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Forklift Safety – Overhead Guards

May 14, 2012

The overhead guard protects a lift truck operator from falling loads. Overhead guards for lift trucks categorized as Class I, II, IV and V must meet the Falling Object Protection (FOP) requirement. In addition to the FOP standards, Class VII rough terrain lift trucks with side operator cab locations must meet the Roll Over Protection (ROP) standard.

It is important to understand overhead guards are not designed to take the impact of a full capacity load dropped from an elevated height. Some overhead guards are designed to “crush and deflect.” While they protect the operator from partial or small loads, when heavy loads impact the overhead guard the leg receiving the heaviest impact is designed to crush and deflect the load to one side.

ANSI (American National Standards Institute) does not test deflection capability but does test crush or maximum deformation. A bundle of lumber of a certain weight and size is the designated test load. The load is dropped from a specified height and the overhead guard must maintain minimum distances between the seat and steering wheel.

Welding an overhead guard is not an acceptable repair and additions to overhead guards such as brackets for inventory control equipment, radios, weather protection or lights should be mounted by clamp brackets or other methods approved by the manufacturer. The design and testing of overhead guards helps to better understand why damages such as a crack in the weld, loose or missing mounting bolt or bent legs are safety concerns and result in the replacement of the overhead guard.

Click here to learn OSHA’s overhead guard requirements and recommended practices.

To discuss the replacement of your lift truck’s overhead guard, contact ProLift to speak to a consultant today.

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Forklift Safety – Mast Assemblies

March 9, 2012

If a forklift mast has sufficient structural strength to lift a pallet of brick, what could it do to an arm or leg? A forklift mast, whether loaded or unloaded, can claim limbs or a life if risks are not understood. Accident prevention much be put into effect.

OSHA CFR 19010.178(m)(4) states: The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck.

It can be said an accident with a forklift mast is worse than losing a limb to a guillotine because at least a guillotine has a sharp edge. A mast assembly can destroy muscle and crush bone, leaving nothing for a doctor to repair or save.

For a technician, getting a service call regarding a mast jammed or stuck in an elevated position should be approached with extreme caution. He/she should use hard wood blocks first and then safety chains, keeping his/her distance as much as possible. Hooked pry bars, wedge bars and locking pliers can assist in placing safety chains so arms are kept out of the mast assembly. As an extra precaution park forklifts with the forks and carriage elevated over the top of a sufficient structure to stop a mast from suddenly dropping.

The design of some smaller forklifts (i.e. stand-up lifts) place the operator within reach of the forklift mast. As operators move an unstable load, the temptation exists to reach through the mast assembly and stabilize the shifting load. Pre-shift examinations and hose/chain inspections also tempt an operator to reach in for a closer hands-on review.

Education & Prevention

The hazards of forklift mast assemblies are real. The resulting injury can be devastating or fatal. While walking through your manufacturing or warehouse operation, watch for dangerous practices such as reaching through or being under a mast assembly. Be explicit with operators this is strictly prohibited for their safety. Ensure all service repairs are made by authorized personnel only and educate your forklift operators about the reality of the hazards when using unsafe practices.

Need help with forklift service and repair? Click here to learn more about ProLift’s capabilities. We can also assist you with forklift operator training.

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Forklift Safety: Can You Remove the Forklift’s Load Backrest?

January 12, 2012

The load backrest can be the highest point of the forklift. Trailer tops, rack systems, lights, HVAC, sprinkler systems and other overhead obstructions come in contact with load backrests.

If an object above the forklift gets hit, do you blame the load backrest … or the operator?
To put another spin on this question, if a co-worker said “I keep backing into things with the bumper on my pick-up truck”, would you suggest removing the bumper? Or would you mention to your co-worker that he or she needs to be more alert to hazards near the pick-up truck?

Many times the answer to a customer’s question about removing the load backrest is “Yes, remove it and remind your forklift operators to be careful.” But, this is not an accurate answer representing OSHA’s code of federal regulations? (*See below)

The answer is a conditional “yes”. All loads handled by the forklift and the facility it operates within must meet one of the requirements below:

1) All loads do not go higher than the top of the forks.

