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You are here: Home / Equipment / Forklifts / 28 Forklift Safety Tips for Operators, Pedestrians, and Managers
28 Forklift Safety Tips for Operators, Pedestrians, and Managers

Updated May 17, 2022

28 Forklift Safety Tips for Operators, Pedestrians, and Managers

This article is all about forklift safety tips to help keep operators, pedestrians, and workers safe.

Why is forklift safety important?

Because forklifts account for 10% of injuries in the workplace.

So knowing how to work safely with and around them is key to reducing worker injuries and fatalities.

Without further ado, let’s dive in!

Table of Contents Expand
  • Know Your Responsibilities
  • Conduct Proper Operator Training
  • Install and Maintain Safety Guards
  • Do Not Modify Your Fork Truck
  • Use Proper Lighting
  • Install Gas Detectors
  • Use Care When Loading and Unloading Trailers
  • Inspect Before Operating
  • Keep Up on Maintenance
  • Know How to Safely Dismount a Tipping Lift Truck
  • Install an Operator Restraint System
  • Don't Speed
  • Handle Loads Properly
  • Keep a Clear Line of Sight
  • Look Out for Pedestrians
  • Separate Foot and Forklift Traffic
  • Do Not Allow Passengers
  • Use the Right Equipment to Elevate Workers
  • Ascend and Descend Ramps Properly
  • Secure Unattended Forklifts
  • Keep Your Equipment Clean
  • Follow Safe Refueling Procedures
  • Never Walk Under Elevated Forks
  • Keep Your Work Environment Clean, Clear, and In Good Repair
  • Do Not Run Over Debris
  • Be Mindful of the Hazards of Your Fork Truck
  • Never Exceed the Rated Capacity
  • Don't Talk and Operate

1. Know Your Responsibilities

Maintaining and improving forklift safety is up to the efforts of multiple different parties.

And each has its own responsibilities.

Let’s briefly go through them:

Employers, Supervisors, and Managers

These individuals should:

  • Create a comprehensive written forklift safety training program
  • Ensure all operators receive proper forklift safety training
  • Place only experienced and competent staff in supervisory roles
  • Monitor employees for compliance with safety rules and protocols
  • Make employees aware of potential hazards
  • Continually identify ways to improve safe operations in the workplace
  • Abide by all government regulations and company policies

Forklift Operators

What are the duties and responsibilities of a forklift operator?

Here are some of the key ones:

  • Complying with all government regulations and company policies
  • Wearing proper personal protective equipment (PPE) when working with hazardous substances like fuel and batteries
  • Reporting any equipment defects to supervisors for correction
  • Working safely at all times than doesn’t endanger themselves, coworkers, or the facility

2. Conduct Proper Operator Training

Quality forklift training is the single best way to improve forklift safety.

In fact, OSHA estimates that 70% of errors can be prevented by properly training operators!

A forklift trainer teaching a class with a slideshow presentation
Quality operator training is the best way to improve forklift safety

So what goes into “proper forklift training?”

Overall, OSHA requires that employers provide:

  • Formal instruction: This includes classroom-based lessons that cover all 22 forklift safety topics listed in standards 1910.178(l)(3)(i) and 1910.178(l)(3)(ii)
  • Hands-on training and evaluation: This is where a qualified instructor demonstrates how to operate a forklift and observes students doing so
  • Certification: This is where the operator trainee is observed using the forklift in the actual workplace

But training doesn’t stop there.

OSHA also mandates that employers provide refresher training at least every 3 years.

And if operators are observed doing something unsafe, or if workplace conditions change, you’ll have to provide refresher more often.

