Forklift Safety Guide: OSHA Requirements and Best Practices

Under OSHA regulation 29 CFR 1910.178, all forklift operators must complete formal training before operating equipment.

Required Training Components:

1. Formal Instruction

• Classroom or online training covering theory and principles
• Operating procedures and safety rules
• Hazard recognition and avoidance
• Load handling and stability
• Typically 4-8 hours

2. Practical Training

• Hands-on operation under supervision
• Specific to the type of forklift being used
• In the actual work environment
• Practice with actual loads and conditions
• Typically 4-8 hours

3. Performance Evaluation

• Written and practical tests
• Conducted by qualified trainer
• Must demonstrate competency
• Documented and filed

Certification and Recertification:

• Initial: Must be completed before unsupervised operation
• Re-evaluation: Every 3 years minimum
• Immediate re-training required if:
  • Operator involved in accident or near-miss
  • Observed operating unsafely
  • Assigned to different type of forklift
  • Workplace conditions change

Important: Certification does not transfer between employers. Each employer must provide training specific to their equipment and workplace.

OSHA requires forklift operators to perform a visual and functional inspection before each shift.

Visual Inspection Checklist:

• ✓ Check for fluid leaks (oil, hydraulic fluid, coolant)
• ✓ Inspect tires for damage, wear, and proper inflation
• ✓ Examine forks for cracks, bends, or excessive wear
• ✓ Check fork positioning pins and retaining mechanisms
• ✓ Inspect overhead guard for damage
• ✓ Check load backrest extension condition
• ✓ Examine seat belts for wear and function
• ✓ Verify fire extinguisher present and charged
• ✓ Check lights, horn, and backup alarm
• ✓ Inspect battery connections (electric) or fuel tank (IC)

Functional Test Checklist:

• ✓ Test steering responsiveness and alignment
• ✓ Check brake function (service and parking)
• ✓ Test lift and tilt hydraulics (smooth operation)
• ✓ Verify all controls respond properly
• ✓ Test horn and warning devices
• ✓ Check visibility (mirrors, windows, lights)
• ✓ Test safety interlocks and emergency shut-off

Defect Reporting:

If any defects are found:

• Tag the forklift as "Out of Service"
• Report defects to supervisor immediately
• Complete written defect report
• Do NOT operate until repaired
• Only qualified maintenance personnel can repair

Before Moving:

• Ensure load is secure and properly positioned
• Check clearances (height, width, overhead)
• Look in direction of travel
• Sound horn at intersections and blind spots
• Ensure area is clear of personnel

Traveling with Loads:

• Forks 4-6 inches off ground (critical safety rule)
• Tilt forks back to stabilize load
• Drive slowly on wet or slippery surfaces
• Never exceed 5 mph in facilities, 8 mph in yards
• Travel in reverse if load blocks forward view
• Look backward when traveling in reverse
• Slow down on turns, ramps, and uneven surfaces

Picking Up Loads:

• Approach squarely and slowly
• Center load on forks
• Insert forks fully under load (2/3 of fork length minimum)
• Level forks before lifting
• Lift load straight up
• Tilt back slightly once clear of stack

Stacking and Placing Loads:

• Approach slowly and squarely
• Raise load to proper height
• Level forks before placing
• Move forward slowly until forks are over placement point
• Lower load gently
• Tilt forks forward slightly to disengage
• Back away before lowering forks

Parking Procedures:

• Lower forks fully to the ground
• Put controls in neutral
• Set parking brake
• Turn off engine/power
• Remove key
• If on incline, chock wheels

Understanding Load Capacity:

Every forklift has a data plate showing rated capacity at a specific load center (usually 24 inches).

Key Principles:

• Load center: Distance from fork face to load's center of gravity
• Capacity decreases: As load center increases
• Capacity decreases: As load is raised higher
• Never exceed: Rated capacity for the load center and height

Stability Triangle:

Forklifts balance on a three-point stability triangle:

• Two front wheels (or points under front axle)
• Pivot point of rear axle/wheel
• Load must stay within this triangle

Factors Affecting Stability:

• Load weight: Heavier = less stable
• Load height: Higher = less stable
• Tilt angle: Forward tilt with load = dangerous
• Speed: Fast turns = tip risk
• Surface: Uneven ground = instability
• Attachments: Change load capacity

Warning: Even if a forklift CAN lift a load doesn't mean it should. Consider travel route, floor condition, and all factors before lifting.

1. Tip-Overs (Leading cause of fatalities)

Causes:

• Overloading
• Turning too fast
• Traveling with elevated load
• Operating on slopes incorrectly
• Uneven loads or floor surface

Prevention:

• Know and respect load capacity
• Keep load low when traveling
• Slow down on turns
• Travel straight on ramps (up forward, down reverse)
• Always wear seat belt (prevents being thrown from cab)

2. Struck-by Incidents

Causes:

• Pedestrians in forklift operating areas
• Poor visibility
• Inadequate warning systems
• Inattentive operators or pedestrians

Prevention:

• Maintain 3-vehicle-length distance from pedestrians
• Use horn at intersections
• Install mirrors and cameras
• Mark dedicated pedestrian walkways
• Use spotters for blind areas

3. Falling Loads

Causes:

• Improper stacking or securing
• Damaged pallets
• Jerky movements
• Uneven loads

Prevention:

• Inspect pallets before lifting
• Center loads properly
• Use load backrest extension
• Secure unstable loads with strapping
• Move smoothly without jerking

4. Carbon Monoxide Poisoning (IC engines)

Prevention:

• Ensure adequate ventilation
• Regular engine maintenance
• Monitor CO levels
• Use electric forklifts in enclosed spaces

Traffic Management:

• Establish designated forklift lanes
• Mark pedestrian walkways with floor tape
• Install mirrors at blind corners
• Post speed limit signs
• Use floor markings for clearances

Lighting and Visibility:

• Adequate lighting in all operating areas
• Functional headlights and taillights on forklifts
• Blue or red warning lights on vehicles
• Strobe lights for increased visibility

Floor Conditions:

• Keep floors clean and dry
• Repair cracks and holes promptly
• Mark wet areas and floor openings
• Ensure proper drainage
• Adequate load capacity for floor/racking

Personal Protective Equipment:

• Operators: Safety shoes, high-visibility vest, hard hat (in designated areas)
• Nearby workers: Safety shoes, high-visibility clothing
• Always: No loose clothing that could catch on controls