Forklift Safety Training

Forklift Fears: Addressing the driving safety for forklifts

2007-06-08T10:49:00.000-04:00

Of all the factory accidents, only one percent is caused by forklift accidents. However, 10 percent of all physical injuries from these factory accidents are due to forklift incidents. According to an article written by Barrett Miller for Safety-engineer.com, although perceived as operator errors, 25 percent of these forklift accidents are caused by “controllable environmental factors.”

Miller recommends evaluating the environmental blind spots in the driver’s path and considering the risk of each. He listed a walk-through guideline to follow:
1. When approaching an aisle, determine at what point the driver can first see an approaching pedestrian.
2. Next, determine the point at which he is likely to see the pedestrian.
3. Compute the desired speed in the area in feet per second. Multiply the measured speed by 1.5 (You may use 3 mph as a standard speed limit.)
4. Multiply the speed, measured in feet per second, by 1.75. This will provide a measure of the mechanical delay of the driver and the vehicle.
5. Add 1.3 feet for each mile per hour of your established speed limit.

Forklift safety posters

2006-09-14T09:16:00.000-04:00

“Safety: It’s in Your Reach,” “Forklift Safety … An Uplifting Experience” and “Keep it Low, Keep it Slow” are three slogans that can be found on forklift safety posters, which are daily reminders that promote safety for forklift operators.

These attention-getting posters, which are often 18” x 24” in full color, reinforce safety rules and forklift safety. Some posters provide OSHA and state regulations that give your operators the specific rules they must follow to stay in compliance and help you fulfill your OSHA requirement to provide operators with complete information for the daily operation of the forklift.

The posters are available in English and Spanish, sometimes printing the languages front and back, so you can hang it in your facility to inform all your operators.

Posters are available from a variety of vendors and frequently sell for less than $20, a small price to pay for a valuable tool that will help you promote safety among your operators and prevent accidents.

Training requirements

2006-09-11T11:00:00.000-04:00

Once trained, the operator should be familiar with the following topics unless the employer can demonstrate that such topics are not applicable to the particular work site where the equipment will be operated, according to Constructionweblinks.com:

* Operating instructions, warnings and precautions for the types of truck the operator will be authorized to use.
* Differences between the truck and automobile.
* Truck controls and instrumentation.
* Engine or motor operation.
* Steering and maneuvering.
* Visibility (including restrictions due to loading).
* Fork and attachment adaptation, operation and use limitations.
* Vehicle capacity.
* Vehicle stability.
* Vehicle inspections, maintenance, refueling and/or charging of batteries.
* Surface conditions where the vehicle will be operated.
* Composition of loads to be carried, load stability, load manipulation, stacking and unstacking.
* Pedestrian traffic, restrictive operating areas and ramps or other sloping surfaces that could affect the operating characteristics of the vehicle.
* Environmental considerations that could result in a buildup of hazardous fumes or exhaust.

Fuel Safety

2006-09-07T14:56:00.000-04:00

Four main fuel types are used to power fork trucks: gasoline, diesel, propane, and electric batteries. Thefabricator.com, a metal fabricating site, reports that each fuel type has safety issues, some more than others. Because gasoline is flammable, it should be used outdoors in a nonsmoking area. Safe gasoline storage and dispensing is both an OSHA and an Environmental Protection Agency (EPA) issue. While less flammable, diesel fuel and diesel exhaust contain known carcinogens, and safe handling procedures must be established for them.

Liquefied petroleum (LP) gas, also known as propane, is a derivative of natural gas. Like gasoline, it's both flammable and explosive. It's also a cryogenic liquid, which means that contact with skin can result in frostbite.

No smoking, open flames, sparks, or electric arcs are permitted near LP tank storage or tank-filling areas. If you fill your own LP tanks, do it outdoors in a well-ventilated area to prevent the buildup of gas vapors. Keep tools and other metallic objects away from LP tanks. Have a charged ABC dry chemical fire extinguisher in filling areas. Ensure that employees understand the proper method of changing an LP tank and the safety precautions to follow. PPE requirements include safety glasses and rubber or leather gloves.

With electric forklifts, electrical shock is a potential hazard, as is the immense weight of the battery—as much as 1,500 pounds. Because hydrogen gas, a byproduct of the industrial battery's charging process, is highly flammable, smoking is prohibited near it. Safety shower and eyewash stations must be readily available in case an employee comes into contact with sulfuric acid.

Inspections

2006-09-05T14:45:00.000-04:00

At the start of each shift, operators should perform a visual inspection of the condition of the lift truck and an operational check to test its proper functioning. If you notice anything that may affect the normal operation of the forklift, immediately alert your supervisor. The Canadian Centre for Occupational Health and Safety offers the following inspection check lists:

Visual Inspection
• floor--clear of objects that could cause an accident
• fire extinguisher present, and charged
• engine oil level, fuel level, radiator water level (LPG, gas and diesel forklifts)
• battery fully charged and securely in place
• cables for exposed wires
• vent caps not clogged
• electrolyte levels in cells
• bolts, nuts, guards, chains, or hydraulic hose reels not damaged, missing or loose
• wheels and tires not worn or damaged
• air pressure of pneumatic tires
• forks not bent or cracked
• positioning latches in good working condition
• carriage teeth not broken, chipped or worn
• chain anchor pins not worn, loose or bent
• no damp spots or drips that may indicate a leak
• hoses held securely, not loose, crimped, worn or rubbing

Operational Pre-Use Inspection
• horn working and loud enough to be heard in working environment; other warning devices operational
• floor brake: pedal holds, unit stops smoothly
• parking brake: holds against slight acceleration
• deadman seat brake: holds when operator rises from seat
• clutch and gearshift: shifts smoothly with no jumping or jerking
• dash control panel: all lights and gauges operational
• steering: moves smoothly
• lift mechanism: operates smoothly (check by raising forks to maximum height then lowering completely)
• tilt mechanism: moves smoothly, holds (check by tilting mast all the way forward and backward)
• cylinders and hoses: not leaking after above checks

2006-08-31T11:48:00.000-04:00

Forklift manufacturer accused of negligence in worker fatality

The family of a Sanford, ME man killed in an industrial accident blames the manufacturer of a forklift for a design flaw that allowed the man to become pinned when he backed up under a shelving unit, according to an AP report.

An adaptation could have corrected the flaw in the 1989 Crown standup lift truck that killed Thomas Brown, the family’s lawyer, Terry Garmey, told jurors in U.S. District Court.

Brown was vulnerable to the type of accident that killed him on Aug. 1, 2003, because Crown Equipment Corp. didn’t share safety information with Brown’s employer, Prime Tanning, Garmey said. The company didn’t notify Crown of 10 other deaths and 90 serious injuries caused in the same manner as Brown’s, nor did it say how to make the truck safer, he said.

Crown contends that Brown was responsible for the accident because he was “careless in the operation of the lift truck,” according to James Campbell, Crown’s attorney.

Brown was backing up the truck when he hit the rack of shelves. The impact knocked his feet off the pedals, automatically engaging the emergency brake. Pinned and unable to move, he died within four minutes, Garmey said.

Brown’s family is seeking $400,000 for wrongful death, $1.2 million in economic damages and $75,000 in punitive damages.

Working with stacks

2006-08-28T09:06:00.000-04:00

Toppling stacks can cause severe accidents, so operators must work cautiously when removing loads from stacks. When you work with high stacks, approach and travel are the same with one difference: the higher you go, the less stable your forklift and load become.

To remove a load from a high stack:

* stop straight on, about a foot away from the stack
* raise the mast until the forks are at the right height
* lift the load high enough to clear the item below; look over both shoulders and back straight out to clear the edge of the stack
* stop and lower the load to the traveling position
* tilt the load back and move out slowly

Handling loads

2006-08-24T09:52:00.000-04:00

Loading and unloading

Thefabricator.com, a metal fabricating site, reports you should preplan and train employees on how to move loads and what the limits are. The size, weight, and shape of the material being moved will dictate the type of equipment used. All material handling equipment has rated capacities that determine the maximum weight the equipment can safely handle and the conditions under which it can handle that weight. The rated capacity must be displayed on each piece of equipment and cannot be exceeded except for load testing.

Before loading or unloading, prevent movement of forklift trucks by ensuring that brakes are set and wheels are chocked.