Relevant OSHA Standards Expand
  • OSHA: "It is a violation of Federal law for anyone UNDER 18 years of age to operate a forklift or for anyone OVER 18 years of age who is not properly trained and certified to do so."
  • 1910.178(l)(1)(i): The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph (l).
  • 1910.178(l)(1)(ii): Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the training required by this paragraph (l), except as permitted by paragraph (l)(5).
  • 1910.178(l)(2)(ii): Training shall consist of a combination of formal instruction (e.g., lecture, discussion, interactive computer learning, video tape, written material), practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator's performance in the workplace.
  • 1910.178(l)(2)(iii): All operator training and evaluation shall be conducted by persons who have the knowledge, training, and experience to train powered industrial truck operators and evaluate their competence.
  • 1910.178(l)(4)(ii): Refresher training in relevant topics shall be provided to the operator when:
  • 1910.178(l)(4)(ii)(A): The operator has been observed to operate the vehicle in an unsafe manner;
  • 1910.178(l)(4)(ii)(B): The operator has been involved in an accident or near-miss incident;
  • 1910.178(l)(4)(ii)(C): The operator has received an evaluation that reveals that the operator is not operating the truck safely;
  • 1910.178(l)(4)(ii)(D): The operator is assigned to drive a different type of truck; or
  • 1910.178(l)(4)(ii)(E): A condition in the workplace changes in a manner that could affect safe operation of the truck.
  • 1910.178(l)(4)(iii): An evaluation of each powered industrial truck operator's performance shall be conducted at least once every three years.
  • 1910.178(l)(6): Certification. The employer shall certify that each operator has been trained and evaluated as required by this paragraph (l). The certification shall include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation.

3. Install and Maintain Safety Guards

Wondering what safety guards do forklifts have?

The answer is that the main ones are the overhead guard and load backrest.

OSHA requires that forklifts have an overhead guard installed.

The overhead guard on a Toyota 8FGCU25 forklift
Forklifts must have an overhead guard installed to protect operators from falling objects

These protect the operator from falling objects.

You should regularly inspect your overhead guards for defects like unauthorized holes and dents.

When found, the truck should be placed out of service until the guard is replaced.

A load backrest is also required by OSHA when there’s a hazard of the load falling backward.

A load backrest on a Toyota 8FGCU25 forklift
A load backrest helps prevent the load from falling backward onto the lift truck

This safety guard helps to keep the load in place.

But often, operators will remove the load backrest.

The reason is usually so they can access higher levels without hitting the ceiling.

But this can increase the chances of items falling off the load.

So whenever possible, keep the load backrest installed for added security.

Relevant OSHA Standards Expand
  • 1910.178(e)(1): High Lift Rider trucks shall be fitted with an overhead guard manufactured in accordance with paragraph (a)(2) of this section, unless operating conditions do not permit.
  • 1910.178(e)(2): If the type of load presents a hazard, the user shall equip fork trucks with a vertical load backrest extension manufactured in accordance with paragraph (a)(2) of this section.
  • 1910.178(m)(9): An overhead guard shall be used as protection against falling objects. It should be noted that 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.
  • 1910.178(m)(10): A load backrest extension shall be used whenever necessary to minimize the possibility of the load or part of it from falling rearward.

4. Do Not Modify Your Fork Truck

If you’re thinking of making modifications to your forklift yourself - STOP!

Unauthorized modifications violate OSHA’s rules, which state:

Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation, and maintenance instruction plates, tags, or decals shall be changed accordingly.

OSHA Standard 1910.178(a)(4)

One particularly worrisome modification that we sometimes see is drill holes in the overhead guard.

A forklift overhead guard with drill holes
Unauthorized drill holes in an overhead guard compromise its integrity and safety

This is usually done to mount accessories like mirrors and safety lights.

But even small drill holes can affect the integrity of the overhead guard.

And that is a major safety concern.

5. Use Proper Lighting

Forklifts are commonly used in low-light areas, like warehouses, semi-trailers, and rail cars.

When operating in these areas without proper lighting, operators are more likely to ram into pedestrians or product.

A forklift operator preparing to enter a semi-trailer
Install headlights when lighting is less than 2 lumens per square foot

So it’s important to have fork truck safety lights to minimize this.

But how much light is too little light?

OSHA says the limit is anything less than 2 lumens per square foot.

For reference, an average bedroom is between 10 to 20 lumens per square foot.

Relevant OSHA Standards Expand
  • 1910.178(h)(2): Where general lighting is less than 2 lumens per square foot, auxiliary directional lighting shall be provided on the truck.

6. Install Gas Detectors

Liquefied petroleum gas (LPG) powered forklifts are often used indoors.

That’s because they emit fewer dangerous gases like carbon monoxide (CO) than gasoline or diesel engines do.

That said, it’s still crucial to monitor the concentration of these gases in your work environment.

A carbon monoxide detector
Carbon monoxide monitors help detect excessive CO levels

If not, workers nearby can become seriously ill or even die due to carbon monoxide poisoning.

