Download - Forklift safety
![Page 1: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/1.jpg)
Forklift Safety
Draft 7 27 2011
![Page 2: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/2.jpg)
July 13, 2011
• One person died Wednesday after a forklift accident in Fluvanna County. The incident happened shortly after 5 p.m. in front of the Tapscott Brothers Lumber Company. (NC)
• The Will County Coroner's line reports that a 35 year old Aurora man was pronounced deceased at Silver Cross Hospital at 7:22 AM Wednesday morning, after a forklift accident in Mokena. The Coroner's line stated that Jose R Barrera-Ruiz died of multiple injuries.
![Page 3: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/3.jpg)
These Deaths Were Preventable• These were not isolated
incidents.
• There were 1000+ deaths in 10 Years 2000-2010.
• Workers have a right to a safe workplace.
• In the operation of forklifts these are the FIVE largest risks among many:– Falls – Hit by Falling or moving
Load– Hit by Forklift– Equipment overturning– Amputation
• All of these are preventable
![Page 4: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/4.jpg)
2010 Injury Causation Statistics• 32 falls: includes 12 pallet, platform or forks, 10 forklift went off dock, 1 ejected
from forklift, 5 fall from load lifted, 1 fall through hole, 1 order picker platform, 2 mezzanine
• 46 struck by falling/moving object or load
• 36 struck by forklift
• 15 forklift overturned
• 29 crushed or caught in forklift/load and an object
• 10 caught in amputation
• 5 burns / fire
• 3 CO, 1 Ammonia
• Type of forklift not included - many not identifying the type
![Page 5: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/5.jpg)
Injury Prevention Basics• Management Leadership
• Employee Participation
• Hazard Prevention and Control
• Education and Training
• Program Evaluation and Improvement
• Communication and coordination on multi-employer sites
• These principles are adopted and recognized by…– 2100 VPP Companies– 1600 SHARPs– 1926.20, 1926.21 – 1910.119– ANSI Z9.10– OHSAS 18001– States AR, CA, LA,
HI, MN, MT NV, NH, NY, OR, WA
![Page 6: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/6.jpg)
Falls
• Pallets used as elevating platforms has lead to many deaths and is not acceptable
• Employees use what is available
• Use proper platforms designed per ANSI/ITSDF B56.1-2005
![Page 7: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/7.jpg)
Elevating/Order Picker Truck
•Fall protection is required when the operator rides up with the load
•Use ANSI Z359 fall arrest equipment
![Page 8: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/8.jpg)
Struck-by
• What should be done?
• Many a foot have been crushed by people getting too close.
• How close is too close?
![Page 9: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/9.jpg)
Struck By
• Leaving forklift trucks without brakes or chocks
• Truck Moves
![Page 10: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/10.jpg)
Struck By
• Falling Loads KILL• Loads improperly
stored kill people.• What can be done?
![Page 11: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/11.jpg)
Struck-by
What should be done
when backing out?
![Page 12: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/12.jpg)
Accidents – Forklift Leaves Dock
• November 1, 2000• An employee was driving
a forklift truck in reverse • She backed off of the
receiving dock and was pinned under the forklift
• Operator was not wearing seatbelt and the forklift didn't have a overhead guard
![Page 13: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/13.jpg)
Overturned• Uneven surfaces
– Curbs– Potholes– Change in grade– Low tire pressure
• Seat belts• Excessive weight
lifted
![Page 14: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/14.jpg)
Is a Forklift a Crane?
Qualified rigger?• OSHA’s Construction
Crane standard may apply in construction.
• Many injuries result from dropped loads when using slings for rigging.
![Page 15: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/15.jpg)
Caught In-Between
Guarding Needed!
SHIB http://www.osha.gov/dts/shib/shib072709.html
There have been fatalities where standup type fork trucks crush the operator under cross bar of a rack system.
Body part outside frame of forklift is dangerous!
![Page 16: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/16.jpg)
Lifting/Moving the Forklift
• Is there a procedure to get forklift off?
• What is the procedure to free a stuck forklift?
![Page 17: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/17.jpg)
Truck Unloading
• Is material palletized?• Will the load stay stable
as straps are loosened? • Many times a person
adjacent to the load being removed is hit.
• Where do people stand?
![Page 18: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/18.jpg)
Lockout or Guarding?
• The person who works on the forklift must know the OSHA lockout standards.
• Any body part can be cut or crushed if caught in a scissor point.
• Forklift maintenance fatalities – employees were crushed after jack failure, or crushed between mast and frame of truck because they didn’t block it.
![Page 19: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/19.jpg)
Forklift Amputation Hazard
• Maintenance hazards:– Scissor point between
lifting carriage and mast.
– Pinch point between overhead guard and mast
• Chain and sprocket can amputate fingers.