Load stacking

Stacking materials can be dangerous if workers don't follow safety guidelines. Falling materials and collapsing loads can crush or pin workers, causing injuries or death. To prevent injuries when stacking materials:
• Ensure that stacks are stable and self-supporting.
• Avoid creating a hazard to passersby when removing supplies by not storing pipes and bars in racks that face main aisles.
• Ensure that employees can identify safe stacking heights easily: Paint walls or posts with stripes to indicate maximum stacking heights for quick reference. Be sure to enforce any rules you have on height limitations when stacking materials

Choosing a forklift

2006-08-21T09:47:00.000-04:00

Many serious forklift accidents occur because the wrong truck is being used for the job. Whether you are thinking of buying a new or used truck, there are several factors to consider in selecting the best truck for the job:

* Indoor operation – Only electric and specially designed LP or diesel trucks are suitable for indoor use.
* Load rating – Survey the loads the truck will handle before selecting a truck; each truck is load rated at different mast extension heights and you should never acquire a truck that cannot handle the heaviest load without exceeding 80 percent of load rating.
* Load handling equipment – Truck should be acquired with the proper fork
lengths, load backrest extensions and any special attachments needed for its
assigned work.
4. Tires/work surface design - Be sure you select a truck designed to
operate on the surfaces that it will be run on. Most hard tired forklifts are
designed to operate on level concrete and are dangerous on loose gravel, snow,
or ice.
5. Incline and clearance - Each type of truck has a maximum ramp slope; use of trucks on ramps that are too steep, or pavement with changes in slope too abrupt for their design is very dangerous.
6. Floor loading - Care should be taken to ensure that the truck is not too heavy
for the floors, ramps, hatches, truck trailers etc. on which it is to operate. An
engineer should determine the safe “wheel load” for floors and ramps.
7. Auxiliary equipment - All trucks will have a basic lighting system, horn, backup alarm, and warning light.

Refresher training

2006-08-17T11:48:00.000-04:00

Forklift safety isn’t just a subject for new operator training, it’s for experienced operators, too, who must be recertified every three years.

Refresher training must be conducted so employees retain the ability to safely operate a truck. Retraining should also be used if there is reason to believe that unsafe acts have been committed, an accident or near-miss occurs, an evaluation reveals a deficiency, an operator is assigned to a different type of truck, or a workplace condition changes that would effect the truck operation.

Evaluations of each operator's performance are required as part of the initial and refresher training, at least once every three years.

Refresher training is essential to keep your operators legally certified to operate forklift trucks.

The official OSHA guideline “requires an evaluation of each forklift operator’s performance at least once every three years … [it] requires operator training to include formal instruction, practical training and performance (hands-on) evaluation.

Forklift cages

2006-08-14T09:17:00.000-04:00

Forklift cages are sometimes use to lift workers to do work or repairs, but they can cause injuries, including one that occurred in 2000 when a man sustained a fractured skull when the cage he was working in tipped over.
The following guidelines should be used for lifting personnel in an OSHA approved safety cage:

* A 8,000 lb capacity forklift or greater required.
* Cage must be attached appropriately to the forklift
* The operator must be in the control position.
* Cordoning the area should be considered.
* Other personnel must be kept clear of cage work area.
* Personnel in the cage must wear a body harness and lanyard attached to the cage.
* The mast must be in the vertical position and never tilted.
* Movement of the forklift, while personnel are in the cage, must not be greater than creep speed.
* Personnel should be at least one foot away from the cage per foot the cage is raised.

Driving in reverse

2006-08-10T10:33:00.000-04:00

There are situations when forklifts should be driven in reverse, including when the load is so bulky that it obstructs your vision and when driving down a ramp.

Extra care must be taken when driving in reverse, because the operator doesn’t have a constant view of the load. There is also a threat of back injury to the driver who has to strain to look over his shoulder while driving in reverse.

Fatalities have occurred when operators were unable to see clearly while operating in reverse, so OSHA offers the following tips for maintaining control of the vehicle:

* face the rear
* look in the direction of travel
* go slowly
* sound horn before moving
* stop when vision is limited or blocked, sound the horn and go slowly

Training Test

2006-08-08T10:07:00.000-04:00

As safety trainers should know, OSHA has very specific operator training requirements that must be followed to prepare operators for certification and 26 states administer their own requirements that sometimes exceed the federal mandate. The state of Michigan Department of Consumer Industry and Services prepared this sample test. As you can see, it is very detailed and demands safe driving skills and knowledge of forklift handling procedures.

You can use this test on your own operators or modify it for your own state requirements:

SAMPLE PERFORMANCE TEST FOR FORKLIFT OPERATORS

G 1. Shows familiarity with truck controls.
G 2. Gave proper signals when turning.
G 3. Slowed down at intersections.
G 4. Sounded horn at intersections.
G 5. Obeyed signs.
G 6. Kept a clear view of direction of travel.
G 7. Turned corners correctly – was aware of rear end swing.
G 8. Yielded to pedestrians.
G 9. Drove under control and within proper traffic aisles.
G 10. Approached load properly.
G 11. Lifted load properly.
G 12. Maneuvered properly.
G 13. Traveled with load at proper height.
G 14. Lowered load smoothly/slowly.
G 15. Stops smoothly/completely.
G 16. Load balanced properly.
G 17. Forks under load all the way.
G 18. Carried parts/stock in approved containers.
G 19. Checked bridgeplates/ramps.
G 20. Did place loads within marked area.
G 21. Did stack loads evenly and neatly.
G 22. Did drive backward when required.
G 23. Did check load weights.
G 24. Did place forks on the floor when parked, controls neutralized, brake on set, power
off.
G 25. Followed proper instructions for maintenance – checked both at beginning and
end.

OSHA cites Florida company for forklift violations

2006-08-03T16:39:00.000-04:00

OSHA cited Coreslab Structures for operating unsafe forklifts and other safety hazards at the company's Medley, Fla., facility. The agency proposed penalties totaling $45,000.

OSHA issued nine serious citations to the pre-cast concrete manufacturer, with proposed penalties of $45,000, for: failing to train forklift operators and require them to wear safety belts; allowing employees to operate trucks that needed repair; and allowing employees, other than the operator, to ride on the equipment. Other cited safety violations included allowing employees to ride on cranes, use unsafe cutting tools and operate machinery without safety guards.

The agency also cited, but did not propose penalties for, the lack of required labels on forklifts, poor housekeeping and some unlabeled hazardous chemicals stored at the facility.

OSHA conducted this inspection last August concurrently with the investigation of a worker's death from carbon monoxide poisoning. Alleged violations in that case, for which OSHA cited Coreslab Structures in November, included exposing workers to carbon monoxide above permissible levels and failing to have alarms that warned workers of elevated levels. Proposed penalties totaled $24,000. In December, the company contested the citations.

Two key training issues

2006-07-31T09:41:00.000-04:00

Logistics Management magazine says forklift-safety training programs should cover OSHA rules and regulations; basic operating principles affecting stability; the equipment's capabilities, limitations, and fueling/charging procedures; and how to conduct a daily safety inspection.

The two areas that require special attention are:

Vehicle stability. Loads should be carried only as high as is necessary to clear floor or ramp surfaces. Operators should keep the masts [down] in the 'traveling position' at all times. Stability is particularly important when driving on ramps because grades can affect the vehicle's balance. When driving up a ramp, always drive with the load first. When driving down a ramp, always back down.

Pedestrian traffic. Common sense might suggest that horns and alarms would enhance pedestrian safety when a forklift is in motion. But research doesn't necessarily bear this out. "We found no scientific evidence that alarms did or would reduce forklift-pedestrian impact accidents," says Marvin Welch, NACCO Material Handling Group’s vice president, risk management, in response to a study the company conducted.
The reason that is true is that employees get too used to hearing horns and back-up alarms. Operators should use horns intermittently, so that pedestrians pay more attention to them. The first line of defense, though, is very low-tech: Operators should always make eye contact with every pedestrian before proceeding forward or in reverse.

The evaluation process

2006-07-27T14:44:00.000-04:00

When training employees for forklift operation, you must evaluate their progress, in the classroom and the field. Rob Vetter, technical director with the Ives Training Group, a mobile equipment training company, offers the following tips on evaluation, which originally appeared at www.Forkliftaction.com.

Classroom training -- Your evaluation of trainees’ classroom training should involve discussion and interaction, followed by a standardized test. When issuing a written test:
• Review the theory content of the training before giving the test.
• Ensure you are satisfied with the trainees’ level of understanding beforehand.
• Do not leave the room while trainees take the test.
• Collect and grade the test yourself.
• Return graded tests to trainees and review them to help trainees understand their mistakes.

In the field -- The practical evaluation process is conducted quite differently from the training process. When conducting practical evaluations in the field:
• Conduct one-on-one evaluations with each trainee.
• Issue simple tasks, one at a time.
• Move around so you can see, but stay out of the way of the trainee’s peripheral vision.
• You can speak to the trainee but do not coach, training is over.
• Always complete the evaluation regardless of early results; remember you are out there to gather information, not pass or fail.
• Stop the evaluation after six to 10 loads or if it becomes hazardous to continue.
• De-brief operators on their performance in the classroom and in the field. This is the time to clear up any concerns you may have regarding a trainee’s knowledge and/or performance.