But what exactly is the CO limit?

OSHA says that it must not exceed 50 parts per million (ppm) at 77° F and 760 torr.

That equates to approximately 55 milligrams per cubic meter of air.

Relevant OSHA Standards Expand
  • 1910.178(i)(1): Concentration levels of carbon monoxide gas created by powered industrial truck operations shall not exceed the levels specified in §1910.1000.

7. Use Care When Loading and Unloading Trailers

One of the main things forklift operators do is load and unload semi-trailers at the dock.

But this routine activity carries plenty of risks if proper procedures aren’t followed.

A forklift operator removing cargo from a semi-trailer
Use extra caution when loading and unloading semi-trailers

What are those procedures?

  • Ensuring semi-truck brakes are set and the wheels are chocked
  • Using fixed jacks to support a semi-trailer when it’s not coupled to the tractor
  • Properly securing dock plates
  • Ensuring the lift truck plus the load doesn’t exceed the dock plate’s rated capacity

By following these procedures, operators can help avoid dangerous situations like run-away trailers and falls from the dock.

Relevant OSHA Standards Expand
  • 1910.178(k)(1): The brakes of highway trucks shall be set and wheel chocks placed under the rear wheels to prevent the trucks from rolling while they are boarded with powered industrial trucks.
  • 1910.178(k)(2): Wheel stops or other recognized positive protection shall be provided to prevent railroad cars from moving during loading or unloading operations.
  • 1910.178(k)(3): Fixed jacks may be necessary to support a semitrailer and prevent upending during the loading or unloading when the trailer is not coupled to a tractor.
  • 1910.178(n)(11): Dockboard or bridgeplates, shall be properly secured before they are driven over. Dockboard or bridgeplates shall be driven over carefully and slowly and their rated capacity never exceeded.

8. Inspect Before Operating

OSHA requires that all forklifts be inspected before being operated.

Why?

To determine the safety of the lift truck.

These inspections are typically performed by the operator.

A forklift operator conducting an inspection before operating
All forklifts must be inspected for safety before operating

Using a checklist, the operator should walk around the fork truck and examine the key areas for any signs of wear, damage, or deficiency.

Download Our Free Forklift Safety Checklists

Anything found in poor condition should be noted, reported, and corrected before operating.

Relevant OSHA Standards Expand
  • 1910.178(q)(7): 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 each shift. Defects when found shall be immediately reported and corrected.

9. Keep Up on Maintenance

Forklift maintenance is key to ensuring your forklifts last as long as possible.

But it’s also a major component of forklift safety procedures.

After all, a defective forklift component - like brakes - can result in injury, fatality, and damage to product.

A forklift technician perform repairs on a forklift engine
Staying on top of forklift maintenance helps improve safety and lower costs

So it’s important to keep up on regular maintenance activities.

If you have an in-house maintenance team, ensure they follow up on any issues noted by your operators.

And if you don’t have an in-house team, consider outsourcing your forklift maintenance to a reliable service center.

Relevant OSHA Standards Expand
  • 1910.178(q)(7): 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 each shift. Defects when found shall be immediately reported and corrected.
  • 1910.178(p)(1): If at any time a powered industrial truck is found to be in need of repair, defective, or in any way unsafe, the truck shall be taken out of service until it has been restored to safe operating condition.
  • 1910.178(q)(1): Any power-operated industrial truck not in safe operating condition shall be removed from service. All repairs shall be made by authorized personnel.

10. Know How to Safely Dismount a Tipping Lift Truck

The number 1 cause of forklift deaths is tip-overs.

So knowing how to handle a situation like this is critical.

A forklift tipped over in a warehouse
Operators must know how to safely dismount tipping forklifts

The guidance for these incidents, however, is different depending on the type of lift truck you’re using.

If you’re operating a sit-down style fork truck and it starts to tip, you should:

  • Stay in your seat
  • Brace yourself
  • Lean away from the point of impact

Here are the standup forklift safety tips if you’re operating a stand-up rider forklift that starts to tip:

  • Step back from the operator compartment
  • Move as far away from the truck as possible
Relevant OSHA Standards Expand
  • 1910.178(q)(7): 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 each shift. Defects when found shall be immediately reported and corrected.
  • 1910.178(p)(1): If at any time a powered industrial truck is found to be in need of repair, defective, or in any way unsafe, the truck shall be taken out of service until it has been restored to safe operating condition.
  • 1910.178(q)(1): Any power-operated industrial truck not in safe operating condition shall be removed from service. All repairs shall be made by authorized personnel.