•http://www.cdc.gov/niosh/face/stateface/ca/04ca012.html
![Page 20: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/20.jpg)
Electrical
• When working around electrical wires be aware of any potential contact (electrocution).– 20ft. safe distance from overhead lines is required by
OSHA’s crane standard (1926.1400).
• If you must use the lift closer, this must be preplanned and elements of the crane standard must be addressed in the planning.
• Triple Fatality in Illinois when a forklift contacted overhead lines in a yard. ~2003
![Page 21: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/21.jpg)
Fire / Burns
• The employee and the forklift were dowsed in toluene.
• The toluene ignited from an unknown source prior to the employee leaving the lift seat.
• The employee was severely burned. • The truck was a destroyed. • What could be done to prevent this?
Forklift strikes overhead pipe containing Toluene.
![Page 22: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/22.jpg)
Many people trust these machines
![Page 23: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/23.jpg)
Sample Safety Rules
• Follow Manufacturer’s instructions and OSHA regulations. Use ANSI/ITSDF B56 standards on forklifts if you cannot get the manufacturer’s rules.
• Follow CAUTION WARNING DANGER Labels. • Prohibit untrained personnel from operating all
forklifts.• A trained person must inspect each forklift at
least daily before use.• And many more!
![Page 24: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/24.jpg)
Training• Hands on training is
necessary. A forklift is not a car.
• The worker must be able to demonstrate – safe operation in their
workplace – follow each forklift
manufacturers’ usage instructions.
BEFORE CERTIFICATION
![Page 25: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/25.jpg)
•Initially
•Every 3 years
•Near Miss
Certification and Re-certification
![Page 26: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/26.jpg)
Evaluation
•Date of Certification
•Operator’s name
•Trainer’s Name
![Page 27: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/27.jpg)
![Page 28: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/28.jpg)
Inspections
Per manufacturer’s guidelines. • At least daily before use.• Check all working components and safety
device.• Address all leakage of fluids.• Search for defective hydraulic/pneumatic
hoses.• Look for quickfix signs (not acceptable)
i.e. electrical tape, rags tied on hoses…
![Page 29: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/29.jpg)
Inspections
Why is this inspection form weak?
![Page 30: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/30.jpg)
Manufactured Attachment
NOTE: Use of such an attachment changes the load capacity of the PIV
DANGER: Manufacturer’s Written Approval Required
![Page 31: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/31.jpg)
• Barrel lifter (liquid = inertia)
• Capacity plate update required?
• Don’t forget unapproved attachments can overload the trucks.
DANGER: Manufacturer’s Written Approval Required
Manufactured Attachment
![Page 32: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/32.jpg)
Lifting Slabs
• Many injuries have occurred while lifting large flat objects
• Use lifting attachments designed and approved for each specific job.
• ANSI B30.20
![Page 33: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/33.jpg)
Seatbelts
• Must be worn when equipped.
• Prevent the operator from being pinned by the truck or overhead guard.
Click for rollover video
![Page 34: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/34.jpg)
Inspection
Labels• Ensure that
capacities for attachments are listed
![Page 35: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/35.jpg)
Inspection
• Load Backrest Extension is damaged
![Page 36: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/36.jpg)
Inspection
• How much wear is acceptable?
![Page 37: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/37.jpg)
Forklift Inspections
• Overhead guard improperly welded
![Page 38: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/38.jpg)
Forklift Inspection
• Broken Fiberglass Housing is a Laceration Hazard
![Page 39: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/39.jpg)
Inspection
• Leaking Hydraulic Fluid
• Can lead to: – Low pressure– Air bubbles– Erratic operation– Slippery surfaces
![Page 40: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/40.jpg)
Personnel Elevating Platforms
• Good Platform must include guardrails
• Secure the platform to the forklift.
• Screen at forklift side
![Page 41: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/41.jpg)
Personnel Elevating PlatformsOSHA 5(a)(1) Violations
– ANSI/ITSDF B56.1-2005:
• No screen (scissor point)• Cannot be secured to
forks or backrest
![Page 42: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/42.jpg)
Emergency Response
• What is the response if the drum contains flammable or toxic liquid?
![Page 43: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/43.jpg)
Fire
• Cylinder gases ignited by forklift.
• What can be done?
![Page 44: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/44.jpg)
Carbon Monoxide
0222 HCOOHC xx
Perfect World:
Real World:
xxxxx HCNOCOOHCONOHC 2222
![Page 45: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/45.jpg)
Acute Exposure
• Headache• Nausea• Weakness• Irritability• Chest Pain • Unconsciousness
![Page 46: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/46.jpg)
Chronic Exposure
• Headache• Dizziness• Anorexia• Ataxia• Confusion
![Page 47: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/47.jpg)
Best Practice and Required in MNGeneral industry: Minnesota Rules § 5205.0116 Carbon Monoxide Monitoring
• Subpart 1. Internal combustion engine powered industrial trucks. The employer shall monitor environmental exposure of employees to carbon monoxide whenever internal combustion engine powered industrial trucks as defined in Code of Federal Regulations, Title 29, section 1910.178(a)(1) are operated indoors to ensure that carbon monoxide levels do not exceed those given in Code of Federal Regulations, Title 29, section 1910.1000, Table Z-1-A.