Forklift stability

2006-07-24T10:46:00.000-04:00

The design of the forklift is based on a stability triangle. The front axle, with its drive wheels, acts as the base of the triangle and supports the weight of the load. The sides of the stability triangle meet at the point where the forklift steers, either at a single wheel or in the middle of the steering axle on four-wheel models.

In real life, your forklift and load become less stable:

* whenever the load is raised
* when you are turning
* on slopes, either front-to-back or side-to-side
* when tilting the load forward or backward, or side-to-side
* on rough or uneven surfaces

On every carry, you need to decide if your stability will be affected by:

* the load and its weight or shape
* the route and conditions along the way
* the destination and maneuvers needed to set down the load

Inside vs. outside trainers

2006-07-10T09:18:00.000-04:00

The OSHA requirement to provide site and equipment-specific forklift operator training puts a burden on many employers, who previously handled their training off-site with an outside trainer.

Unless an outsourced trainer could accurately reproduce the same conditions found in the employer’s workplace (load, terrain, storage and stacking of product, operating environment, etc.), the training performed would not meet the OSHA standard. Then there are the specific issues concerning the forklift: type, classification, attachments, fueling, charging, etc.

Reputable outside training providers must be familiar with the operating conditions and equipment at the site as well as any in-house policies and/or operating procedures to provide training that satisfies the OSHA requirements. Then they must insert this information into the class and ensure that everyone understands it.

Many employers choose the option of having their own people trained as instructors to conduct in-house operator training. This effectively addresses the issues of providing site and equipment-specific training because the employee who conducts the training is familiar with the machinery and working conditions that no outside trainer could match. It also addresses the issue of the trainer’s competence, which is significant in light of the OSHA standard.

Pedestrian accidents

2006-06-30T10:02:00.000-04:00

Eighteen percent of forklift accidents occur when a walking employee or other pedestrian is struck by a lift, according to Construction-injuries.com.

How can they be prevented? A report from Yale Materials Handling Corp. notes that the best way is to separate forklift and pedestrian traffic to the greatest extent possible. Facilities can use travel lanes for forklifts and pedestrians marked with paint on the floor or separated by physical barriers. Limitations may also be placed on travel areas for forklifts to keep them away from high density pedestrian traffic, such as near break rooms or time clocks.

Workplace rules for pedestrian safety can also be established, including:

* require forklift operators to sound the horn at intersections
* restrict customers and non-employees from areas where forklifts may be operating
* limit forklift travel speed
* use hi-visibility work clothes or vests for pedestrians
* require pedestrians not to come closer than a predetermined distance from the forklift, even when speaking with an operator

Training tips

2006-06-26T09:16:00.000-04:00

Forklift training is a multi-faceted procedure, Rob Vetter, technical director of the Ives Training Group, told Forkliftaction.com.

He says that interaction is the key to classroom training. Instructors should:

* Ask questions to encourage discussion, and avoid yes/no responses
* Ask provocative questions that cover key issues, such as seat belt use and pedestrian right of way
* Make yourself available during breaks to interact with trainees

Out in the field, trainers must properly demonstrate techniques. Instructors should:

* Explain exactly what is required before putting trainees in the seat
* Issue clear, simple tasks, one at a time
* Ask trainees questions to initiate interaction and communication
* Have trainees repeat tasks until they are demonstrated correctly
* Review how things went with each training following the session

Thanks, Rob!

Don’t hire youths to operate forklifts

2006-06-22T09:15:00.000-04:00

With the beginning of summer comes this important reminder to employers: don’t hire youths to operate forklifts!

OSHA regulations and the Fair Labor Standards Act are consistent in their forklift operator restrictions, including 29 CFR 570 of the FLSA, which specifically prohibits employees under 18 years of age from operating forklifts in non-agricultural employment.

Two recent forklift fatalities involving operators under 18 in Georgia and Massachusetts prompted OSHA to release this important message: “Given the significant number of young workers employed, especially during the summer months, OSHA believes that it is important to remind all employers of the regulations that prohibit workers under 18 from operating specified hazardous machines and equipment, including forklift trucks.”

Kaylex Co., Newnan, GA, was fined by the U.S. Labor Department after a 15-year-old forklift operator died from a forklift overturn in 2003. Avoid fines and keep youth safe by prohibiting them from operating your forklifts!

New Hampshire manufacturer faces OSHA fines following forklift fatality

2006-06-19T13:29:00.000-04:00

A Milford, N.H., manufacturer of stone countertops faces $46,250 in OSHA fines following the Oct. 21, 2005 death of an employee who was crushed by a granite slab that fell on him after it was struck by a forklift.

Northern Marble & Granite Co. Inc. was cited for 29 alleged serious and two alleged other than serious violations of the Occupational Safety and Health Act.

"Our inspection found that the granite slabs were not stored in a safe manner, exposing employees to fatal crushing injuries," said Rosemarie Ohar, OSHA's New Hampshire area director.

Other conditions cited during the inspection included inadequate employee forklift training; uninspected and improperly modified forklifts; no specific procedures and training for locking out machines' power sources before performing maintenance; unguarded saws and grinders; unmarked exits, and exposed electrical parts. The company was also cited for lack of personal protective equipment and training; lack of a hearing conservation program; not surveying the workplace to identify hazardous confined spaces; and no written hazard communication program.

The company had 15 working days from receipt of its citations in April to comply by requesting and participating in an informal conference with OSHA or contesting them before the independent Occupational Safety and Health Review Commission.

Pre-use inspection

2006-06-15T13:05:00.000-04:00

Before operating a forklift, drivers must complete an inspection which involves checking both the power plant and the forklift truck for damage and proper operation.

To check the power plant on a battery operated truck, inspect the battery for damage and loose connections and make sure vent holes are clean. On a truck powered by gasoline, diesel or propane, check for fuel tank damage or leaks and make sure all valves are secure.

When checking the forklift truck, look for damage to the mast, carriage, forks, overhead guard, backrest, hydraulic system and tires. Check all fluid levels, including oil, coolant and hydraulic fluid.

After starting the forklift, operators should check the lift, tilt, brakes, steering, lights and horn.

If anything is out of line, turn off the forklift and report the problem. Operators should never try and fix anything themselves.

Forklift attachments

2006-06-08T09:33:00.000-04:00

Forklifts can be used to do many different jobs with a variety of attachment options, but you must follow the correct steps for adding attachments or expose operators to danger and your company to liability. If you buy a new forklift and attachment combination, the forklift will be properly labeled and safe to use, but if you try to add an attachment to an existing forklift, the process may be very challenging.

David Hoover, president of Forklift Training Systems, notes that forklift standards state that modifications must not be performed without the manufacturer’s consent. Any changes to a forklift must be reflected in its plate, tag and decals. The forklift must be marked to identify the attachment and show the weight and capacity of the new forklift/attachment combination. The nameplate and marking must be maintained in a readable condition.

To make these arrangements with a dealer or manufacturer, Hoover recommends these steps:

* Contact the local dealer for the brand of forklift to which you intend to add an attachment.
* If the dealer is not responsive, contact the factory directly.
* If you get no response from the dealer or manufacturer, OSHA permits hiring a registered engineer to test and approve the modification.

Parts of the forklift

2006-06-05T13:19:00.000-04:00

The parts of a forklift include:

* Mast – the upright section that contains a set of tracks that house ball-bearing rollers and chains. It tilts forward or backward and may shift from side to side.

* Carriage – Housed within the mast, it contains the rollers that allow the load to move up and down. Forks are mounted to the carriage.

* Backrest – Mounted to the carriage, it keeps the load from falling back when forks are tilted back.

* Overhead guard – Keeps falling objects from hitting the operator but is not strong enough to withstand the force of a heavy load.

Note: These are basic parts of a forklift but each forklift has different controls, weight capacities and restrictions on where they can operate so every operator needs proper training in the requirements of the particular forklift in use.

Forklift vibration is a health hazard

2006-06-01T15:40:00.000-04:00

Many kinds of machinery, including forklifts, produce vibrations, which can negatively impact an operator’s body and cause permanent disability, writes Dirk Zeinstra, a mechanical engineer, at Forkliftaction.com.

When exposed to vibrations and shock from machinery, employees can suffer hand and arm injuries and long term exposure can lead to hand, wrist and shoulder aches and limited blood flow. Reduced grip force, less flexibility in the hands and arthritis are also possible.

