Forklift Safety Policy | Checklist | Safety Toolbox Talk | Devices

1. PURPOSE

1.1       This procedure provides guidelines for safe forklift truck operations at Company facilities, including the safety of all workers in the areas where forklifts are operated.

2. Forklift Safety Policy | Checklist | Safety Toolbox Talk | Devices

2.1      This procedure is applicable to all facilities where forklift trucks are operated.

3. DEFINITIONS

3.1      None

4. SUMMARY

4.1       Forklift trucks are used at facilities to assist in performing a wide variety of tasks, including lifting, moving, stocking, and arranging materials of varied sizes, shapes, and weights. Frequently, these activities take place in close proximity to other workers, equipment, or materials. As such, the potential for an incident to occur which may damage assets and may cause an injury to personnel is highly probable if safe work practices are not followed.

5. PROCEDURE – FORKLIFT TRUCK SAFETY

5.1      Design

5.1.1   Powered forklift trucks must meet the appropriate national design and construction requirements and the specific design requirements of this standard. If the forklift will be operated in an area that is classified as hazardous, then the forklift must meet the design criteria to be operated in that area or a safety work permit must be issued once the hazards are removed.

5.1.2   Forklifts must be equipped with occupant restraint systems. The system must be of a type provided or approved by the manufacturer and installed by the manufacturer or their authorized representative.

5.1.3   Forklift trucks shall have a reversing (backup) alarm, except where prohibited by local regulation.

5.1.4   Nameplates and markings must be in place and maintained in a legible condition. As a minimum, the following information must be shown on the truck:

• Empty (Unladen) weight.
• Maximum safe working load.
• Load center distances related to load capacity.
• Maximum lift height related to load capacity.

5.1.5   Replacement Parts and Modifications

• Only replacement parts that are safe equivalents to original parts must be used.
• Forklift trucks must not be altered so that the relative positions of the various parts are different from what they were when originally received from the manufacturer.
• Forklifts must not be altered either by the addition of extra parts not provided by the manufacturer or by the elimination of any parts.
• Additional counter weighting of fork lift trucks must not be done unless approved by the manufacturer.

Note:  All equipment modifications that affect capacity and safe operation must be approved in writing by the manufacturer or a registered Professional Engineer. When these changes are made, the capacity, operation, and maintenance instruction plates, tags, or decals must be changed accordingly.

5.2      Lifting Attachments

5.2.1   A lifting attachment is a device, other than the forklift manufacturer’s installed equipment, that is installed (permanently or temporarily) on the lifting mechanism of the forklift.

Pallets, cylinder platforms and similar material handling items that keep the load on the forks or design lifting attachment are considered part of the load and are not lifting attachments as defined in this standard.

5.2.2   The use of Personnel Lift Platforms has specific requirements and is addressed in Section 5.6 of this standard.

5.2.3   The following requirements apply if you use a lifting attachment:

• The lifting attachments must not affect the safe operation of the forklift. Consider consulting your forklift manufacture or distributor for advice.

Note:  Any attachment that applies a lifting force other than vertical can be expected to affect the safe operation of the forklift. Typically forklifts are designed to lift vertically (within the tilt movement of the mast). Consult the manufacturer if you are considering using an attachment that will exert a push or pull force on the lifting mechanism. You must calculate the attachment’s affect of the forklift’s load capacity. If the capacity can be exceeded, then you must install a label on the forklift to identify the attachment and forklift capacity when using the attachment.

Refer to Appendix B for information regarding capacity calculations. Also, the attachment manufacturer may be able to provide load charts for using their attachment with specific forklifts.

• The lifting attachment must be labeled to indicate the capacity of the attachment structure.
• Attachments must be used, inspected and maintained in accordance with the design use of the attachment and the attachment manufacturer’s instructions. For example: Lifting booms and hooks must be inspected at the same frequency as specified in the crane standards.

• You must instruct forklift operators in the proper use of the attachment.

5.3      Operator Training (Refer to 25-021406 Forklift Safety for details)

5.3.1   Only properly trained and authorized personnel (Company and contract) or someone who is undergoing formal training under supervision are permitted to operate powered forklifts on Company sites.

• A qualified trainer or supervisor may choose to certify a participant to operate a specific forklift model or to operate all forklifts that have similar operating features, characteristics, and limits.
• The certification for employees and contractors must specify the equipment on which the trainee has been qualified, must be kept on file until it expires, and retraining scheduled before expiry date.

5.3.2   Before contract personnel are allowed to operate any powered forklift truck on site, the contract employee’s management must provide Company site management with written certification that the employee(s) is currently trained on the equipment.

