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FORKLIFT http://www.cdc.gov/niosh/docs/2001-109/default.html What is a Forklift • A forklift (or lift truck, high/low) is a powered industrial truck used to lift and transport materials. • First developed in 1920s, due to the labor shortages caused by the World War I. • World War II also spurred the use of forklift trucks that were with more maneuverability and could reach greater heights. http://en.wikipedia.org/wiki/Forklift Types of Forklifts • Power Supply – Electric – Internal Combustion (diesel / gasoline / LP gas) • Specialized Narrow Aisle Rough Terrain http://www.buyerzone.com/industrial/forklifts/forklift-types.html Variable Reach Components of a Forklift The operator sits in the cab which is mounted on a truck frame and moves the forks up and down to lift and transport pallets or other materials. http://en.wikipedia.org/wiki/Forklift Special Safety Concerns • A forklift has its LIMITS! – Which are indicated as the maximum loads listed on the nameplate visible to the operator • A forklift is REAR-WHEEL STEERING! – Which differs from a driver’s traditional experience with other wheeled vehicles • A forklift is UNSTABLE! – Especially when loaded and when turning http://en.wikipedia.org/wiki/Forklift Forklift Accidents are REAL! • Forklifts results in 100 deaths and over 20,000 serious injuries annually in the United States Alone. • Each year, an additional 94,750 injuries related to forklift accidents are reported. • The costs incurred due to forklift accidents are estimated to be over a hundred million dollars. NIOSH Publication 2001-109 http://www.cdc.gov/niosh/docs/2001-109/default.html http://www.forklift-safety-site.com/ Top Forklift Killers • • • • #1: Forklift Overturns #2: Nearby Workers Struck by Forklift #3: Victim Crushed by Forklift #4: Fall from Forklifts • NOTE: This is generous data and not for construction industry only. NIOSH Publication 2001-109 http://www.cdc.gov/niosh/docs/2001-109/default.html http://www.blr.com/topic.cfm/topic/67 Top Forklift Killers Distribution 25 22 20 20 16 15 10 9 5 0 #1 Ti p p i n g #2St ru ck #3Cru sh #4Fal l NOTE: This is generous data and not for construction industry only. NIOSH Publication 2001-109 http://www.cdc.gov/niosh/docs/2001-109/default.html http://www.blr.com/topic.cfm/topic/67 % t o t al vi ct i ms Top Forklift Killers from OSHA Construction Data 60 Accident Type (No. of Victims) 59 n o . o f v i ct i ms 52 50 1: Forklift tip over (59) 2: People struck or run over by forklift (34) 41 40 34 3: People crushed by forklift to other things (19) 30 20 4: People fall off the fork (52) 19 10 0 9 7 1 2 3 4 5 6 6 7 NOTE: This is for construction industry only. Total: 227, about 2% of all listed fatalities. Information extracted from OSHA construction worker fatality data (1990-2007) 8 5: Improper maintenance (7) 6: Load falling off the fork hit people underneath (41) 7: Operator or other people electrocuted (6) 8: Other (9) Typical Case Report: Overturn on Turning • A man was backing a forklift down an incline. While on the incline, the employee turned his wheels, causing the forklift to become top-heavy and overturn. He attempted to jump from the overturning forklift, but the overhead protection struck him behind the head. He died. Information extracted from OSHA construction worker fatality data (1990-2007) Typical Case Report: Overturn on Grade • A man was operating a forklift to unload roofing materials from a flatbed trailer that was positioned on a slight grade. He fully extended the hydraulic boom and forks. Although the forks were not loaded, the fully extended boom and the slight grade caused the forklift to overturn. He was thrown from the forklift, pinned under the forklift cage, and killed. Information extracted from OSHA construction worker fatality data (1990-2007) Typical Case Report: People Fall • A man was installing additional conduit in the ceiling. He asked a coworker to elevate him up to the ceiling in a forklift. The wooden box/crate personnel lifting device was not secured to the forks or to the vertical mast. He has been elevated 11 ft when he and the box fell off the left side of the forks to the concrete floor. He died. Information extracted from OSHA construction worker fatality data (1990-2007) Typical Case Report: Load Fall • A man was supervising the unloading of large pieces of electrical equipment using a forklift. When the third cabinet was being unloaded it fell off the forks as it was being lowered. It struck and pinned the man to