2) All loads are one piece, shrink wrapped, banded or crated.

3) No loads in the facility are stacked or racked higher than the operator’s head that does not meet the load requirements above. Lift trucks with the load backrest removed must be restricted to handling only loads meeting the requirements above or is restricted to a specific area of the facility that does not contain any loads presenting a hazard.

Provide safe operations while meeting OSHA requirements
Forklift manufacturers offer various heights for the load backrest. When selecting a lift truck, research the warehouse application and the heights of loads to purchase load backrests that meet rather than exceed the requirements. The proper load backrest will provide protection for the forklift operator while reducing the possibility of product and facility damage.

Other solutions include shrink wrapping or banding the loads and restricting a forklift with a removed load backrest to specific areas (i.e. the dock for loading and unloading trailers).

Do you have employees in need of lift truck safety training or pedestrian awareness? Contact ProLift to discuss available training and dates.

* Federal Regulations
OSHA CFR1910.178(e)(2)
Safety Guards: If the type of load presents a hazard, the user shall equip fork trucks with a vertical load backrest extension.

OSHA CFR1910.178(m)(10)
Truck Operations: A load backrest extension shall be used whenever necessary to minimize the possibility of the load or part of it from falling rearward.

OSHA CFR1910.178(q)(6)
Maintenance of Industrial Trucks: Industrial trucks shall not be altered … either by the addition of extra parts … or by the elimination of any parts.

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Forklift Safety: Who Has the Right of Way?

With a weak economy and consumer confidence low, companies are closely watching revenue and profit margins. The few companies that are experiencing growth are holding off on non-essential costs such as building expansions or moving to larger facilities.

More work is being accomplished in tighter areas … that means forklifts and pedestrians are in closer proximity.

This is an increasing problem with dire consequences. Statistically, a forklift operator is more likely to kill a co-worker than themselves in an accident (NIOSH Statistics). This statement makes sense when you consider the scenario: A forklift operator is sitting on an average-sized machine (9,000 lbs) inside a sturdy metal cage and carries a heavy load at top speeds of 6-12 mph. The pedestrian is unprotected and vulnerable.

OSHA states the pedestrian has the right of way; therefore, operators must be on constant alert. The forklift operator is required to slow down and sound their horn at doorways, intersections, blind spots and when entering or exiting a building. Approaching a pedestrian requires the operator to slow down and sound the horn. If the attention of the pedestrian is not achieved, the operator should stop the forklift.

Technology has increased the safety risk. The use of blue tooth phone devices and MP3 players with ear buds drown out the sound of an approaching forklift. The popularity of cell phone texting also reduces the awareness of both operators and pedestrians.

A warehouse has various “Red Zones” that involve pedestrians and forklifts. These include an elevated load, which allows a pedestrian to walk underneath. A pedestrian may also walk onto the dock or into a trailer while the forklift operator is loading or unloading product. The use of a forklift with a racking system offers a plethora of hazards such as blinds spots and falling loads.

Overhead and rear view mirrors, alarms and flashing beacons are safety accessories that help reduce pedestrian injury. Marked walkways and restricted access areas, designated forklift traffic lanes, hand rails to limit access to risk areas and use of man doors instead of overhead doors are excellent efforts toward a safe working environment for pedestrians.

Be proactive!
Nothing takes the place of educating both the forklift operator and the pedestrian about the risks of working in a warehouse. For example, pedestrians rarely understand a typical warehouse forklift weighs as much as three empty automobiles – and this does not include the weight of the load.

Completing a walk-around of the company warehouse allows the opportunity to find hazards and create solutions to reduce the chance of a forklift and pedestrian accident. It is also an outward sign to employees that the company is committed to the greater good – a safer work environment.

Do you have employees in need of lift truck safety training or pedestrian awareness? Contact ProLift to discuss available training and dates.

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Forklift Safety: Trash on the Floor – Big Deal!

Lift trucks are used in various environments. They are exposed to shrink wrap, banding materials and other debris from the manufacturing and warehouse process.

Is housekeeping important to the safe and proper operation of a powered industrial truck? … Yes!

