THE TEN FORKLIFT SAFETY RULES

BY GRAPHIC PRODUCTS EDITORIAL STAFF

OSHA estimates that 110,000 forklift accidents take place every year at U.S. jobsites. For all
their benefits to the modern workplace, forklifts bring with them numerous hazards.

Stay Safe with These Forklift Safety Tips

This infographic looks at the rules and regulations concerning forklift safety, lays out
important statistics, and provides tips for eliminating forklift hazards.

For all their benefits, forklifts and powered industrial trucks brings with them numerous
hazards that endanger both the pedestrians and the drivers. While they move heavy loads and
increases efficiency, forklifts can also cause serious injuries when used unsafely. Here ae 10
rules for how forklift trucks should be used in the workplace, common hazards and what
OSHA has to say about forklift training.

 Know the statistic

 Know the classes
 Know the common forklift truck hazards
 Know the requirements
 Know what to watch for
 Stay safe while using a forklift truck
 Keep an eye out around your facility
 Implement floor marking system to keep workers safe
 Develop visual communication system
 Implement solutions for forklift safety
The following is a transcript of the 10 Rules for Forklift Safety
Infographic:

The 10 Rules for Forklift Safety

For all their benefits, forklifts and powered industrial trucks bring with them numerous
hazards that endanger both pedestrians and drivers. While they move heavy loads and
increase efficiency, forklifts can also cause serious injuries when they are used unsafely. Here
are 10 rules for how forklifts are used in the workplace, common hazards, and what OSHA
has to say about forklift training.

1.   Know the Stats

It’s important to know the dangers that come with using forklifts on loading docks and in
warehouses. Keep these statistics in mind while training workers and safely operating
forklifts. In the United States,
 More than 1,000,000 forklifts are in operation throughout the United States
 Forklift accidents cost businesses $135,000,000 every year
 Roughly 70% of all accidents could have been avoided with proper training
 OSHA estimates there are 110,000 forklift accidents every year
 Roughly 20,000 workers are injured every year in forklift-related accidents
 Forklift-related citations are routinely among OSHA’s top 10 violations each year:
o 2,860 violations in 2016 (sixth most-cited citation)
o 2,760 violations in 2015 (sixth most-cited citation)
o 3,147 violations in 2014 (fifth most-cited citation)
o 3,340 violations in 2013 (sixth most-cited citation)
o 1,993 violations in 2012 (seventh most-cited citation)
o 3,432 violations in 2011 (seventh most-cited citation)
 Forklift and powered truck fatalities
o 2014 – 89 cases
o 2013 – 91 cases
o 2012 – 95 cases
o 2011 – 66 cases
 Overturned forklifts are the leading cause of deaths involving forklifts; they account
for 22% of all forklift-related fatalities
 Workers on foot struck by forklifts account for 20% of all forklift-related fatalities
 Victims crushed by forklifts account for 16% of all fatalities and falls from forklifts
account for 9% of all forklift fatalities
 Between October 2015 and September 2016:
o 1,619 federal inspections led to 2,349 forklift-related violations, totalling to
$4,266,235 in penalties
o Of that total …
 756 federal inspections led to 1,076 forklift-related violations in the
manufacturing industry, totalling to $1,640,164 in penalties
 212 federal inspections led to 332 forklift-related violations in the wholesale
trade industry, totalling to $566,827 in penalties
 175 federal inspections led to 219 forklift-related violations in the construction
industry, totalling to $326,605 in penalties
 188 federal inspections led to 292 forklift-related violations in the transportation
and warehousing industry, totalling to $943,617 in penalties
 118 federal inspections led to 169 forklift-related violations in the retail trade
industry, totalling to $350,548 in penalties

2.   Know the Classes

These are classifications of six commonly-used types of forklifts, as recognized by OSHA,
along with different types of trucks unique to each class.
 Electric Motor Rider Trucks (such as rider-type counterbalanced forklifts and sit-down,
three-wheel electric trucks)
 Electric Motor Narrow Aisle Trucks (such as reach trucks & platform side loaders)
 Electric Motor Hand Trucks or Hand/Rider Trucks (such as low lift pallet trucks and
high lift straddle trucks)
 Internal Combustion Engine Trucks (such as counterbalanced fork trucks)
 Internal Combustion Engine Trucks with Pneumatic Tires (such as counterbalanced fork
trucks with pneumatic tires)
 Electrical and Internal Combustion Engine Tractors (such as sit-down riders)
 Rough Terrain Forklift Trucks (such as vertical mast type forklifts, variable reach type
forklifts, and truck trailer mounted)