11. Install an Operator Restraint System

What is the most important safety device on a forklift?

Answer: The seat belt.

Why?

Because seat belts are the best way to prevent operators from being crushed in the event of a tip-over.

A forklift operator buckling their seat belt
Seat belts are essential for preventing injury and death from tip-overs

Sit-down rider forklifts manufactured after 1992 are required to have seat belts installed from the factory.

But if your forklifts are older than 1992 models, you should still arrange to have seat belts installed on them.

Furthermore, managers should ensure that their maintenance activities include replacing any worn or damaged seat belts.

12. Don't Speed

Speed kills!

And considering that the average warehouse forklift weighs around 9,000 lbs., this adage is especially true.

Because with that much weight, forklifts take longer to stop.

A forklift speeding through a warehouse
Forklift take longer to stop, so operators should never speed

How long does it take to stop a forklift at full speed?

According to National Safety, Inc. it’s as follows:

  • At 4 mph it will take 17 feet to come to a stop
  • At 8 mph it will take 42 feet
  • And at 9 mph it will take at least 51 feet

Now, you might be wondering: What is the maximum safe speed for a forklift?

The University of Rochester recommends:

  • 8 mph when no pedestrians are present
  • 3 mph when pedestrians are present

But keeping operators under the speed limit can be a challenge.

Fortunately, facility managers who struggle with this have an effective option: Electronic speed control.

Speed control button on the instrument panel of an internal combustion Toyota forklift
Speed control can help facility managers eliminate forklift speeding issues

Many modern forklifts have this feature standard from the factory.

All it takes is having the dealership set the speed and a password to prevent unauthorized changes.

Relevant OSHA Standards Expand
  • 1910.178(n)(1): All traffic regulations shall be observed, including authorized plant speed limits. A safe distance shall be maintained approximately three truck lengths from the truck ahead, and the truck shall be kept under control at all times.
  • 1910.178(n)(8): Under all travel conditions the truck shall be operated at a speed that will permit it to be brought to a stop in a safe manner.
  • 1910.178(n)(10): The driver shall be required to slow down for wet and slippery floors.
  • 1910.178(n)(15): While negotiating turns, speed shall be reduced to a safe level by means of turning the hand steering wheel in a smooth, sweeping motion. Except when maneuvering at a very low speed, the hand steering wheel shall be turned at a moderate, even rate.

13. Handle Loads Properly

Forklifts are designed to pick stuff up and put them down.

But proper load handling isn’t quite that simple.

That’s because loads come in all different shapes, sizes, and weights.

A forklift transporting a pallet of barrels with one barrel falling off and spilling on the ground
Operators should ensure their loads are steady and stable before transporting them

So ensuring your loads are stable and balanced is key.

To do so, operators should make sure they:

  • Use extra caution when handling off-center loads
  • Secure loose items on loads to prevent them from falling
  • Put the forks as far as possible under the load
  • Refrain from tilting unless directly above the deposit position

Following these load-handling safety tips will help minimize falling loads as well as forklift instability.

Relevant OSHA Standards Expand
  • 1910.178(o)(1): Only stable or safely arranged loads shall be handled. Caution shall be exercised when handling off-center loads which cannot be centered.
  • 1910.178(o)(5): A load engaging means shall be placed under the load as far as possible; the mast shall be carefully tilted backward to stabilize the load.
    • Note: "Load engaging means" refers to the forks or attachment
  • 1910.178(o)(6): Extreme care shall be used when tilting the load forward or backward, particularly when high tiering. Tilting forward with load engaging means elevated shall be prohibited except to pick up a load. An elevated load shall not be tilted forward except when the load is in a deposit position over a rack or stack. When stacking or tiering, only enough backward tilt to stabilize the load shall be used.

14. Keep a Clear Line of Sight

Forklift operators routinely deal with oversized loads that obscure their vision.

But it’s crucial to maintain maximum visibility at all times to prevent accidents.