OSHA CFR1910.143(a)(3) Housekeeping.
All places of employment shall be kept clean to the extent that the nature of the work allows.

If plastic banding material can hold a 3,000 lb load together, imagine what it can do to brake lines, park brake systems, steering systems and axle seals and bearings when tightly wrapped around the wheels and axles of an operating lift truck!

Ground clearance of lift trucks is generally kept to a minimum for stability concerns. This makes it easy for materials on the floor to get caught in rotating assemblies. The cooling systems are designed to pull air off the floor underneath the truck, push the air through the radiator and out the back of the truck. This creates a “vacuum effect” that sucks debris (i.e. shrink wrap and dust) into the mechanisms and radiator of the lift truck. This can cause damage and overheating.

OSHA CR1910.178(q)(9) basically states it is illegal to operate an overheating lift truck. Why? When overheating, the lift truck does not meet UL classification. It can become a source of ignition for other materials or a fire hazard itself.

Serious or fatal accidents can also be the result of a lift truck damaged by floor debris. It takes only one piece of banding to compromise the brake or steering systems. Operators can lose control of heavy equipment, possibly costing someone their life.

It is important to promote housekeeping within your warehouse. The removal of floor debris hazards matters to everyone’s safety.

Do you have operators in need of lift truck safety training? Contact ProLift to discuss available training and dates.

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Forklift Tip-Over: Buckle Up!

December 9, 2011

The sole purpose of seatbelt use on a forklift is not for front-end collisions. The number one cause of counterbalanced forklift operators going to the morgue instead of home to supper with their families is tip-over accidents. On average 100 people lose their lives each year working on, or around forklifts, and almost half of those casualties are tip-over accidents. Engineering, accident statistics, eye-witness, and first-hand accounts tell us that if an operator stays inside the overhead guard area in the seat of the truck, his or her chances of survival (or at least reducing the severity of injury) increase.

The seat belt is first and foremost designed to keep you in the seat in case of tip-over. Normal human behavior says “jump” when the forklift starts to tip. In that split second needed to make a decision, two things motivate you in the wrong direction. First, momentum is throwing you to the low side of the machine (direction of tip). Secondly, in your mind, ground means safety, and the ground is closest on the low side (direction of tip). The problem is you can’t get away from the machine fast enough, and the overhead guard crushes you at the head, neck, shoulders, or chest.

Furthermore, you need to keep your hands and feet inside the confines of the forklift and overhead guard. Humans have another peculiar habit; as the machine tips, we stick our arms and legs out toward the direction of the tip as if to magically stop the 9,000 lb forklift from tipping over – doesn’t work unless you are Superman with a capital “S” on your chest.

To survive a tip-over accident, do the following:

1) Put on the seat belt every time you operate a truck. Adjust the seatbelt as needed.

2) Push hard against the steering wheel and brace your feet firmly into the floorboard on the machine, which will firmly plant you in the seat.

3) Place both hands on the steering wheel, lean forward, and use the steering wheel as upper body support.

4) Always lean away from the point of impact. For example, if the forklift is tipping left, lean right.

Be a Superman or Superwoman to your family! Remember these tips and make it home safely from work every single day.

Interested in forklift operator safety training? Our trainer will review forklift tip-over and other safety factors during a 4-hours classroom and hands-on training course. Contact ProLift to schedule your operators.

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Lift Truck Safety – Should You Have an In-House Trainer?

October 21, 2011

Every company using forklifts or aerial equipment is responsible for providing operator safety training to keep in compliance with federal law. When developing a safety plan for your company and its lift truck operator, the first decision to make for your company is whether to have an in-house trainer or outsource the training to a specialist. Having an in-house trainer may seem like an easy solution; however, there are potential pitfalls to consider.

When your company is able to dedicate a full-time employee to training, having an in-house trainer can be a good fit. As an employee of the company, he or she is familiar with the culture, equipment, products, site-specific hazards and accident history. Another advantage can be the flexibility of scheduling training for new hires, ensuring operators attend the training prior to using equipment.