3.   Know the Common Forklift Hazards

Here’s a quick look at a few common hazards associated with forklifts.
 Unsecured loads may fall, crushing pedestrians or drivers.
 Forklifts may tip over, due to excessive speed or imbalanced loads
 Workers may fall if they stand on the forks
 Drivers may not see pedestrians, leading to collisions and fatal accidents
 Improper or missing floor marking may lead to accidents between forklifts and
pedestrians

4.   Know the Requirements

Before any employee takes control of a forklift, ensure they’re trained in accordance with
OSHA requirements. 29 CFR 1910.178, OSHA’s standard on powered industrial trucks,
requires the following:
 Employers must have a training program that incorporates general principles of safe
operation, the types of vehicle(s) used, any hazards created by using forklifts and
powered industrial trucks, and OSHA’s general safety requirements.
 Trained forklift operators must know how to do the job safely, as demonstrated in a
workplace evaluation.
 Employers must provide formal and practical training. This may include using some
combination of lecture, video, software training, written material, demonstrations, and
practical exercise.
 Employers must certify that operators have received all necessary training and evaluate
each operator at least once every three years.
 Employers must evaluate the operator’s performance and deem the employee competent
to operate a powered industrial truck prior to operating the truck.

5.   Know What to Watch For

Employees and employers should work together to ensure a forklift is safe to use before
getting behind the wheel. Follow these steps before using a forklift.
 Perform a daily inspection of all forklifts in use
 Examine the tires and oil levels
 Check for water, oil, or radiator leaks
 Ensure forks are straight and not cracked
 Test brakes, lights, the horn, and the steering wheel
 Look for obstructions, uneven surfaces, overhead obstacles, and other potential hazards

6.   Stay Safe While Using Forklift

Workers should do the following while behind the wheel to protect themselves and co-
workers:
 Make sure the load is balanced & fully secure to prevent forklift from tipping over
 Ensure both forks are as far under the load as possible before lifting
 Drive with the load as low as safely possible
 Pay attention to posted speed limits and warning signs
 Always look in the direction you’re traveling; if a load blocks the view ahead, travel in
reverse
 Steer clear of areas where forklifts are prohibited or restricted
 Keep an eye out for signs, floor marking, & other warnings for pedestrians & forklifts
 Use the horn at intersections and in areas where pedestrians may be present

Facilities of any size should have clear forklift safety rules.

7.   Keep an Eye Out Around Your Facility

Even if you’re not operating a forklift, you can take steps to keep workers safe:
 Post forklift safety signs, aisle markers, and forklift procedure labels—using premade
signs, custom labels, or a combination of the two
 Implement a floor marking system in your facility
 Ensure safety signs at all intersections where pedestrians & vehicles intersect
 Use steering wheel covers and padlocks when necessary
 Use proper LOTO equipment to prevent forklifts from inadvertently starting up

8.   Implement a Floor Marking System to Keep Workers Safe

OSHA maintains basic rules and regulations for effective floor marking. 29 CFR 1910.22(b)
(2), part of the standard for walking & working surfaces, states: “Permanent aisles &
passageways shall be appropriately marked.” The broader standard sets no guideline for floor
marking colours unless floor marking is used for preventing physical injuries.
The standard for outlining safety colour codes mentions that red & yellow are designated
safety colour codes for marking physical hazards.
 Red is for fire-related hazards (including the identification of fire protection equipment
and containers of flammable liquids), as well as emergency switches, bars, and buttons
on hazardous machines.
 Yellow designates caution and is used to mark physical hazards (including stumbling,
falling, and “caught in between”).
Improve visual communication with Graphic Products' floor marking resource centre. Access
your floor marking colour codes to improve your floor marking system

9.   Develop a Visual Communication System

Here are a few tips for successful visual communication, which can alert operators and
pedestrians to hazards caused by forklifts:
 Use “Stop” signs, speed limit signs, and other traffic control devices
 Implement wayfinding to improve the flow of traffic, keep pedestrians away from
forklift paths, and direct forklifts along safe routes
 Point out loading docks, shelves for inventory, and other important places within a
warehouse
 Post signs at junctions to warn pedestrians and forklift operators to stop and look for
hazards
 Display checklists and inspection requirements where forklifts are stored

10.   Implement Solutions for Forklift Safety

Many of the hazards posed by forklifts can be mitigated with custom signage and clear visual
communication. There are industrial printers that help you create custom signs on demand,
including speed limit signs, printed floor marking tape, maintenance labels, safety reminders,
and more.