5.4      Inspection and Maintenance

5.4.1   All new or leased forklift trucks must be inspected by a competent person, certified, and marked as described in the Design section before use. If the truck is leased, a copy of the last inspection and its certification must be reviewed.

5.4.2   Periodic Inspections and Maintenance

• Forklifts must be inspected daily before being placed in service. You may use the manufacturer’s inspection form and/or the model form in Appendix A.
• When a forklift must be used on multiple shifts during a day, it must be inspected before each shift.
• Forklift must be maintained as per the manufacturer’s recommended preventative maintenance. As a minimum; all forklift trucks will be maintained every 12 months.
• The forks, chains, mast, cylinders and hoist mechanism shall be inspected by a competent person every 12 months.
• Preventative maintenance programs and all service and inspections must be carried out by people who are qualified/experienced in the type of fork lift truck concerned.

5.4.3   Defective Equipment

• Forklifts must not be placed in service if inspections or observations identify any condition adversely affecting the safety of the vehicles.
• A danger tag must be placed on the steering mechanism stating the problem and ignition key must be removed. Units must not be used until defects are corrected.
• Only qualified individuals who are authorized may make repairs or adjustment on forklifts.

5.4.4   Documentation of Inspections and Maintenance

• All daily inspections must be documented and maintained on file for at least 30 days.
• 12 Month Inspection records must be maintained for three years.
• Maintenance records are to be kept on the controlling site relating to each truck operated.

Each truck file must contain lifting/test certificates, check lists, service/repair sheets, and defect reports. These records shall be kept for at least three years.

5.5      Operating Safety Rules and Practices

Before operating any forklift, the operator must be familiar with any unusual operating conditions which may require additional safety precautions or special operating instructions.

The operator must be familiar with the operation and function of all controls and instruments before undertaking to operate a particular forklift.

5.5.1   Personal Safety Rules

• For protection in the event of collision, roll-over, or tip-over, occupants must use all safety and restraint systems (seat belts).
• Forklift trucks must not be driven up to anyone standing in front of a bench or other fixed object.
• Standing or passing under the elevated portion of any forklift, whether loaded or empty, is prohibited.
• Passengers must not be permitted to ride on forklift trucks unless a safe place to ride has been provided by the manufacturer.
• Personnel must be certain to stand clear of the rear swing area before forklifts conduct turning maneuvers.
• Arms or legs are prohibited from being placed between the uprights of the mast or outside the running lines of the forklift when it is operating.

5.5.2   Safe Practices for Unattended Forklifts

Note:  A forklift truck is determined unattended when the operator is 7.5 meters (25 feet) or more away from the vehicle that remains in view, or whenever the operator leaves the vehicle and it is not in view.

• Lower load engaging controls fully.
• Neutralize controls.
• Shut off the power.
• Set the brakes to prevent movement.
• Block the wheels if the forklift is parked on an incline.

5.5.3   Safety Rules around Materials and Other Equipment

• A safe distance must be maintained from the edge of ramps or platforms while on any elevated dock, platform, or freight car.
• A forklift truck must not be used to open or close freight doors unless it is equipped with a device specifically designed for that purpose and the operator is trained in its use.
• Brakes must be set and wheels blocked on trucks, trailers, or railroad cars, in order to prevent movement while loading or unloading by forklift.
• Fixed jacks must be used to support a semi-trailer during loading or unloading when the trailer is not coupled to a tractor.
• The flooring of trucks, trailers, and railroad cars must be checked for breaks and weakness before a forklift is driven onto it.
• A forklift truck must be equipped with an overhead guard to protect against falling objects.

Note:  An overhead guard is intended to offer protection from the impact of small packages, boxes, bagged material, etc., representative of the job application, but not to withstand the impact of a falling capacity load. It is not “rollover” protection.

5.5.4   Forklift Traffic Safety

• Forklift trucks must be operated at a speed that permits them to be brought to a stop in a safe manner under all travel conditions.
• Stunt driving and horseplay are prohibited.
• Forklift operators must look in the direction of and keep a clear view of the path of travel.
• Operators are required to travel with the load trailing if the load being carried obstructs the forward view unless operating on gradients, see paragraph 5.5.5.
• Operators must observe all traffic regulations including authorized plant speed limits.
• Forklift operators are required to slow down and sound the horn at locations where vision is obstructed.
• Operators must not pass another forklift traveling in the same direction at intersections, blind spots, or other dangerous locations.
• Operators must stay at least three forklift lengths behind another forklift.
• Forklifts must cross railroad tracks diagonally if possible.

5.5.5   Safe Operation On Grades

• Forklift operators are required to slowly ascend or descend grades.
• When ascending or descending grades in excess of 10%, loaded forklifts must be driven with the load upgrade.