If your in-house trainer’s primary responsibility isn’t forklift or aerial equipment safety training, consider how to address these pitfalls and if your company should outsource the operator training.

Trainer Availability
An in-house trainer that is responsible for other roles in the company may not have the flexibility needed to keep operators in compliance. For example, if a new hire starts, can he or she complete training prior to the employee operating equipment? Can time be allocated to tracking employees for refresher training? Will accidents and near-misses be addressed timely with operators and/or management?

Trainer Effectiveness
Your in-house trainer has ownership for keeping your employees safe. Doing so means engaging the operators and helping them to understand the importance of safe operation. Are his or her presentation skills effective for adult learners? Does he or she hesitate to challenge co-workers or current operations? Are his or her personal experiences shared and relatable?

Trainer Knowledge
The federal law is a large amount of information to digest and interpretations can vary. Your in-house trainer will be relied on to provide guidance to your company and operators to keep in compliance. How familiar with the laws is your in-house trainer? Is he or she a fast learner and comfortable using the internet as a resource? Does he or she have hands-on experience with the company’s equipment?

Trainer Materials
Materials used during training are important and must be as effective as the trainer. Using a variety of visuals will keep training fresh and easy to understand. Does he or she have a variety of tools such as a presentation, videos, models and pictures? Are operators provided with booklets containing the information and an area for notes? Is he or she providing recent articles related to OSHA, ANSI and lift truck safety? Are wallet cards and other documentation provided after the training?

Trainer Support
An in-house trainer must have management support to implement and enforce safety measures. Without support, the efforts are dismissed and inevitably trainer burn-out will occur. Can your in-house trainer communicate big picture needs with management? Are safety concerns quickly addressed? Does management support scheduling dates for training and allocate budget funds for safety hazards?

If you conclude your company does not have the needed time, management support or resources for an in-house trainer, many lift truck dealers or training companies can provide this service. Hiring a specialist also brings a level of expertise, acting as a credible source that can help support the training efforts your company made if an accident does occur. Based on the number of lift truck operators, type of equipment and other factors, a training specialist can find the class to best fit your needs.

Currently have a need for forklift or aerial lift safety training?

Learn more about ProLift’s class options – forklift training, aerial lift training and pedestrian awareness.

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Safety Accessories for Your Forklift

September 23, 2011

A forklift operator has a responsibility to be aware of pedestrians and other operators. In a busy warehouse this is not an easy task. To help keep their employees safe, many companies are investing in safety accessories for their forklifts, such as mirrors, back-up alarms, strobe lights and fire extinguishers.

Mirrors are affordable, easy to install and can be placed either indoors or outdoors. A benefit of having a mirror for a forklift operator is the decrease in physical strain on the body and neck as he or she attempts to watch all sides of the path. Most importantly, the wide angle views and capability to see blind spots can prevent a collision with other forklifts and pedestrians.

Back-up alarms are installed to alert others that a forklift is near, adding a sound dimension beyond the forklift’s horn. If the level of noise varies in the work environment, a “smart alarm” option gives flexibility by listening to the surroundings and adjusting the decibel level accordingly. Although the option is not required by federal law, if the forklift is manufactured with a back-up alarm it must be kept in working condition and never disconnected.

Strobe lights are flashing lights used as a visual cue to pedestrians and other operators that a forklift is approaching. To be effective, the strobe light must be seen by workers and like the back-up alarm, it must be kept in working condition if the forklift is manufactured with the option.

Fire extinguishers are not a required feature on a forklift; however, the work environment is the key factor when determining its placement. Forklifts can be considered a source of ignition. If the work environment includes flammable material, it provides the forklift operator additional protection.

When placed in the proper warehouse atmosphere, safety accessories can be effective for accident prevention; however, they should never replace the use of horns, spotters or areas restricted to pedestrian traffic. And because an accessory is only as effective as the person using it, advantages of using the safety accessory should be stressed to those conducting pre-shift forklift inspections and operating the forklift.

Think a safety accessory is right for your forklift and warehouse application? Answer our 11 questions to learn the best accessory to put in place or click here to review our online product catalog.