Forklift operators should drive in a style that minimizes exposure to shock and vibration. They should drive slowly and handle loads carefully. Forklifts can be equipped with better tires and seats to provide comfort. Other solutions include changing driver routes and improving road conditions to fix potholes and road bumps.

Power source hazards

2006-05-30T11:41:00.000-04:00

Forklift power sources can pose a hazard to employees. The most common power sources, battery and LPG/propane are regulated by OSHA standards, for example, “Precautions shall be taken to prevent open flames, sparks or electric arcs in battery charging areas (1910.178)

The following procedures should be followed by employees to safeguard themselves from power source accidents:

* Eye or face protection must be worn when connecting a charger to a battery.
* Chargers must be turned off when leads are being connected or disconnected.
* All leads and cables must be checked and in good condition.
* When charging and moving batteries, vent caps must be kept firmly in place to avoid electrolyte splashing.
* If charging is to be conducted on a battery in a mobile piece of equipment, the battery compartment cover must be left open to dissipate heat and explosive gases.
* Any additional safety requirements specified by the manufacturer of the battery or charging system must be followed.
* There must be adequate ventilation to keep explosive atmospheres less than 20% of the Lower Explosive Limit in the charging area.
* Facilities for quick drenching or flushing of the eyes and body must be provided at or near the charging area.
* Smoking and other ignition sources must be prohibited in the charging area. “No smoking” signs must be posted.

Parking safety

2006-05-26T09:22:00.000-04:00

A forklift operator who was pinned against a dumpster after the forklift slipped into drive during a dump operation suffered a severe injury, which could have been prevented if he had set the parking brake before he dismounted the lift.

Every time forklift operators leave a forklift unattended, they must secure it:

* Park in an approved location
* Set the brakes
* Lower the forks to the floor
* Neutralize the controls
* Turn off the motor switch
* Disconnect the batter or go through the propane shut down procedure
* Always park on a level surface
* Don’t block emergency exits or equipment
* Park away from other hazards

Trailers and rail cars

2006-05-22T10:54:00.000-04:00

On September 9, 2004, a truck driver was standing on the bed of his tractor-trailer rig watching a forklift move a milling machine onto his vehicle. As the forklift moved forward, the milling machine tipped over and crushed the driver.

Loading or unloading trailers or rail cars can be hazardous for forklift or trailer operators. Before forklift operators enter trailer or rail cars:

* If the trailer is connected to the tractor, set brakes on the tractor and chock wheels on both trailer and tractor
* If the trailer is not connected to a tractor, support it with jack stands
* Use a dock lock to hold the trailer to the dock
* Check to see that the floor is strong enough to hold the combined weight of you, the forklift and the load
* Make sure you have enough overhead clearance, including the additional height of the bridge plate
* Use safety sidebars on flat-bed trailers as guides to keep your forklift from going over the side

Material handling hazards

2006-05-19T08:47:00.000-04:00

Employees who were struck and crushed by a stack of crates that toppled over during a forklift operation were involved in a material handling accident that could have been avoided.

David Hoover, president of Forklift Training Systems, says material handling hazards should be corrected before forklift training starts and the training should reinforce the changes.

The following material handling hazards endanger forklift operators and should be corrected:

* Poor floor or lot conditions
* Loads beyond the rated capacity of the forklift
* Missing or non-functioning safety devices, such as horns, seatbelts, alarms and strobes
* Poorly stacked or stored loads and structurally damaged storage racks
* Damaged or broken pallets
* Lack of proper pre-shift checks and preventative maintenance
* Lack of enforcement of any type of safety issues

Lifting personnel

2006-05-15T13:51:00.000-04:00

Forklifts were never intended by manufacturers as a means of lifting personnel to perform job tasks at heights, but they are often used to get to light fixtures, top storage racks and other items too high to reach from the floor.
Regulatory groups and manufacturers have developed a safe method for lifting personnel with forklifts (OSHA 1926.602). Forklifts may be used to lift personnel only if the following guidelines are followed:

• A work platform equipped with standard guardrails or equivalent means, and firmly secured to the lifting carriage or forks, must be used.
• The hydraulic system must be so designed that the lift mechanism will not drop faster than 135 feet per minute in the event of a failure in any part of the system.
• An operator must attend the lift equipment while workers are on the platform.
• The operator must be in the normal operating position while raising or lowering the platform.
• The vehicle must not travel from point to point with the work platform elevated at a height greater than 4 feet while workers are on the platform. When necessary, at heights greater than 4 feet, inching is permitted provided it is done at a very slow speed.
• The area between workers on the platform and the mast must be guarded to prevent contact with chains or other shear points.

Accident statistics

2006-05-11T13:25:00.000-04:00

OSHA estimates there are about 85 forklift fatalities per year, 34,900 serious injuries and 61,800 non-serious injuries. According to the Industrial Truck Association, there are about 855,900 forklifts in the U.S., so over 11 percent will be involved in some type of accident each year (assuming only one accident per forklift).

The ITA also reports that the useful life of a lift truck is eight years, which means that about 90 percent of all forklifts will be involved in some type of accident during their useful life.

The main cause of forklift fatalities is tipovers (42 percent). The other causes are crushed between vehicle and a surface (25 percent), crushed between two vehicles (11 percent), struck or run over by a forklift (10 percent), struck by falling material (8 percent) and fall from platform on the forks (4 percent).

Fatalities occur most likely in manufacturing facilities (42 percent), followed by construction (23.8 percent), wholesale trades (12.5 percent), transportation (11 percent), retail trade (9 percent) and mining (1.2 percent).

Studies show that most accidents could have been prevented by better training and training can also reduce the severity of an accident.

Refresher training and re-evaluation

2006-05-08T11:34:00.000-04:00

Refresher training, including an evaluation of the effectiveness of that training, shall be conducted to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely.

Refresher training is required by OSHA when:

* The operator has been observed operating a forklift in an unsafe manner.
* The operator has been involved in an accident or near-miss incident.
* The operator has received an evaluation that reveals that the operator is not operating the forklift safely.
* The operator is assigned to drive a different type of powered industrial truck.
* A condition in the workplace changes in a way that could affect safe operation of the forklift.
Once operators has been trained and evaluated, they must be re-evaluated at least once every three years according to OSHA standard 1910.178. Although the standard allows this time period without re-evaluation, prudent employers will choose to conduct a re-evaluation and refresher training annually.

Avoiding tipovers

2006-05-05T08:57:00.000-04:00

In a recent 14 year period, 1,021 workers died from forklift injuries, 22 percent due to tipovers.

One of the best ways to prevent tipovers is to know the forklift’s load capacity. When operators stay within the load-carrying limits issued by the manufacturer, they avoid tipovers. WorkSafe magazine says the risk of tipovers can also be reduced by:

* Tilting the mast forward only when picking up or dropping off a load.
* Tilting the load back and raising the forks only as high as you need to clear the ground surface while driving.
* Carrying loads forward up inclines and backward down inclines.
* Avoiding excessive speed and using caution when turning and braking.
* Checking for alternative routes for long or wide loads.
* Never turning on inclined surfaces such as ramps.
* Driving in reverse if the load obstructs the view.
* Being aware of the mast’s clearance when driving under pipes, through doorways or in areas with other overhead obstructions.

Lighting problems

2006-05-01T09:57:00.000-04:00

Barrett Miller of the American Society of Safety Engineers notes that 25 percent of forklifts accidents aren’t caused by drivers, but by controllable environmental factors, including lighting.

An accident that occurred in a dark warehouse where light readings measured 5 candlepower was “far under the acceptable level for general operations,” Miller says.

Dark environments are especially harmful to drivers over 40, whose vision deteriorates. “The effect on the worker is predictable,” Miller says. “As we lose our ability to discriminate objects in dim settings, we become more sensitive to glare. A forklift driver may have too little depth perception in a dark warehouse. He may not see a fellow employee in time to respond.
“OSHA established a minimum standard for lighting in areas where forklifts operate,” he says. “If the light level in an area is below 2 lumens per square foot, the truck must use auxiliary lights. The light in a warehouse measuring 2 candlepower is seriously substandard. All safety codes recommend a minimum light level of 20 footcandles in warehouses. This level of illumination should be adequate for older workers.”

Moving high loads

2006-04-27T11:14:00.000-04:00

Many loads are so high that they can completely obscure the forklift operator's line of sight. If the load can be split and carried on two separate pallets, this is the preferred mode of operation. Occasionally, a single piece of machinery or other object is so large that no other alternative is possible. In these circumstances the operator must use a spotter and must rely on the spotter as he would his own eyes or drive the load backwards. Spotters should be chosen with care. They must be able to respond to danger quickly, must be responsible and be able to and willing to effectively communicate with the driver.

