Forklifts, also known as Powered Industrial Trucks (PIT)
By Mike Rich- Safety Services Company
Published: July 25, 2011
Summary
Forklifts, also known as Powered Industrial Trucks (PIT), are used in numerous work settings, primarily to move materials. Each year in the United States, nearly 100 workers are killed and another 20,000 are seriously injured in forklift-related incidents.
Forklift overturns are the leading cause of these fatalities representing about 25% of all forklift-related deaths.
In order to reduce the potential for a forklift related accident OSHA requires employers to certify all their employees in the proper operation of forklifts, properly maintain the lifts and train those who may come into contact with lifts on hazards and best practices.
In terms of certification many believe this is something that has to be completed through private contractors. However, OSHA regulations allow you to certify your own employees through the creation of an OSHA verified program.
Independent studies have confirmed forklift training reduces operator errors by 70%. [2]
Forklift overturns are the leading cause of these fatalities representing about 25% of all forklift-related deaths.
In order to reduce the potential for a forklift related accident OSHA requires employers to certify all their employees in the proper operation of forklifts, properly maintain the lifts and train those who may come into contact with lifts on hazards and best practices.
In terms of certification many believe this is something that has to be completed through private contractors. However, OSHA regulations allow you to certify your own employees through the creation of an OSHA verified program.
Independent studies have confirmed forklift training reduces operator errors by 70%. [2]
Related
- Hand and Power Tools requirements and hazards (July 26, 2011)
- Confined Spaces Hazards and Requirements (July 25, 2011)
- Scaffolding requirements and hazards (July 25, 2011)
Fork Hazards
Each year in the U.S. more than 20,000 workers are injured and 100 killed in forklift related accidents. [1]
As a further illustration of the risk associated with forklift operation OSHA estimates that of the 1 million forklifts in the United States two-thirds are involved in an accident in their normal eight year life span. [2]
These incidents are attributed to three causes according to OSHA:
1. Insufficient or inadequate forklift training - On April 25, 1995, a 37-year-old shop foreman was fatally injured after the sit-down type forklift he was operating over-turned. The victim was turning while backing down an incline with a 4% grade. The forklift was transporting a 3-foot-high, 150-pound stack of cardboard with the forks raised approximately 60 inches off the ground. No one witnessed the incident. The victim was found with his head pinned under the overhead guard. With proper training the operator would have known to keep the forks low and to avoid turning on an incline. [3]
2. Failure to follow safe forklift operating procedures - On October 19, 1995, a 39-year-old female punch press operator was fatally injured by a forklift traveling in reverse at high speed toward the victims' workstation. A witness observed the forklift strike a metal scrap bin (about 3 by 5 by 3½ feet), propelling it toward the punch press station. The bin hit the press and rebounded toward the forklift. There it was hit once again and shoved back against the corner of the press, striking and crushing the victim against the press. If the driver had followed proper speed requirements the accident could have been avoided. [2]
3. Lack of safety rule enforcement - On September 6, 1995, a 47-year-old warehouse manager was fatally injured while working with a forklift operator to pull tires from a storage rack. The two workers had placed a wooden pallet on the forks of the forklift, and the victim then stood on the pallet. The operator raised the forks and victim 16 feet above a concrete floor to the top of the storage rack. While retrieving merchandise the victim fell and fatally struck his head on the floor. The act was a violation of one of OSHA's most basic forklift safety regulations and completely avoidable. [2]
Most Common Causes of Forklift Fatalities
Each year in the U.S. more than 20,000 workers are injured and 100 killed in forklift related accidents. [1]
As a further illustration of the risk associated with forklift operation OSHA estimates that of the 1 million forklifts in the United States two-thirds are involved in an accident in their normal eight year life span. [2]
These incidents are attributed to three causes according to OSHA:
1. Insufficient or inadequate forklift training - On April 25, 1995, a 37-year-old shop foreman was fatally injured after the sit-down type forklift he was operating over-turned. The victim was turning while backing down an incline with a 4% grade. The forklift was transporting a 3-foot-high, 150-pound stack of cardboard with the forks raised approximately 60 inches off the ground. No one witnessed the incident. The victim was found with his head pinned under the overhead guard. With proper training the operator would have known to keep the forks low and to avoid turning on an incline. [3]
2. Failure to follow safe forklift operating procedures - On October 19, 1995, a 39-year-old female punch press operator was fatally injured by a forklift traveling in reverse at high speed toward the victims' workstation. A witness observed the forklift strike a metal scrap bin (about 3 by 5 by 3½ feet), propelling it toward the punch press station. The bin hit the press and rebounded toward the forklift. There it was hit once again and shoved back against the corner of the press, striking and crushing the victim against the press. If the driver had followed proper speed requirements the accident could have been avoided. [2]
3. Lack of safety rule enforcement - On September 6, 1995, a 47-year-old warehouse manager was fatally injured while working with a forklift operator to pull tires from a storage rack. The two workers had placed a wooden pallet on the forks of the forklift, and the victim then stood on the pallet. The operator raised the forks and victim 16 feet above a concrete floor to the top of the storage rack. While retrieving merchandise the victim fell and fatally struck his head on the floor. The act was a violation of one of OSHA's most basic forklift safety regulations and completely avoidable. [2]
Most Common Causes of Forklift Fatalities
| Type of Incident | Percentage of total victims |
| Forklift overturns | 22% |
| Worker on foot struck by forklift | 20% |
| Victim crushed by forklift | 16% |
| Fall from forklift | 9% |
Death and Injury Can Cripple Your Company
Workplace deaths and injuries are heart breaking to families and financially crippling to employers.