11 questions to ask when considering safety accessories:

Could a safety accessory have prevented a recent accident?
Are blind spots prevalent throughout the warehouse or in a specific area?
Have operators complained of neck strain?
Do operators frequently forget to sound the forklift’s horn?
Is the warehouse well lit?
Are forklifts used primarily in daylight?
Is the warehouse very large or small, causing sounds to be distant or overwhelming?
Is the warehouse naturally noisy?
Would a back-up alarm potentially cause hearing loss?
Are forklifts operated near flammable materials?
Were the forklifts manufactured with a safety accessory?

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The Basics of a Pre-Shift Lift Truck Inspection

September 9, 2011

When attending a lift truck safety class, there is a lot of focus placed on preventative measures. While attention is expected to be placed on the operator and his or her skills, your company must also emphasize the importance of equipment pre-shift inspection and maintenance.

Pre-shift inspections are required by federal law CFR1910.178(q)(7). ^(*) It states “Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily. Where industrial trucks are used on a round-the-clock basis, they shall be examined after every shift. Defects when found shall be immediately reported and corrected.”

Inspections can be completed by the lift truck operator or other personnel. The person conducting the pre-shift inspection should receive training on how to complete it and be familiar with information found in the operator’s manual and any site specific policies required by the employer.

Every shift requires a pre-shift inspection. The person charged with inspection must visually and operationally inspect the machine for safe and proper operation. If a defect is found with a lift truck, it must be tagged and placed out of service until repaired by authorized personnel.

If a unit failure causes an accident resulting in a serious injury or fatality, OSHA will ask if pre-shift inspections were carried out properly. Although paper or electronic documentation is not required by federal law, it is a great assistance proving compliance with pre-shift inspection.

The compliance of a daily pre-shift inspection can be your answer to knowing what repairs lie ahead for your lift truck, allowing you to budget for repairs. Most importantly, it will prevent accidents caused by mechanical failure and keep your employees safe.

Looking for a pre-shift inspection form?
Click here to download complimentary pre-shift inspection forms for your lift truck fleet. Options include forms for electric forklifts, LP forklifts, gas/diesel forklifts, reach trucks, order pickers, electric pallet trucks and aerial lift equipment.

^(*) OSHA Letters of Interpretation regarding CFR1910.178(q)(7)

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Personal Protective Equipment – Inspect to Protect

July 7, 2011

If your company uses aerial work platforms, you know it can be a challenge to enforce the proper safety practices. Couple this with a low level of understanding in how to inspect the equipment and you now have the potential of safety violations or a serious accident at your facility.

Training operators to inspect their PPE before every use may prevent a fatal accident. Review of the PPE should include an inspection of the belt and body harness as well as the lanyard. If you find any of these conditions during the inspection, do not use the equipment.

Belts & Body Harnesses:

Thoroughly inspect all nylon webbing on belt/body harnesses for frayed edges, broken fibers, burn marks, deterioration or other visible signs of damage.
Ensure buckles and “D” rings are not distorted or damaged. Look closely at all components for stress cracks, deformity, gouging, corrosion and sharp edges. Inspect connection points where the buckle or “D” ring is attached to the belt or body harness. Check that no stitching is pulled and the buckle or “D” ring is securely attached.
Inspect all rivets and grommets to be certain they are not deformed, are securely fastened to the belt or body harness and cannot be pulled loose.

Lanyards:

Check the entire length of the lanyard. Look for cuts, fraying, deterioration, knots, kinks, burns or visible signs of damage. Ensure the lanyard is somewhat “soft” and not stiff from dirt or contaminants.
Snap hooks and eyes should not be distorted or bent. Inspect them for cracks, sharp edges, gouges or corrosion. Be certain the locking mechanism is operating properly and there is no binding of the mechanism.
If using a shock absorber type of lanyard, it should not be too long when extended to allow an operator to travel outside the confines of the handrails. Look for the warning tag which indicates the lanyard has been exposed to a fall.

To learn more, view these additional resources:

Statement of Best Practices of Personal Fall Protection Systems for Aerial Work Platform Equipment

OSHA Regulations
1926.451
1926.452
1926.453

ANSI

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