Materials that are to be stacked have special risks. Operators must be extremely precise in the placement of stacked loads: any deviation from the center could cause the load to topple over. Further the operator must know the weight limitation of pallets (the lowest pallet supports the entire weight of the stack) as well as the nature of materials to be stacked (i.e. will they collapse under the weight of even a single pallet).

Lessons learned

2006-04-24T13:41:00.000-04:00

During the routine transfer of radioactive waste containers at a waste disposal trench, an improperly balanced waste container fell from a forklift. The situation could have resulted in serious injury if the container had struck a worker and the container could have been damaged, resulting in radiological contamination.

Normally, containers are moved one at a time, but this time the driver was attempting to move two at once and miscommunication with the spotter contributed to the accident. When the driver asked the spotter if everything was okay, he said yes, assuming the driver knew what he was doing. The driver admitted he should have only lifted one container at a time while the spotter said he should have stopped the lift. Both workers exhibited a certain level of complacency, which was a major cause of the accident.

Lessons learned:

* Remind workers that routine tasks require attention to safety and that complacency reduces safety consciousness.
* Train operators and spotters to communicate with formal words and signals, and encourage spotters to always notify operators of their concerns.

Avoiding accidents

2006-04-20T10:21:00.000-04:00

Working with a forklift requires constant attention to the hazards in front, above and around the area of operation. Despite one's best intentions there is always a possibility for accidents to occur. Forklift operators should take precautions to minimize accident potential. They should verify that the charge on the forklift is adequate to the task (at least 1/2 full for normal loads and 3/4 full for heavy loads), they should survey the travel route before making a lift to familiarize themselves with any potential obstacles, they should warn people in the area that forklift operations are underway, they should arrange for a spotter if there is any potential obstacle that could have serious consequences if hit by the forklift, or blind spots along the way. If their vision is impaired due to the size of the load, a spotter is essential for safe completion of the lift or the forklift must be driven backwards to ensure a clear line of sight. Most of all the driver must be on the look-out for any behavior that could jeopardize the operation such as exceeding the load center or the forklift maximum weight.

OSHA fines Florida company for forklift violations

2006-04-17T11:29:00.000-04:00

OSHA has cited Coreslab Structures for operating unsafe forklifts and other safety hazards at the company’s Medley, FL facility. The agency is proposing penalties totaling $45,000.

OSHA issued nine serious citations to the pre-cast concrete manufacturer, with proposed penalties of $45,000, for: failing to train forklift operators and require them to wear safety belts; allowing employees to operate trucks that needed repair; and allowing employees, other than the operator, to ride on the equipment. Other cited safety violations included allowing employees to ride on cranes, use unsafe cutting tools and operate machinery without safety guards.

The agency also cited, but did not propose penalties for, the lack of required labels on forklifts, poor housekeeping and some unlabeled hazardous chemicals stored at the facility.

OSHA conducted this inspection last August concurrently with the investigation of a worker's death from carbon monoxide poisoning. Alleged violations in that case, for which OSHA cited Coreslab Structures in November, included exposing workers to carbon monoxide above permissible levels and failing to have alarms that warned workers of elevated levels. Proposed penalties totaled $24,000. In December, the company contested the citations.

The company has 15 days to contest the latest citations and proposed penalties before the independent Occupational Safety and Health Review Commission.

Training Spanish speaking employees

2006-04-13T09:29:00.000-04:00

If OSHA visits your workplace, will you be able to show how your company provides forklift safety training to Spanish-speaking employees?

Before beginning work, each employee must receive safety orientation training. If there is any question about whether Spanish speaking employees can understand the material, it should be provided in Spanish by a bilingual trainer. PowerPoint handouts that provide technical information should also be available in Spanish.

Facility evacuation plans, maps and procedures should also be translated into Spanish.

Employees who will be using powered tools, equipment or machines should also receive information in Spanish. Most contemporary manuals come in Spanish. If you only have them in English, call the manufacturer.

Also, make sure safety labels, postings and warnings on machines and equipment are posted in Spanish.

Safe loading

2006-04-10T14:08:00.000-04:00

Fourteen percent of forklift accidents occur by the load falling off of the forklift, according to LegalMatch.

Tower Times, a publication of the National Association of Tower Erectors, offers these tips for safe loading:

* Make sure the load is within the forklift’s rated capacity. Never exceed the maximum weight you may carry that is listed on the nameplate.
* Check for a stable and centered load and stack or tie uneven or loose loads.
* Use the proper lift fixture for the type of load – carpet spike, drum grappler, etc.
* Spread the forks as widely as possible for even distribution.
* Drive in to the loading position and insert the forks far enough to be sure the pallet is completely in the forks – take care not to damage materials stacked next to the pallet.
* Drive under the load until it slightly touches the carriage. Tilt the forks back to shift the weight of the load back, making it more stable.
* If the load is unbalanced, keep the heavier end closer to you. Tilt the mast back.
* Lift the load and tilt it back a little more before traveling.

Everyone needs Forklift Training

2006-03-30T10:24:00.000-05:00

While it’s true that only employees with specific training can operate a forklift, any employee who works around forklifts should know the basics of safe operation and maintenance, and how to avoid getting hurt accidentally.

Try holding a basic forklift safety session for all employees that reminds them of the forklift dangers – they can topple over, collide with objects, drop heavy loads and represent a fire and explosion hazard when refueling. Review some of the forklift safety basics, including:

* Never exceed the rated load capacity
* Make sure the load is balanced on the forks
* Never ride as a passenger on a forklift
* Never stand under the forks when they’re raised
* Never smoke when the forklift is being refueled
Encourage all employees to be on the lookout for forklift safety hazards including unsafe operation or maintenance problems and report any hazards to supervisors as soon as possible.

Proper training

2006-03-27T14:23:00.000-05:00

David Hoover, president of Forklift Training Systems, is worried that forklift training is often inadequate. “Many times the driving test amounts to no more than moving some empty pallets around in a parking lot or weaving through a course at a forklift dealership. Most written tests consist of 15 or less questions that the average 10-year-old could easily pass.”

He says, “Businesses that use forklifts must start putting together tougher pass or fail criteria in place that weed out weak operators for more training prior to certification.”

Proper training works this way, he says: “We expect trainees to be able to handle substantially heavy loads and stack as high as they would be expected to in real conditions. We also might require them to load a trailer, use attachments and negotiate a map.”

He also says, “Don’t look for someone such as OSHA to come out with specific pass or fail criteria. It is our job as trainers to make those judgments. There is no guarantee that even well trained operators will not have an accident some time, but at least you can be comfortable knowing that you did your part to ensure they were properly trained and qualified.”

Forklift exhaust

2006-03-23T14:11:00.000-05:00

Forklifts powered by propane, gasoline, and to a lesser degree diesel fuel, significantly contribute to carbon monoxide (CO) hazards in the workplace. Propane fuelled vehicles also emit potentially dangerous nitrogen dioxide (NO2).

Here are some options to control the hazards of forklift exhaust:
• Use electric forklifts to eliminate CO and NO2 emissions.
• Use catalytic converters to reduce CO and NO2 emissions (by up to 97%) on most forklifts.
• Regularly tune up forklifts to reduce CO and NO2 emissions. For propane or natural gas units, exhaust gas analysis should periodically be performed as part of the tune ups.
• Use commercial soot traps to help clean the exhaust from diesel-powered forklifts.
• Consider using a cleaner-grade fuel, such as diesel, with reduced sulfur content.

How much do you know about forklift safety? (Quiz)

2006-03-20T09:28:00.000-05:00

How familiar are you with forklifts and their safe operation? Take this quiz and find out:

1.) It is very easy to tip over on ramps and sloped surfaces whether the forklift is loaded or unloaded.
a.) True. b.) False.

2.) When driving on ramps with a grade of 10 percent or more with a loaded forklift, you must always keep the load uphill, even if it means driving in reverse down the ramp.
a.) True. b.) False.

3.) Because a forklift weighs more, it is much easier to brake to a stop than an automobile.
a.) True. b.) False.

4.) A forklift driver must always look…
a.) In the mirrors.
b.) Around his/her load.
c.) In the direction of travel.
d.) Forward.

5.) What should you do when you approach an intersection?
a.) Slow down and sound the horn.
b.) Check for hazards by leaning out of the cab.
c.) Turn slowly and smoothly.
d.) Get through as quickly as possible.

6.) To lift people using a forklift, the operator must…
a.) Lift people with bare forks.
b.) Use a pallet to provide a platform.
c.) Move a truck near a wall for fall protection.
d.) None of the above.