the floor of the trailer. He died. Information extracted from OSHA construction worker fatality data (1990-2007) A Not-So-Typical Case Report: Using Forklift as a Jack • A man had the back end of the truck raised with the forks of a forklift truck while lying face up under the right rear axle to repair the rear end of the truck. The bumper of the truck slid off the forks, causing the weight of the truck to fall on his chest. He died of massive chest injuries. Information extracted from OSHA construction worker fatality data (1990-2007) Current OSHA Standard • OSHA – 1910.178 – Powered Industrial Trucks • NOT specific to construction industry – 1926.600 – Equipment – 1926.602 – Material Handling Equipment • The two above are for construction industry • Details are incorporated into the following Safety Procedures section http://www.cdc.gov/niosh/docs/2001-109/default.html Key Safety Procedures: PPE • • • • • Hard hat Safety gloves Safety goggles Safety footwear High visibility shirt or vest http://www.cdc.gov/niosh/docs/2001-109/default.html Key Safety Procedures: Even Before You Start • Properly maintain the vehicle. • Inspect vehicle condition before each shift. • Do NOT operate a forklift unless you have been trained and licensed. • Know where the operation manual is located on the forklift, and refer it whenever necessary. • Always use seatbelts on sit-down rider forklifts. http://www.cdc.gov/niosh/docs/2001-109/default.html Key Safety Procedures: Pre-Shift Inspection Detail • • • • • • • • Operating and emergency controls Safety devices, including seatbelt and horn Air, hydraulic, and fuel system leaks Cables and wiring harnesses Loose or missing parts Tires and wheels Warnings, control markings, and operation manuals Forks and fork attachment points – – – – No welds or holes allowed Check for and replace bent forks Forks should be marked as to their capacity Forks are to be replaced as sets only http://www.cdc.gov/niosh/docs/2001-109/default.html Key Safety Procedures: When Starting • Tilt the load back and make sure it’s stable and secured. • Raise the load only as far as needed to clear the road surface, that is to say, keep it as low as possible. • Inspect the surrounding area, especially when backing up. • Look forward the travel path and keep a clear view. http://www.cdc.gov/niosh/docs/2001-109/default.html Key Safety Procedures: On the Move • If view is blocked by load, travel in reverse direction. • Accelerate and brake gently, especially with a load. • Operate only at a speed that will permit it to be stopped safely. • Do NOT raise or lower the forks while moving. • Use extreme caution on grades or ramps. • Slow down and horn at cross aisles or corners or other vision-obstructed locations. • Do NOT drive towards anyone standing in front of fixed object. http://www.cdc.gov/niosh/docs/2001-109/default.html Key Safety Procedures: When It’s Overturning!!! • Do NOT jump from the forklift. • Stay under the covered guard. • Hold on firmly. • Leaning in the opposite direction of the overturn. http://www.cdc.gov/niosh/docs/2001-109/default.html Key Safety Procedures: When Loading and Unloading • Neutralize the controls and set the parking brake. • Level the frame prior to lifting a load. • Do NOT handle loads that are heavier than the weight capacity of the forklift. • Never allow people appear under the load. • Tilt forks forward to deposit load. • Observe landing and load while lowering forks. http://www.cdc.gov/niosh/docs/2001-109/default.html Key Safety Procedures: If People is Elevated • Do NOT allow workers standing on the forks, use specially designed platform. • Place the vehicle directly below the work area. • Secure the elevating platform to the lifting carriage or forks. • Use a restraining means or deceleration device for the workers on the platform. • Do NOT drive to another location with the work platform elevated. http://www.cdc.gov/niosh/docs/2001-109/default.html Key Safety Procedures: If People is Transported • Do NOT allow passengers to ride on the vehicle unless a seat is provided. http://www.cdc.gov/niosh/docs/2001-109/default.html Key Safety Procedures: After It Stops • Lower forks to the ground when parking. • Exit from a stand-up forklift with rear-entry access by stepping backward if a lateral tipover occurs. • Report any damage or problems occurred. • NO smoking in refueling or charging areas. • Chock wheels in maintenance, especially when operating under the vehicle. http://www.cdc.gov/niosh/docs/2001-109/default.html http://forkliftsafety.com