The air monitoring shall be done at least quarterly and represent exposures during a day of highest usage in the areas where employee carbon monoxide exposure is most likely.
• Subpart 2. Tailpipe exhaust gas analysis. The employer shall ensure that powered industrial truck engine exhaust gases do not contain more than one percent carbon monoxide for propane fueled trucks or two percent carbon monoxide for gasoline fueled measured at idle and at three-fourths throttle during final engine tuning in a regular maintenance program.
![Page 48: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/48.jpg)
Exposure Limits
• OSHA 50 ppm 8-hour Time Weighted Average (TWA)
• NIOSH 35 ppm 8-hour TWA
• 200 ppm Ceiling by NIOSH
• ACGIH Threshold Limit Value is 25 ppm 8-hour TWA; 40-hour work week
![Page 49: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/49.jpg)
PPM CO Time Symptoms
200 2-3 hours Headache, fatigue, nausea.
400 1-2 hours Symptoms intensify. Life threatening after 3 hours.
800 45 minutes
Dizziness, nausea, convulsions. Death after
2-3 hours.
1600 20 minutes
Dizziness, nausea, convulsions. Death within
1 hour.
![Page 50: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/50.jpg)
ACGIH Recommendations
• Limit CO concentration to 1% or less for propane fueled trucks
• Limit CO concentration to 2% or less for gasoline fueled trucks.
![Page 51: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/51.jpg)
Forklift Exhaust Test
• No Violation – Forklift emits low
level of CO
![Page 52: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/52.jpg)
Prevention of CO Poisoning
• Maintain equipment in good working order
• Provide periodic tune-ups for forklifts to ensure that they run “lean”
• Periodic CO analysis of exhaust gases to determine emission concentrations
• Provide adequate ventilation• Install CO monitors
![Page 53: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/53.jpg)
Storage
• What is the problem and solution?
![Page 54: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/54.jpg)
Storage
• No Violation– Material stored
properly in racks
![Page 55: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/55.jpg)
Material Handling
• Rack was hit by forklift and tagged out and pallets removed.
![Page 56: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/56.jpg)
Material Handling
• No Violation– Aisle properly
marked
– Smooth Clean lanes
![Page 57: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/57.jpg)
Struck By
• No Violation– Corner marked so
forklift operation can see around corner
![Page 58: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/58.jpg)
Cautions
• Watch for any holes. These will flip some forklifts. These should be identified in advance and plans to prevent a forklift from going into one is necessary.
• Watch for aerial lifts and other mobile equipment. Barricade the equipment to prevent contact with each other.
![Page 59: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/59.jpg)
Quiz
• How often does a forklift driver have to be re-evaluated/certified? __________
• Forklifts must be inspected every ________ before use.
• OSHA’s limit for Carbon Monoxide in an 8 hour shift is ____ ppm.
![Page 60: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/60.jpg)
Resources
• www.osha.gov• Compliance Assistance Specialists in OSHA
offices• On-site Consultation• Quick Takes
http://www.osha.gov/as/opa/quicktakes• www.aiag.org Pedestrian & Vehicle Safety
Guidelines Comments or Corrections go to John Newquist
![Page 61: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/61.jpg)
What is the pending hazard?
![Page 62: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/62.jpg)
Summary
Training
Job Hazard Analysis
Written procedures
Manufacturer rules
Inspections
![Page 63: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/63.jpg)
Further
• This ppt was prepared by John Newquist as a preliminary aid for people required to evaluate forklifts.
• Thanks to Misette Kobler, Carlos Gallegos and Janet S., for corrections and suggestions.
• Thanks to Joe Schwarz, Marc Snitzer, Walter Visage, Rick Dvorak, Cynthia Evans, Aaron Priddy, for previous work on the topic.
• This is not an official OSHA publication. Those will be on the OSHA.gov website.
• [email protected] is my email if you see any errors. This is just a draft as of the cover date.
• 312-353-5977
![Page 64: Forklift safety](https://reader030.vdocuments.mx/reader030/viewer/2022012906/5555c165d8b42afe5d8b52fd/html5/thumbnails/64.jpg)
Wage & Hour Referral
• No one under 18 allowed on a PIT
“Order 7 of Hazardous Occupations” prohibits employees under 18 years of age from operating forklifts, employers must make certain that workers under 18 years of age are not permitted to use PIT’s.