Each day, forklift operators perform a balancing act—moving product from one location to another in a safe and efficient manner. However, that balance doesn’t always happen. In fact, most forklift-related injuries and deaths occur because the vehicle tips over. This often results in the driver being thrown from the forklift and becoming trapped underneath. Injuries also occur when the vehicle collides with another object, such as a warehouse rack. In this case, inventory can come crashing down, falling on top of the driver and others. And, if work is taking place on a loading dock, the forklift can fall off the dock to the ground several feet below.

What your employees need to know about using a forklift

Seatbelts. Just like driving a car, seatbelts are always required. Some may consider this to be an inconvenience, especially if they need to enter and exit the vehicle frequently. The seatbelt helps keep drivers from being thrown from the forklift and from being trapped underneath.

Balanced load. When the carried load leans to one side or another or it’s too heavy, the load is not balanced, and neither is the forklift. This can lead to the vehicle tipping over. Load weight information must be clearly displayed on the vehicle so that it is readily visible to the operator.

Unsafe speed. Driving too fast is one of the most common causes of a forklift tipping over, especially when rounding a corner or taking a sharp turn. Many forklifts don’t have speedometers, but some may be equipped with governors to prevent the vehicle from exceeding a certain speed. Workers must know what the forklift is and is not equipped with and act accordingly to maintain a safe speed.

Carbon monoxide risk. If propane forklifts are in use, there’s a risk of carbon monoxide exposure. Should a CO monitor sound at the workplace or there is other evidence of an exposure, work must stop. Shut down forklifts, contact a supervisor, and clear the workplace.

What your employees need to do when using a forklift

All forklift operators must have employer authorization and be certified on how to operate the vehicle safely. Training and a performance evaluation must be completed before an employee may operate a forklift. The operator must be re-evaluated at least once every three years.

Operators must complete refresher training if they’re in an accident or have a near miss. They also must complete refresher training if they’re observed operating a forklift in an unsafe manner, they’re assigned to drive a different type of vehicle, or workplace conditions change that could affect the safe operation of the forklift. No one under the age of 18 may operate a forklift.

Other steps to follow include:

  • Operate the forklift within the set speed limit as determined by management.
  • Drive even slower when rounding corners, if the ground is slippery, or if pedestrians or other vehicles are present.
  • Keep loads balanced.
  • Plan the route and anticipate any turns along that route.
  • Never turn on a grade, as a forklift can tip even on a small hill.
  • Never turn with the forks elevated.
  • Drive loaded forklifts forward while going up a ramp and in reverse when coming down.
  • Do not perform any stunts.
  • Consider using electric forklifts indoors instead of gas-powered ones.
  • Report carbon monoxide exposures and other injury/illness risks to a supervisor.

Should a tip over occur, employees need to know how to protect themselves.

  • Stay in the forklift. Never jump out. Jumping also can lead to a driver being struck by the vehicle or trapped underneath. Since drivers must wear a seatbelt, jumping out should not be an option.
  • Hold tight to the steering wheel.
  • Brace feet.
  • Lean forward and away from the impact.

What to cover at your safety meeting about forklifts

Review the amount of space available for operating forklifts and discuss the challenges such as any uneven ground, inclines, or tight spaces.

Remind employees of the speed and weight limits and why they must follow them.

Consider conducting a live demonstration on how to operate forklifts safely. Include information about the consequences of driving too fast, performing stunts, or otherwise not following the safe operating rules.

Discuss training requirements, operator evaluation requirements, and when to take refresher training.

Remind your employees that when used properly, forklifts provide a quick and easy method to move inventory—no matter how heavy—to the intended location. When not used properly, forklifts can lead to serious and even tragic accidents.