7.) When forward visibility is obstructed or blocked…
a.) Look around the load.
b.) Proceed forward slowly and with due caution.
c.) Drive in reverse.
d.) None of the above.

8.) Never enter a trailer or railroad car unless…
a.) The watchman is present.
b.) The forklift’s fuel tank and battery are fully charged.
c.) The trailer or railcar is locked in place with wheel chocks.
d.) There is a spotter inside the trailer or railroad car.

9.) A forklift operator’s first concern should be…
a.) Increasing the speed of loading and unloading.
b.) Making sure the vehicle is in safe working condition.
c.) Checking shift changes for the load/unload schedule.
d.) Stabilizing the forks on all trucks used in a shift.

10.) Which of the following is a warning sign that the forklift may need to be taken out of service and repaired?
a.) Leaks for the fuel system.
b.) A brake pedal that feels spongy.
c.) Exhaust fumes that make you feel sick.
d.) All of the above.

Answers:
1. a
2. a
3. b
4. c
5. a
6. d
7. c
8. c
9. b
10 d

Driver’s daily checklist

2006-03-06T10:17:00.000-05:00

Driver’s daily checkists, stickers that can be attached to forklifts, can be used to insure forklifts are safe for every use. Drivers can check each item on the list before they drive the forklift:

* Tires – check all tires for damage
* Fluids – check oil, hydraulics, battery, fuel and coolant
* Seating – check the condition and adjustment of the seat
* Warning devices – check lights, horn and reversing beeper
* Capacity – load-capacity plate must be fitted, legible and correct
* Mast – check mast for wear to lift chains and guides, inspect hydraulic cylinders and look for leaks
* Forks – inspect forks for damage
* Seat belt – must be securely fastened
* After start-up – check pedals and controls, brakes and parking brake

Forklift safety -- Australian style

2006-02-27T16:03:00.000-05:00

Forklifts have killed 54 employees in Victoria, Australia since 1985 and injured many more. As a result, WorkSafe Victoria, the Victorian Work Cover Authority, has issued a detailed booklet on forklift safety that helps employers prevent forklift incidents through improved forklift traffic management.

The booklet provides details on every important forklift safety subject – from the risks of overturning and tipping, to speed and stopping distances, to getting on and off properly in order to prevent slips, trips and falls, to load carrying, to pedestrian risks.

There is information for operators (“when a forklift overturns, the safest place for the operator is in the cabin with a seatbelt on”) and employers (“An effective traffic management plan can use a range of devices, including pedestrian and forklift exclusion zones, safety barriers, containment fences and reduced speed limiting devices.”).

“These are the problems, but on a positive note, they are all fixable,” says Trevor Martin, director of WorkSafe’s transport and storage industry program. “And how to fix them is detailed in the Forklift Safety Pack.”

View it free online at
http://www.worksafe.vic.gov.au/dir090/vwa/publica.nsf/Site+Search/F27C2AF239DC19DDCA2570270011DAD5

Don't rush training

2006-02-23T09:27:00.000-05:00

Training forklift operators is not something that can be done quickly, or according to a set plan. Each operator must be trained on an individual basis to insure he or she understands the procedures of operating a truck in his specific work environment.

According to David Hoover, president of Forklift Training Systems, “The trainer must look at the demands that will be put on a specific operator, on a certain type of lift and in a specific application and then determine if the person can perform at that level. If they cannot, the answer to getting them ‘up to speed’ is supervised practice. For some operators, lifts and applications, that may take hours, for others weeks. There is no “instant” forklift operator, no matter how badly production would like to have them up and running. Rushing the process can spell disaster for the operator or a co-worker.

“Trainers must take their jobs seriously and look at operators’ skills, not their personalities or other aspects. Sliding everyone through, no matter what the skill level, is a thing of the past and something we don’t want to continue for safety’s sake. My advice to trainers is to train people thoroughly, invest time in getting them up to speed and then expect a certain level of proficiency before handing them the keys.”

Fleet management

2006-02-20T10:54:00.000-05:00

The poor management of forklift fleets leads to a loss or productivity and potential accidents.

Forklift management problems include running forklifts beyond their economic and functional lives and using too many different manufacturers with different controls. It is common to find companies that have trucks up to 30 years old from many different manufacturers. Some companies operate two pedal brake systems, one pedal brake systems, multidirectional travel pedals and hydrostatic drive systems all in one warehouse. There is no problem with any of these controls but it makes cross training more difficult and operating them more dangerous, since it takes time to become familiar with each set up.

Here are some basic forklift management recommendations:

* Inventory your fleet and track operating costs and hours for each forklift in your fleet
* Bring in several forklift dealers or national account managers to evaluate your current situation and make recommendations
* Settle on one manufacturer and purchase trucks with common control set ups
* Whether you replace your entire fleet now, or over several years, ensure older forklifts that might be unsafe are eliminated from your fleet as soon as possible.

Explosion-proof trucks

2006-02-17T10:09:00.000-05:00

Forklifts don’t just overturn, they explode. When forklifts work in hazardous conditions and their ignition sources or hot surfaces are exposed to flammable gases, vapors, liquids or combustible powders, fires or explosions can occur.

Two kinds of explosion-proof trucks are available. EE trucks have all the electrical equipment enclosed and are sometimes called “spark enclosed,” according to Ed Campbell, sales manager for Landoll Corp. These trucks are typically used when flammable liquids and gases are in containers.

EX trucks meet the same criteria as EE, but also “have all electrical fittings and equipment sealed so that they can operate in areas where the atmosphere contains flammable gases, dust or fibers,” Campbell says. Some EX models also have bronze clad forks and bronze bumper strips around the perimeter of the frame to prevent sparking.

OSHA requires EX trucks for “atmospheres in which combustible dust is or may be in suspension continuously, intermittently or periodically under normal operating conditions, in quantities sufficient to produce explosive or ignitable mixtures.”

Industries involved in manufacturing, handling, processing or storing explosive or hazardous materials, including perfumes, cosmetics, paints, varnishes, printing ink and chemicals use EX forklifts. It represents two percent of the total forklift market.

Are your trainers qualified?

2006-02-14T09:58:00.000-05:00

“Many trainers have received little, if any, training on the standards that apply and how to motivate people to work safely,” says David Hoover, president of Forklift Training Systems, Newark, OH.

OSHA says trainers must have the “knowledge, training and experience” to train others, but doesn’t require any kind of accreditation. So it is the employer’s responsibility to ensure the trainer is qualified to train operators and achieve safe working conditions.

Trainers should be familiar with a wide range of topics, relating to the truck and to the specific workplace.

Truck topics include:

* Truck controls and instrumentation – where they are located, what they do, how they work
* Engine or motor operation
* Steering and maneuvering
* Visibility (including restrictions due to loading)
* Fork and attachment adaptation, operation and use limitations
* Vehicle capacity
* Any vehicle inspection and maintenance the operator must perform
* Refueling and recharging batteries
* All other operating instructions listed in the operator’s manual for the type of vehicle to be used
* Proper use of seat belts and operator restraint

Workplace topics include:

* Surface conditions where vehicle will be operated
* Composition of loads to be carried
* Load manipulation, stacking and unstacking
* Pedestrian traffic
* Narrow aisles, other restricted places and hazardous locations where vehicle will be operated
* Ramps and other sloped surfaces
* Closed environments with insufficient ventilation

Periodic refresher training

2006-02-09T10:13:00.000-05:00

Today’s blog features comments from Kent O’Sullivan, a master trainer with the Columbia Compliance Group, Abbotsford, British Columbia, which originally appeared at Forkliftaction.com:

“Periodic refresher training is required by many regulations, codes and standards. It is essential for keeping safety skills sharp and preventing a dangerous sense of complacency. But if employees come to repeat training sessions with the attitude that they’ve heard it all before, how can you keep them from tuning out?

One of the best ways to start a repeat training class is with a pre-test to find out how much trainees remember from previous training sessions. That way you can quickly review what they already know, then concentrate on new information and material.
To make refresher training interesting and relevant, emphasize what has changed since the last training session, including new policies, work rules and regulations. Have new hazards been introduced into your facility? Have new work procedures been instituted or new equipment been installed? Have there been any accidents relating to the subject of your training?
Here are some other ideas to help make training fresh and new:

* Have trainees pair off and do an activity, such as going into work areas and finding as many hazards as they can
* Bring in slides of work areas, equipment and operations and have employees identify any hazards they see
* Invite a guest speaker, with expertise in a safety area, such as a firefighter or PPE rep
* Lead a discussion about safety problems and brainstorm with the group for solutions”

Thanks, Kent

Mandatory training hours

2006-02-06T13:07:00.000-05:00

Today’s blog features comments from David Hooper, president of Forklift Training Systems, Newark, OH, which originally appeared at Forkliftaction.com:

“As a U.S. based trainer, I have not dealt with any standards that require a specific number of hours to certify an operator, unlike other countries’ standards. Mandatory hours are both good and bad. The positive side is that you can at least ensure drivers have a certain number of hours under their belts before they are qualified to operate on their own. The downside is it does not allow the flexibility to fast track people who are more advanced, or to deal with folks who are slower learners.