5.5.6   Safety Rules for Loads

• Forklifts must handle only loads within the rated capacity of the forklift.
• Operators must handle only stable or safely arranged loads.
• Operators must exercise caution when handling loads that cannot be centered.
• All long or high (including multiple-tiered) loads which affect capacity must be adjusted.
• Operators must place the load engaging device under the load as far as possible.
• The mast should be tilted back carefully to stabilize the load.

5.5.7   Safe Work Practices for Fuel Tanks

• Fuel tanks must not be filled while the engine is running. Spillage must be avoided.
• Spillage of oil or fuel must be carefully cleaned up using sand or absorbent granules and disposed off in accordance with local or national regulations or completely evaporated and the fuel tank cap replaced before restarting the forklift’s engine.
• No forklift must be operated with a leak in the fuel system until the leak has been corrected.
• Open flames must not be used for checking electrolyte levels in storage batteries or gasoline levels in fuel tanks.
• Forklifts or any of their functions or attachments must not be started or operated from any place other than from the designated operator position.
• Propane driven forklift trucks must have an excess flow valve fitted and the condition of the hose must be checked. Leak checks must be performed every month.

5.6      Lifting Personnel

5.6.1   Mobile Elevating Work Platforms, scaffolds, and ladders are preferred methods of gaining access to elevated work. The use of forklifts with properly designed lift platforms is less desirable because forklifts are normally not designed to lift personnel.

5.6.2   When a task and risk assessment determines that other methods are not practical, you may lift personnel when the requirements in this section and any local regulations are met.

• You must use a personnel lift platform that is approved in writing by the forklift manufacturer.
• The personnel lift platform must have standard guardrails, toeboards, and be equipped with guards so the occupants cannot come in contact with moving parts of the lift truck.
• The platform must be securely attached to the lift structure so that it cannot move from its design position.
• You must analyze and safeguard hazards, such as pinch points and electrical equipment, that present a risk to workers.

• The lift truck must be on a stable, level surface.
• The lift truck may not be driven when occupants are in the platform.
• The lift truck must be attended by a qualified operator at all times when personnel are in an elevated platform.

6. RELATED INFORMATION

6.1      Company Engineering Standard

⊕    GGE-4005                   Site Operated Forklift Truck

6.2      Company EH&S Document

25-011450	Control of Traffic Movements on Site
25-021406	Forklift Safety

Appendix A

Pre operational Forklift Inspection

1. Load back rest extension is in place and not bent, cracked, or loose.
2. Forks and mast are not bent, worn, or cracked. Upper limit stops are OK.
3. Tires/ Wheels are inflated and free of excessive wear or damage. Nuts are tight.
4. Overhead guard is in place and not bent, cracked, or loose.
5. Attachments (if equipped) operate OK and are not damaged.
6. Forklift body is free of excessive lint, grease, or oil.
7. Engine oil is full, clean, and free of leaks.
8. Hydraulic oil is full, clean, and free of leaks.
9. Radiator is full, clean, and free of leaks.
10. Fuel level is OK and free of leaks.
11. Battery connections are tight, electrolyte is full, battery is charged. (Use goggles when checking electrolyte level)
12. Covers over battery and other hazardous parts are in place and secure.
13. Load rating plate is present and readable.
14. Warning decals are present and readable.
15. Operator Restraint / Seat belt is accessible and not damaged, oily, or dirty.
16. Horn works.
17. Turn signal (if equipped) operates smoothly.
18. Lights (head, tail, and warning) work and are aimed correctly.
19. Gauges and instruments are working.
20. Lights (head, tail, and warning) work and are aimed correctly.
21. Motor runs smooth without sudden acceleration.
22. Engine runs smooth and quiet without leaks or sparks from the exhaust.
23.  Lift and lower operates smoothly without excessive drift.
24. Tilt operates smoothly without, excessive drift or “chatter”.
25. Control levers are labeled, not loose or binding and freely return to neutral.
26. Steering is smooth and responsive free of excessive play.
27. Brakes work and function smoothly without grabbing. No fluid leaks.

Forklifts must be inspected before use to ensure that they are in a safe operating condition. Inspections must be performed before each shift when they are used. This checklist provides inspection documentation.

Note:  Any items marked “Unsafe” will require repairs before use. Equipment must be tagged out.

Appendix B Calculating Load Capacity

The attached link provides basic information regarding load capacity calculations for forklifts. The information is an excerpt from Forklift Safety Guide from the Illinois Department of Commerce and Economic Opportunity – Safety and Health Consultation Program.

You may also consult your forklift manufacturer regarding instructions for calculating the load capacity for your specific equipment.

Load Capacity Calculations for Forklifts