Forklift trucks

There are many types of forklift truck, but they share common hazards and safety precautions. The hazards are:

• Improper use. Some people still misuse a forklift, trying to race, taking sharp turns or using it in destructive ways.
• Overturn of the truck. The narrow, short wheelbase makes the truck unstable, so it can tip sideways, forwards or backwards very easily.
• Fall of the load. The load may fall from the forks onto the driver or others standing nearby during a lifting operation.
• Attachment hazards. Most forklifts can take many kinds of attachment, but like the machine itself, if they are not fitted or maintained properly they can cause serious injury.
• Striking pedestrians. Like any vehicle, a forklift will cause serious injury if it hits a pedestrian.
• Blind spots. Ignoring blind spots can cause unexpected impacts and serious injuries. When a full load blocks the operator's view, they cannot see what is in front of them.
• A person riding on the forks. Workers often use the forks as a working platform. This can cause a fall from height, or leave the worker trapped between the mast of the forklift and a fixed structure.

• Falls from a loading dock. Another common accident, where the truck falls through or off the loading dock it is driving over to reach the back of a lorry.
• Fuelling. Refuelling and recharging are hazardous because the energy sources are flammable. Diesel and propane are both flammable, and charging a battery gives off combustible gas.

When moving materials with a forklift:

• Centre the load on the forks, as close to the mast as possible, to reduce the chance of the truck tipping or the load falling.
• Keep clear visibility of the work area and make sure there is enough clearance when raising, loading and operating.
• Consider the noise level at the worksite, and do not assume other workers can hear a reversing alarm.
• Pile and cross-tier stacked loads correctly where possible.
• If a load obscures the view, use an assessed route and method that provides adequate visibility. Reverse travel may be appropriate on suitable level routes, but slope travel needs the truck-specific method, normally keeping the load uphill; do not apply a blanket reverse-travel rule.
• Tilt the load and the load-engaging means back, and raise them only as far as needed to clear the road surface.
• Handle only stable and safely arranged loads, and take care with off-centre loads.
• Use the restraint or protective system specified for the truck and assessed overturning risk. A seated counterbalance truck and a stand-on truck do not have identical arrangements.
• Separate pedestrian and forklift traffic with designated walkways and travel ways.
• Keep people out of areas where the forklift is working. If that is not possible, develop safe work procedures to protect workers who must enter.
• Pedestrians should always let the driver know they are in the area, and make eye contact to be sure the driver is aware.
• Make sure the area is well lit and free of obstructions.
• Be careful near blind corners, doorways and narrow aisles, and sound the horn at intersections.
• Use high-visibility clothing where appropriate.
• Limit travel speed.
• Do not walk near or under raised forks.
• Plan loading and travel so obscured views are managed safely; do not proceed into an unseen area without the assessed precautions.
• Avoid driving near areas where pedestrian traffic is high, such as lunch rooms, time clocks and entrances and exits.
• Do not run a diesel or petrol forklift in confined or poorly ventilated spaces. Use an electric truck.

Summary notes for Element 6 · Cheat sheet · Glossary. A study aid, not published or endorsed by NEBOSH.