Forklift Safety Toolbox Talk - Safety Checklist & Resources

Forklifts, commonly referred to as powered industrial trucks (PITs), are a staple at construction sites and warehouses across the globe. These machines come in various forms and serve diverse purposes (for more information on different forklift types, click here). However, each type comes with unique safety considerations. While forklifts are generally safer than larger equipment like cranes or excavators, they still pose significant risks that can result in serious workplace injuries.

According to OSHA statistics, forklift overturns are the leading cause of fatalities related to these vehicles, accounting for approximately 25% of all forklift-related deaths. In the U.S., nearly 100 workers die each year due to forklift accidents, with another 20,000 sustaining severe injuries (refer to the NOISH report for further details).

Diesel-powered forklifts are specifically designed for outdoor use due to the harmful fumes they emit. Operating such a machine indoors without proper ventilation can be extremely hazardous.

Many factories employ color-coded tape to mark forklift zones, ensuring workers are mindful of their surroundings. Additionally, mirrors placed strategically around corners assist forklift operators and employees in maintaining visibility when their line of sight is obstructed by shelving.

Preparing the Forklift Load

Before handling any load, always confirm that it is centered and balanced. An off-center load greatly increases the risk of the forklift tipping over.

• Secure the load securely to prevent movement during transport.
• Inspect the load thoroughly to ensure there is no damage. Damaged goods should be wrapped or banded to ensure stability.
• Center the load as much as possible.
• Exercise extra caution when dealing with off-center loads that cannot be centered. Operate the forklift at a slower pace and take additional care.
• Position the heaviest portion of the load closest to the front wheels of the forklift to maintain balance.
• Avoid overloading the forklift. Familiarize yourself with the vehicle's weight limit and account for any attachments being used.
• Remember that a forklift’s capacity rating assumes a specified load center. Off-center or oversized loads can exceed this capacity, making the forklift unstable.
• Utilize the load extension backrest to provide added stability.

Key Takeaway: The top image demonstrates a properly balanced forklift load. The bottom image shows an unbalanced and potentially hazardous load. Incorrectly balanced loads significantly increase the likelihood of the forklift tipping over.

Approaching the Load

• Approach the load gradually, stopping approximately 8 to 12 inches away.
• Align the forklift perpendicularly to the load with the forks at the appropriate height.
• Set the direction control to neutral.
• Refrain from adjusting the forks until the forklift has come to a complete stop and the brakes are engaged.
• Use the inching pedal to gently move the load towards the stack.

Note: Stopping 8 to 12 inches in front of the load provides ample space to maneuver the forks effectively.

Mast Positioning

• Keep an eye on the load while adjusting the mast. Loads can shift unexpectedly.
• Exercise caution when tilting loads. Avoid tilting forward with elevated forks unless necessary for loading or unloading.
• When stacking or arranging loads, tilt backward only as needed to stabilize the load.
• Travel with the mast tilted back to enhance load stability.
• Tilt the mast forward cautiously when placing the load onto the stack.
• Never travel with the load tilted forward. Doing so increases the load distance and decreases stability.

Note: The mast should remain vertical when approaching a load.

Note: Proceed with caution when the mast is tilted forward. Forward tilting increases the load distance and heightens the risk of imbalance.

Note: Tilting the mast back reduces the load distance and helps center the load's weight.

Positioning the Forks

• Ensure the forks are level before inserting them into the pallet.
• Insert the forks as deeply as possible beneath the load. This improves stability.
• Slide the forks completely under the pallet until they are at least two-thirds the length of the load. If this isn’t possible, consider using a different forklift for the task.
• Be cautious not to puncture or damage items on the opposite side of the pallet.
• Distribute the load evenly between the forks. Make adjustments as necessary to achieve balance.
• Tilt the mast back carefully to stabilize the load. Backward tilting enhances the center of gravity.

Note: Slide the forks fully under the pallet until they are securely positioned. Avoid extending beyond the pallet’s boundaries to avoid collisions. The forks must cover at least two-thirds of the pallet length to lift it safely.

Lifting the Load

• Confirm there is sufficient clearance above before raising the load. Look out for overhead fixtures, lighting, pipes, etc.
• Lift the load slowly, just four inches above the lower stack, and check that it is stable.
• After lifting, tilt the mast back slightly to secure the load against the backrest extension.
• Verify that the load is not snagged on anything, tied down, or interfering with other items.
• Gradually return the lift control lever to the neutral position.

Note: Lift the load slowly and steadily 4 inches off the ground. Ensure the load remains stable and well-controlled.

Lowering the Load

• Be vigilant about falling loads and potential strikes when lowering the load.
• Revert the mast to the vertical position prior to lowering the load.
• Lower the load until its lowest point is approximately 6 to 8 inches above the floor.

Note: Tilt the mast backward to improve load stability.

Group Discussion Topics

• Is your forklift in good working order? (e.g., check tires, hydraulic lines, signs, etc.). Perform a visual inspection daily.
• What are some forklift hazards specific to your work environment?
• Is the forklift designed for indoor or outdoor operation?
• Are bystanders and other workers aware that a forklift is operating nearby?
• What factors could lead to a forklift rollover?

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