Forklift Safety

Draft 7 27 2011

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.

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

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

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

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

Elevating/Order Picker Truck

•Fall protection is required when the operator rides up with the load

•Use ANSI Z359 fall arrest equipment

Struck-by

• What should be done?

• Many a foot have been crushed by people getting too close.

• How close is too close?

Struck By

• Leaving forklift trucks without brakes or chocks

• Truck Moves

Struck By

• Falling Loads KILL• Loads improperly

stored kill people.• What can be done?

Struck-by

What should be done

when backing out?

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

Overturned• Uneven surfaces

– Curbs– Potholes– Change in grade– Low tire pressure

• Seat belts• Excessive weight

lifted

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.

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!

Lifting/Moving the Forklift

• Is there a procedure to get forklift off?

• What is the procedure to free a stuck forklift?

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?

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.

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

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

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.

Many people trust these machines

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!

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

•Initially

•Every 3 years

•Near Miss

Certification and Re-certification

Evaluation

•Date of Certification

•Operator’s name

•Trainer’s Name

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…

Inspections

Why is this inspection form weak?

Manufactured Attachment

NOTE: Use of such an attachment changes the load capacity of the PIV

DANGER: Manufacturer’s Written Approval Required

• 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

Lifting Slabs

• Many injuries have occurred while lifting large flat objects

• Use lifting attachments designed and approved for each specific job.

• ANSI B30.20

Seatbelts

• Must be worn when equipped.

• Prevent the operator from being pinned by the truck or overhead guard.

Click for rollover video

Inspection

Labels• Ensure that

capacities for attachments are listed

Inspection

• Load Backrest Extension is damaged

Inspection

• How much wear is acceptable?

Forklift Inspections

• Overhead guard improperly welded

Forklift Inspection

• Broken Fiberglass Housing is a Laceration Hazard

Inspection

• Leaking Hydraulic Fluid

• Can lead to: – Low pressure– Air bubbles– Erratic operation– Slippery surfaces

Personnel Elevating Platforms

• Good Platform must include guardrails

• Secure the platform to the forklift.

• Screen at forklift side

Personnel Elevating PlatformsOSHA 5(a)(1) Violations

– ANSI/ITSDF B56.1-2005:

• No screen (scissor point)• Cannot be secured to

forks or backrest

Emergency Response

• What is the response if the drum contains flammable or toxic liquid?

Fire

• Cylinder gases ignited by forklift.

• What can be done?

Carbon Monoxide

0222 HCOOHC xx

Perfect World:

Real World:

xxxxx HCNOCOOHCONOHC 2222

Acute Exposure

• Headache• Nausea• Weakness• Irritability• Chest Pain • Unconsciousness

Chronic Exposure

• Headache• Dizziness• Anorexia• Ataxia• Confusion

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.

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

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.

ACGIH Recommendations

• Limit CO concentration to 1% or less for propane fueled trucks

• Limit CO concentration to 2% or less for gasoline fueled trucks.

Forklift Exhaust Test

• No Violation – Forklift emits low

level of CO

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

Storage

• What is the problem and solution?

Storage

• No Violation– Material stored

properly in racks

Material Handling

• Rack was hit by forklift and tagged out and pallets removed.

Material Handling

• No Violation– Aisle properly

marked

– Smooth Clean lanes

Struck By

• No Violation– Corner marked so

forklift operation can see around corner

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.

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.

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

What is the pending hazard?

Summary

Training

Job Hazard Analysis

Written procedures

Manufacturer rules

Inspections

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.

• Newquist.john@dol.gov is my email if you see any errors. This is just a draft as of the cover date.

• 312-353-5977

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.