Some trainers may have a problem with a required number of hours since it cuts their flexibility. However, I would ask whether it is better to have no required hours at all. It scares me that some operators in the U.S. get only minutes of operation before they are certified to operate.

One solution might be to keep mandatory hours fairly low and then allow more or less time, depending on what the trainer sees in the student. Some operators might progress immediately into the final evaluation stage, while others would enter remedial training.

Nothing can replace a seasoned trainer’s opinion of an operator. But mandatory hours guidelines could assist in getting operators prepared to succeed in the workplace.”

Thanks, David!

Lifting personnel

2006-02-02T11:05:00.000-05:00

Contractors frequently use forklifts to elevate personnel to items too high to reach from the floor or a ladder. But falls from high levels have resulted in fatalities and serious injuries.

Forklifts should be used to lift personnel only if the following guidelines are followed:

* A 8,000 lb capacity forklift or greater required.
* Cage must be attached appropriately to the forklift
* The operator must be in the control position.
* Cordoning the area should be considered.
* Other personnel must be kept clear of cage work area.
* Personnel in the cage must wear a body harness and lanyard attached to the cage.
* The mast must be in the vertical position and never tilted.
* Movement of the forklift, while personnel are in the cage, must not be greater than creep speed.
* Personnel should be at least one foot away from the cage per foot the cage is raised.

Electrical power lines

2006-01-30T13:47:00.000-05:00

A forklift operator in Tampa, FL was performing a routine maneuver, hoisting trusses onto the third floor of a complex when the forklift arm broke a 7,620-volt power line, starting a fire that spread quickly over a two block area.

Forklift operators must always be aware of overhead electrical power lines, because they are the leading cause of death in forklift operations, along with overturns.

Forklifts are usually equipped with bronze forks that are formulated to reduce spark formation in flammable areas. But the remainder of a forklift is electrically conductive and the forks are susceptible to damage if they’re grounded.

Operators should take these precautions to avoid electrical accidents:

* Know where power lines are located
* Treat all power lines as though they are bare and uninsulated
* Maintain a safe working clearance of at least 10 feet from energized electrical lines
* Lower the loads to avoid interacting with power lines
* Keep all equipment away from power lines

Company must pay full fine for youth fatality

2006-01-23T11:36:00.000-05:00

An administrative law judge reduced the $132,575 fine a Massachusetts fish processing company was ordered to pay in connection with a 2000 forklift accident that led to a fatality, but the Department of Labor’s Administrative Board reversed the decision, because the victim was a minor, according to the Boston Business Journal.

The violation by Fisherman’s Fleet, Malden, Mass., “resulted in the most severe consequence, the death of a 16-year-old boy,” the DOL said. “Given that fact and the review of the other factors, the board found that the penalty assessed against the company should not be reduced.”

The Fair Labor Standards Act prohibits employees less than 18 years old from operating forklifts.

The DOL found that over the course of two years, Fisherman’s had hired 26 minors between the ages of 14 and 18 as cleaners. The work required the use of a forklift, and the minors received no safety training. Joseph Marzullo, 16, died from injuries sustained from a forklift overturn.

After the accident, the Massachusetts Department of Health developed a “Forklift Stop Sticker” that employers can affix to the equipment to remind workers and their supervisors of the law.

NIOSH offers these safety tips for operating a forklift:

2006-01-16T11:35:00.000-05:00

NIOSH offers these safety tips for operating a forklift:

* Do not jump from an overturning, sit-down type forklift. Stay with the truck, holding on firmly and leaning in the opposite direction of the overturn.
* Exit fro a stand-up type forklift with rear-entry access by stepping backward if a lateral tipover occurs.
* On grades, tilt the load back and raise it only as far as needed to clear the road surface.
* Do not raise or lower the forks while the forklift is moving.
* Do not handle loads that are heavier than the weight capacity of the forklift
* When dismounting from a forklift, set the parking brake,lower the forks or lifting carriage and neutralize the controls
* Do not allow passengers to ride on the forklift unless a seat is provided
* When a truck is used to elevate personnel, secure the elevating platform to the lifting carriage or forks of the forklift

Teens on forklifts

2006-01-12T16:17:00.000-05:00

A 16-year-old summer worker at a warehouse was driving a forklift down a loading dock ramp with the forks lifted 10 feet high. The forklift became unstable and tipped over, and the boy was crushed to death.

Of the 613 forklift fatalities in a recent six-year period, six involved minors. The National Consumer League ranks forklift driving as one of the five worst teen jobs, based on government statistics and reports. It notes that teens die driving forklifts, but can also be run over by a forklift they’re not operating, struck by a load that fell from a forklift or die as a passenger in a forklift.

Employers should note the Fair Labor Standards Act and state child labor laws prohibit anyone under 18 from operating forklifts. They are not prohibited from riding on them or working in an environment where they are in operation, so employers should take special precautions to protect teen employees from the dangers of forklifts to passengers and pedestrians.

Seatbelts

2006-01-03T10:25:00.000-05:00

A 37-year-old shop foreman in Oklahoma died in a forklift accident because the truck wasn’t equipped with a seatbelt and when it overturned the victim fell out of the truck and was crushed.

Since 1992, all forklifts come equipped with seatbelts and older ones can be retrofitted. But some forklifts still don’t have seatbelts and they are not required by OSHA, which creates a severe hazard for drivers.

Seat belts are essential to protect drivers from overturn situations, because the risk of being crushed is reduced if the driver is secured and remains inside the vehicle.

Employers should provide seatbelts to forklift operators and train them to use them. It’s the best way to promote safe operating procedures in the event of overturns, which are the leading cause of forklift fatalites.

Safe forklift speeds

2005-12-27T10:33:00.000-05:00

If there was a forklift fatality at a workplace and the vehicle was traveling at 10 mph instead of the designated 8 mph, who would be responsible?

“Regulating the speed of an industrial truck is an important part of the environmental design of the workplace,” according to the American Society of Safety Engineers. Yet OSHA “does not have specific speed limits set for the safe operation of a powered industrial truck,” it said in answer to a query.

Forklift speed should be considered because of the destructive power of a fast moving forklift. A 5,000-pound forklift moving through a warehouse at 10 mph with a 4,000 pound load has a potential destructive force of 135,000 pounds of energy, according to the ASSE. Also, a forklift truck moving at 10 mph may take 40 feet to stop.

In response to these figures, the ASSE says the maximum speeds allowable for a forklift truck with no pedestrians present is 8 mph and 3 mph in areas where pedestrians are present.

Answers to the most frequently asked questions about forklift training

2005-12-22T14:14:00.000-05:00

* Must employees be trained?
Yes, all employees operating a forklift must be trained. The training consists of three elements: formal, practical and a visual evaluation of the operator’s skill.

* Does an employer have to hire a professional trainer?
No, anyone with forklift knowledge and the ability to evaluate forklift operators can conduct the training.

* Can employers develop their own training program?
Yes, as long as they cover the required topics and evaluate the operators properly.

* Do employees have to be evaluated after training?
Yes, they must be evaluated after initial training and every three years after that to insure they maintain their skills.

* Does the training have to be documented?
Yes, the employer must keep a record of the names of the operators, dates of training and evaluation and the name of their evaluators.

* Does training from a previous employer count?
Yes and no. The training can meet the general requirement but the new employer must provide site-specific hands on training for the forklift the employees will use and must evaluate the employees on it.

* Is a license or certification required to operate a forklift?
No, the requirement is that operators receive complete training.

Krispy Kreme fined for forklift violation

2005-12-19T16:30:00.000-05:00

The Canadian subsidiary of Krispy Kreme Doughnut Corp. has been fined $90,000 for an OSHA violation that resulted in a serious leg injury to a new employee.

KremeKo Inc., whose parent company is Winston-Salem, N.C.-based Krispy Kreme, pleaded guilty to failing to ensure that a lifting device was operated only by a competent person, as prescribed by Section 51(2)(a) of the Regulations for Industrial Establishments.

On Aug. 13, 2004, a truck driver at KremeKo's Mississauga, Ontario, industrial facility was on a small ramp using a lift truck to move some large flowerpots when the driver lost control of the lift truck. The driver's left leg became pinned between the lift truck and some metal bakery racks, resulting in a broken leg bone.

