// Forklifts

Forklift Trucks - Common Factors in Forklift Incidents

What factors contribute to forklift truck incidents? Many work-related factors, such as work organization, workplace design and mechanical conditions, can contribute to incidents.

high-visibility clothing

What factors contribute to forklift truck incidents?

context Many work-related factors, such as work organization, workplace design and mechanical conditions, can contribute to incidents. Grouping them into specific categories may help to analyze incidents and, eventually, to prevent them.

What factors of work organization can contribute to forklift truck incidents?

context Production factors such as speed or stress.
context Lack of proper tools, attachments and accessories.
context Improper assignment of forklifts and operators.
context Poor maintenance of forklifts.
context Age of forklifts.
context Lack of training or improper training of workers who have to operate forklift trucks.
context Improper blocking of wheels on semi-trailers or railway cars.

What factors related to forklift operation can contribute to incidents?

context Travelling at excessive speed.
context Riding with the load elevated.
context Improper backing-up techniques.
context Improper turning, braking or accelerating.
context Improper warnings to others about a forklift in use nearby.
context Poor communication during shared tasks or in shared spaces.
context Not being aware of the route to be travelled (e.g., narrow passages, obstacles, poor surface conditions, etc.).
context Riding or giving rides on forklift or load.
context Parking the forklift improperly.
context Horseplay; stunt driving; jerky, erratic driving.

How can workplace design contribute to forklift truck incidents?

requirement Narrow aisles.
requirement Crowded, cluttered aisles.
requirement Shelving that has components that could hit or intrude into the operator area.
requirement Obstructions at intersections and doors.
requirement Volume of traffic in the work area.
requirement Pedestrians who are walking and working in the general area of forklift operations.
engineering Other workplace conditions such as noise, inadequate ventilation, or poor lighting.
requirement Ramps or flooring with different surfaces.
requirement Condition of the loading dock.

What characteristics of the load create a hazard?

general Items are poorly stacked or piled on the pallet in a way that results in an unstable load.
general Pallets are in poor repair.
general Load is too heavy.
general Load is unstable or blocking the operator's vision.

What mechanical conditions or design features increase the risk of forklift incidents?

context Malfunction of brakes.
context Malfunction of steering.
context Malfunction of clutch, shift linkage, or transmission.
context Malfunction of mast assembly.
context Leaks in hydraulic systems or transmission.
context Safety devices lacking, inadequate, or malfunctioning.
context Emissions from forklifts.
context Blind spots or obstructions blocking the driver's view.
context Poor layout of controls and displays.

How can incidents with pedestrians be reduced or avoided?

requirement Separate the pedestrian and forklift traffic by creating designated walkways or travel ways.
administrative Restrict people from entering areas where the forklift is operating. If not possible, develop safe work procedures to protect workers when they must enter areas where forklifts are operating.
requirement Keep a safe distance from the forklift whenever possible.
requirement Pedestrians should always let the driver know they are in the area. Make eye contact with the driver to ensure your presence is known.
requirement Make sure the area is well-lit and there are no obstructions.
requirement Be cautious near blind corners, doorways, and narrow aisles. Sound the forklift horn at intersections.
requirement Install mirrors at intersections.
ppe Use high-visibility clothing, where appropriate.
requirement Limit forklift travel speed.
requirement Install additional warning devices, such as lights or blinkers, where appropriate.
requirement Do not walk near or under raised forks.
requirement Do not load the forklift in a way that restricts the driver's viewing area.
requirement Avoid driving forklift near areas where pedestrian traffic is high (e.g., lunch rooms, time clocks, entrances, exits).