www.blr.com/topic.cfm/topic/67
Top Forklift Killers
from OSHA Construction Data
Accident Type
60 59 (No. of Victims)
no. of victims
52
50
1: Forklift tip over (59)
41 2: People struck or run
40
over by forklift (34)
34
3: People crushed by
30 forklift to other things (19)
4: People fall off the fork
20 19 (52)
5: Improper maintenance
10 9 (7)
7
6
6: Load falling off the
0 fork hit people underneath
1 2 3 4 5 6 7 8
(41)
NOTE: This is for construction industry only. 7: Operator or other
Total: 227, about 2% of all listed fatalities. people electrocuted (6)
Information extracted from OSHA construction worker fatality data (1990-2007) 8: Other (9)
Typical Case Report:
Overturn on Turning
• A man was backing a forklift
down an incline. While on
the incline, the employee
turned his wheels, causing
the forklift to become top-
heavy and overturn. He
attempted to jump from the
overturning forklift, but the
overhead protection struck
him behind the head. He
died.
Information extracted from OSHA construction worker fatality data (1990-2007)
Typical Case Report:
Overturn on Grade
• A man was operating a forklift
to unload roofing materials
from a flatbed trailer that was
positioned on a slight grade.
He fully extended the hydraulic
boom and forks. Although the
forks were not loaded, the fully
extended boom and the slight
grade caused the forklift to
overturn. He was thrown from
the forklift, pinned under the
forklift cage, and killed.
Information extracted from OSHA construction worker fatality data (1990-2007)
Typical Case Report:
People Fall
• A man was installing
additional conduit in the
ceiling. He asked a
coworker to elevate him
up to the ceiling in a
forklift. The wooden
box/crate personnel lifting
device was not secured to
the forks or to the vertical
mast. He has been
elevated 11 ft when he
and the box fell off the left
side of the forks to the
concrete floor. He died.
Information extracted from OSHA construction worker fatality data (1990-2007)
Typical Case Report:
Load Fall
• A man was supervising
the unloading of large
pieces of electrical
equipment using a forklift.
When the third cabinet
was being unloaded it fell
off the forks as it was
being lowered. It struck
and pinned the man to the
floor of the trailer. He
died.
Information extracted from OSHA construction worker fatality data (1990-2007)
A Not-So-Typical Case Report:
Using Forklift as a Jack
• A man had the back end of the truck raised with
the forks of a forklift truck while lying face up
under the right rear axle to repair the rear end
of the truck. The bumper of the truck slid off the
forks, causing the weight of the truck to fall on
his chest. He died of massive chest injuries.
Information extracted from OSHA construction worker fatality data (1990-2007)
Current OSHA Standard
• OSHA
– 1910.178 – Powered Industrial Trucks
• NOT specific to construction industry
– 1926.600 – Equipment
– 1926.602 – Material Handling Equipment
• The two above are for construction industry
• Details are incorporated into the following
Safety Procedures section
http://www.cdc.gov/niosh/docs/2001-109/default.html
Key Safety Procedures:
PPE
• Hard hat
• Safety gloves
• Safety goggles
• Safety footwear
• High visibility shirt or vest
http://www.cdc.gov/niosh/docs/2001-109/default.html
Key Safety Procedures:
Even Before You Start
• Properly maintain the vehicle.
• Inspect vehicle condition before each shift.
• Do NOT operate a forklift unless you have
been trained and licensed.
• Know where the operation manual is
located on the forklift, and refer it
whenever necessary.
• Always use seatbelts on sit-down rider
forklifts.
http://www.cdc.gov/niosh/docs/2001-109/default.html
Key Safety Procedures:
Pre-Shift Inspection Detail
• Operating and emergency controls
• Safety devices, including seatbelt and horn
• Air, hydraulic, and fuel system leaks
• Cables and wiring harnesses
• Loose or missing parts
• Tires and wheels
• Warnings, control markings, and operation manuals
• Forks and fork attachment points
– No welds or holes allowed
– Check for and replace bent forks
– Forks should be marked as to their capacity
– Forks are to be replaced as sets only
http://www.cdc.gov/niosh/docs/2001-109/default.html
Key Safety Procedures:
When Starting
• Tilt the load back and make sure it’s stable
and secured.
• Raise the load only as far as needed to
clear the road surface, that is to say, keep
it as low as possible.
• Inspect the surrounding area, especially
when backing up.
• Look forward the travel path and keep a
clear view.
http://www.cdc.gov/niosh/docs/2001-109/default.html
Key Safety Procedures:
On the Move
• If view is blocked by load, travel in reverse direction.
• Accelerate and brake gently, especially with a load.
• Operate only at a speed that will permit it to be
stopped safely.
• Do NOT raise or lower the forks while moving.
• Use extreme caution on grades or ramps.
• Slow down and horn at cross aisles or corners or
other vision-obstructed locations.
• Do NOT drive towards anyone standing in front of
fixed object.
http://www.cdc.gov/niosh/docs/2001-109/default.html
Key Safety Procedures:
When It’s Overturning!!!
• Do NOT jump from
the forklift.
• Stay under the
covered guard.
• Hold on firmly.
• Leaning in the
opposite direction
of the overturn.
http://www.cdc.gov/niosh/docs/2001-109/default.html
Key Safety Procedures:
When Loading and Unloading
• Neutralize the controls and set the parking
brake.
• Level the frame prior to lifting a load.
• Do NOT handle loads that are heavier
than the weight capacity of the forklift.
• Never allow people appear under the load.
• Tilt forks forward to deposit load.
• Observe landing and load while lowering
forks.
http://www.cdc.gov/niosh/docs/2001-109/default.html
Key Safety Procedures:
If People is Elevated
• Do NOT allow workers standing on the forks,
use specially designed platform.
• Place the vehicle directly below the work area.
• Secure the elevating platform to the lifting
carriage or forks.
• Use a restraining means or deceleration
device for the workers on the platform.
• Do NOT drive to another location with the
work platform elevated.
http://www.cdc.gov/niosh/docs/2001-109/default.html
Key Safety Procedures:
If People is Transported
• Do NOT allow
passengers to ride
on the vehicle
unless a seat is
provided.
http://www.cdc.gov/niosh/docs/2001-109/default.html
Key Safety Procedures:
After It Stops
• Lower forks to the ground when parking.
• Exit from a stand-up forklift with rear-entry
access by stepping backward if a lateral
tipover occurs.
• Report any damage or problems occurred.
• NO smoking in refueling or charging areas.
• Chock wheels in maintenance, especially
when operating under the vehicle.
http://www.cdc.gov/niosh/docs/2001-109/default.html http://forkliftsafety.com