An investigation found the driver had never operated a lift truck before and had not received the company's formal lift truck training.

A justice of the Ontario Court of Justice imposed the fine, along with a 25 percent victim fine surcharge.

Tip overs

2005-12-15T11:03:00.000-05:00

What should forklift operators do if the lift truck starts to tip over? Should they stay in the vehicle, or jump out quickly?

If you said “Jump out,” you’d be wrong. If operators do that, they put their lives in danger. The safest way to survive a tip over is to stay in the vehicle, seat belt fastened, with a tight grip on the steering wheel and feet braced against the floor, leaning forward and away from the direction of the tip over.

Staying in the forklift during a tip over keeps the operator from being pinned by the mast or forklift structure. Wearing a seat belt keeps the head and torso with the confines of the truck and reduces the risk of the head and torso being trapped between the lift guard and the ground.

Tip overs are the second leading cause of forklift-related deaths. Proper training helps operators avoid them or deal with the properly if they occur.

The controversy over forklift alarms

2005-12-12T09:51:00.000-05:00

Should you or shouldn’t you install alarms on your forklifts? While alarms can reduce pedestrian fatalities and injuries, they are ineffective in certain situations -- when the ambient sound level is too great or the physical dimension of the worksite too small.

OSHA recommends but doesn’t require the use of alarms and manufacturers oppose them for a variety of reasons:

* excessive noise to the operator results in annoyance, fatigue and long term hearing loss
* pedestrians become habituated to the alarm and ignore it
* operators depend on the alarms to clear the path, without looking ahead
* multiple alarms from more than one lift truck cause confusion

The use of alarms remains optional, although forklifts with enclosed cabs need them because the cab obstructs vision, and if an alarm is supplied by the manufacturer it cannot be altered or removed.

Forklift rodeos

2005-12-08T12:06:00.000-05:00

Want to promote forklift safety? Hold a rodeo.

The Industrial Managers Association of Lincoln County, NC sponsored one recently, with drivers competing on an obstacle course in events that emphasized safety, driving ability and accuracy.

The event in Lincoln County was one of many forklift rodeos that are held around the country. The events “provide an excellent opportunity for industrial managers to emphasize and promote the importance of forklift safety in the workplace,” John Dancoff, IMA’s chairman said. “It’s also an interesting way to boost employee morale and create excitement for forklift training.”

The sponsor of another forklift rodeo agrees that the events generate interest in proper driving but warned that “only the most experienced drivers should compete in the events.”

Protecting pedestrians

2005-12-05T09:38:00.000-05:00

During a recent 15 year period, 20% of the fatalities from forklift accidents were pedestrians. The accidents occur when pedestrians are struck by a moving truck, hit by a falling load, trapped by a moving part of the truck or slip, trip or fall trying to avoid a truck.

Preventing pedestrian accidents can be accomplished through driver training and creating a safer work environment.

Since forklift drivers are “required to look in the direction of, and keep a clear view of the path of travel,” according to OSHA Standard 1910.178, they should be aware of pedestrians. Drivers should look around cab supports and load engaging apparatus and inspect all areas in front and behind the machine for pedestrians before putting the machine in motion. They must drive at safe speeds because even a slow moving forklift can crush a bystander. They should use alarms to make pedestrians aware of their location.

The forklift work environment must be designed to separate forklifts and pedestrians.
Areas can be closed off to pedestrian or forklift traffic. Safe routes and walkways can be created. Pedestrians who frequently work in forklift areas should wear high visibility vests. In-plant mirrors can be used to add vision to blind intersections for drivers and pedestrians. Warning signs should be erected.

How to operate a forklift

2005-12-01T11:09:00.000-05:00

According to OSHA regulations, “Only trained and authorized operators shall be permitted to operate a powered industrial truck." Once individuals are trained and authorized, they should follow these guidelines for the safe operation of a forklift:

* Never exceed the recommended load limit of the forklift.
* Know how to assess the weight of the load to be lifted.
* Check for adequate overhead clearance before raising the load.
* Operate a forklift smoothly when stopping, starting, lifting and tilting.
* Know the blind spots of the lift truck with and without a load.
* Keep pedestrians away from a forklift in operation.
* Stop when anyone crosses the route being traveled.
* Operate only as fast as conditions safely permit.
* Wear leather gloves and safety boots.
* Keep hands, arms, feet and legs inside the confines of the forklift.
* Stay in the truck in case of overturns.

2005-12-01T10:46:00.000-05:00

Forklift Accidents

Every year, 100 workers are killed and 20,000 seriously injured in forklift accidents in the U.S.

* 26% of the accidents are caused by lifts tipping over.
* 14% of the accidents are caused by loads falling on workers.
* 18% of the accidents are caused when a walking employee is struck by a lift.
* 14% of the accidents are caused when a lift is used inappropriately to elevate workers.
* 3% of the accidents are caused when operators lose control of the vehicles.

Lack of training or improper training is a main factor contributing to forklift accidents. Forklift operators must be trained to understand the controls and instrumentation; to pre-inspect the vehicle before use; and to understand forklift stability and the factors that affect it. A thorough knowledge of forklifts and their operation is required for the safe operation of a forklift by certified drivers.

2005-12-01T10:43:00.000-05:00

Lessons learned

On March 6, 1995, a loading dock worker for a gypsum company in Iowa was killed when a forklift suddenly lurched forward pinning him against a flatbed truck. The accident occurred because the forklift driver neglected to set the manual parking or service brake when he left the forklift to help the victim, so the forklift lurched forward when he returned to it, crushing the victim.

The company changed its loading procedures in response to the accident, with loading now a one-man operation with drivers prohibited from allowing forklifts to idle perpendicular to a truck edge where workers may be present adjusting a load.

In addition, the company expanded its forklift training, with drivers taught to follow safe procedures when dismounting and leaving a forklift unattended when other workers are in close proximity. Drivers are also trained to park or idle a forklift a safe distance from stationery objects and allow sufficient time for someone to escape in case of machine malfunction or operator error.

According to OSHA, forklift accidents cause 100 deaths and 95,000 injuries in the U.S. each year. Lessons learned from them prompt safety improvements that protect workers from future fatalities.

2005-12-01T10:42:00.000-05:00

OSHA enforces forklift safety standards

Shelter Enterprises, a Cohoes, NY insulation manufacturer, was recently fined more than $134,000 by OSHA after forklift accidents revealed the company hadn’t properly trained employees.

OSHA began its inspection last year after three employees were injured in a scaffolding accident. The inspection found the employees hadn’t received forklift training. Other alleged violations included using an improper platform on the forks of a forklift; modifying a forklift without the manufacturer’s approval; allowing employees’ arms and legs to extend outside the running lines of the forklift; and unstable loads on the forklift.

“The significant penalty demonstrates our commitment to protecting the health and safety of America’s workers,” an OSHA spokesman said.

Make sure you provide complete forklift training for your employees!

2005-12-01T10:41:00.000-05:00

Forklift safety training needed for Spanish speaking employees

A recent forklift fatality in Bluffton, SC emphasizes the importance of providing forklift safety training for workers in their native languages.

The victim, a Mexican construction worker for Southern Palmetto Landscapes, fell from a tree and was run over by a forklift.

The incident prompted the SC Labor Department to issue a statement urging employers to provide Spanish language training for their employees. OSHA regulations require employers to “establish a written [safety] program, in the language and literacy level of workers,” but not all employers do it.

As a result of the language barrier and cultural differences, workplace injuries among the Hispanic population has become a nationwide problem, according to federal officials. More than 14% of workplace fatalities in 2003 were Hispanic workers, according to OSHA, higher than African Americans and Asians combined.

“Not only do they not know the OSHA regulations, many don’t know their employers are responsible for their safety,” one observer said.

Hispanics are the largest minority in the U.S. and many don’t speak English, so employers should provide safety training for them in Spanish to prevent fatalities.

2005-12-01T10:39:00.000-05:00

Forklift driver certification

All forklift drivers must be certified in compliance with the OSHA regulation that was passed in 1998 (1910.178). Employers must complete and maintain certification of the driver’s training record, containing the name of the driver, the date of the training and the date of the evaluation and name of the trainer.

Once trained, the driver should be familiar with the following topics:

* Operating instructions, warnings and precautions for the types of trucks the driver will use
* Truck controls and instrumentation
* Engine or motor operation
* Steering and maneuvering
* Visibility (including restrictions due to loading)
* Fork and attachment operation
* Vehicle capacity
* Vehicle inspections, maintenance, refueling and charging of batteries
* Surface conditions where vehicle will be operated
* Composition of loads to be carried
* Pedestrian traffic
* Environmental considerations that could result in buildup of hazardous fumes or exhaust