The US Department of Labor estimates these injuries and deaths cost employers $1 billion a week in worker's compensation costs. And when lost productivity, increased insurance premiums and other costs are added in , the total economic impact of occupational accidents is more than $4 billion a week or $668 for every citizen in the United States. [5]
An annual study conducted by the Liberty Mutual Research Institute for Safety in 2010, revealed that the direct cost to employers from injuries in 2008 was $53.42 billion. [6]
Furthermore the study concluded that accidents at the workplace were estimated to cost employers an additional $80 to $200 billion annually.
A second report by the U.S. Department of Labor cemented the finding of the insurance groups report. This report stated the average workplace injury cost an employer $43,000. The same study estimated the cost from wage replacement due to injury to be roughly $50 billion a year.
"An accident at the workplace can often be the difference between operating in the black and falling into the red," said Safety Services Company CEO Devon Dickenson.
In addition to the financial ramifications due to health related issues, OSHA can fine employers for not having a policy in place. These fines start at $7,000.
The US Department of Labor estimates these injuries and deaths cost employers $1 billion a week in worker's compensation costs. And when lost productivity, increased insurance premiums and other costs are added in , the total economic impact of occupational accidents is more than $4 billion a week or $668 for every citizen in the United States. [5]
An annual study conducted by the Liberty Mutual Research Institute for Safety in 2010, revealed that the direct cost to employers from injuries in 2008 was $53.42 billion. [6]
Furthermore the study concluded that accidents at the workplace were estimated to cost employers an additional $80 to $200 billion annually.
A second report by the U.S. Department of Labor cemented the finding of the insurance groups report. This report stated the average workplace injury cost an employer $43,000. The same study estimated the cost from wage replacement due to injury to be roughly $50 billion a year.
"An accident at the workplace can often be the difference between operating in the black and falling into the red," said Safety Services Company CEO Devon Dickenson.
In addition to the financial ramifications due to health related issues, OSHA can fine employers for not having a policy in place. These fines start at $7,000.
OSHA Requirements Intervention
To protect employers and employees from the danger of operating forklifts OSHA crafted regulation 29 CFR 1910.178, which outlays a strict series of training, operating and maintenance requirements for all companies utilizing PITs.
This next chapter is a survey of some of the requirements in forklift operation that a novice may not know.
This next chapter is a survey of some of the requirements in forklift operation that a novice may not know.
Forklift Operation
Your employees need training on the basics of forklift operation. These topics must include.
• The proper distance forks are to be raised when transporting a load and the operating of the forks while the lift is moving in a forward or reverse direction. [29 CFR 1910.178 (n)(7)(iii)].
• The safe speeds at which the forklift is to operate to facilitate proper stopping. [29 CFR 1910.178 (n)(8)].
• The operator is required to look forward and keep a clear view of the travel path [29 CFR 1910.178(n)(6)].
• The riding on a lift by a person other than the primary operator. [29 CFR 1910.178 (m)(3)].
• The driving of forklifts into fixed objects that other objects may be resting on. These objects include benches, tables and more.[29 1910.178 (m)(1)]
• The proper distance forks are to be raised when transporting a load and the operating of the forks while the lift is moving in a forward or reverse direction. [29 CFR 1910.178 (n)(7)(iii)].
• The safe speeds at which the forklift is to operate to facilitate proper stopping. [29 CFR 1910.178 (n)(8)].
• The operator is required to look forward and keep a clear view of the travel path [29 CFR 1910.178(n)(6)].
• The riding on a lift by a person other than the primary operator. [29 CFR 1910.178 (m)(3)].
• The driving of forklifts into fixed objects that other objects may be resting on. These objects include benches, tables and more.[29 1910.178 (m)(1)]
Stability
The stability of a loaded truck is affected by a number of factors including size, weight, shape, and position of the load. Also affecting the stability is the height at which the load is elevated, the amount of forward or backward tilt, tire pressure, and the dynamic forces created when the truck is moving. Your employees must be trained in controlling these variables to maintain proper stability.
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