A forklift operator about to transport a tall load that's blocking their sight
When your sight is blocked, travel backward or get a forklift spotter to help

Thus, operators should take precautions when their sight is blocked.

This includes:

  • Traveling backward when the load blocks their view
  • Slowing down and honking the horn at intersections
  • Using a forklift spotter to navigate blind spots

Facility managers can help in this effort by installing mirrors on lift trucks and at intersections.

A common question is: Does OSHA require forklift mirrors?

A military forklift operator looking behind them
Forklift mirrors are not required by OSHA, but should be present if factory-installed

According to EHS Daily Advisor, OSHA doesn’t specifically require them.

But if they’re factory-installed, they must not be removed.

Relevant OSHA Standards Expand
  • 1910.178(n)(4): The driver shall be required to slow down and sound the horn at cross aisles and other locations where vision is obstructed. If the load being carried obstructs forward view, the driver shall be required to travel with the load trailing.
  • 1910.178(n)(6): The driver shall be required to look in the direction of, and keep a clear view of the path of travel.

15. Look Out for Pedestrians

Of the many things forklift operators have to look out for, pedestrians are the biggest concern.

In fact, the U.S. Bureau of Labor Statistics found that pedestrian collisions resulted in 13% of forklift fatalities in 2017.

A pedestrian laying on the ground after being struck by a forklift
Pedestrian collisions are one of the top causes of forklift fatalities

Operators can improve how they interact with pedestrians in the following ways:

  • Sound the horn around corners or any areas where you don’t have a clear view
  • Make eye contact with pedestrians to alert them to your presence
  • Grant pedestrians the right-of-way whenever you encounter them
  • Use verbal or hand signals to let pedestrians know your next move
  • Never drive up to a person who’s in front of a fixed object

Pedestrian safety isn’t all on the operators, however.

By doing the following, pedestrians can help minimize their risk of collision with forklifts:

  • Walk on the right side of the aisles
  • Keep distance from operating forklifts
  • Watch out for tail swing to avoid being pinned

By keeping in mind these forklift pedestrian safety tips, you can greatly improve safety in your workplace.

Relevant OSHA Standards Expand
  • 1910.178(m)(1): Trucks shall not be driven up to anyone standing in front of a bench or other fixed object.

16. Separate Foot and Forklift Traffic

Separating the different types of traffic in your facility can go a long way towards improving pedestrian safety.

We’ve covered many pedestrian safety tips in the previous section.

A pedestrian gateway separating foot traffic from forklift traffic
Use gates, barriers, and markings to separate foot and forklift traffic

But because this is so important, we wanted to include a few more:

  • Keep proper aisle widths to allow safe distances between equipment and workers on foot
  • Mark pedestrian and forklift traffic in aisles
  • Keep some aisles designated for pedestrian- or forklift-only traffic
  • Limit the use of forklifts near places where pedestrians congregate. This includes break rooms, restrooms, time clocks, and exits
  • Install physical barriers and pedestrian safety gates around workstations and walkways
  • Install forklift traffic signs to alert foot traffic to the presence of equipment

17. Do Not Allow Passengers

Can you carry passengers in your forklift?

The answer is no - unless there’s a designated seat for them.

A sign indicating the passengers aren't allowed on the vehicle
Never allow passengers to ride on a forklift, unless there’s a designated seat for them

Because without a safe spot for passengers, they’re at greater risk of harm if the lift truck tips over.

Relevant OSHA Standards Expand
  • 1910.178(m)(3): Unauthorized personnel shall not be permitted to ride on powered industrial trucks. A safe place to ride shall be provided where riding of trucks is authorized.

18. Use the Right Equipment to Elevate Workers

Falls from forklifts caused 15% of forklift fatalities in 2017.

How does this happen?

Usually, it’s when the forklift operator allows a coworker to stand on the forks while they lift them to the worksite.

Illustration of an employee falling off the forks of a forklift
Elevating unsecured workers on a forklift is extremely dangerous

But this is extremely dangerous.

Because even a fall from as little as 7 feet can cause death.

So, what’s the solution?

Ideally, you should only lift personnel with equipment designed exclusively for that purpose.

And that means using mobile elevated work platforms (MEWPs), like scissor lifts and boom lifts.

But if you don’t have this equipment available, there’s another option: Lifting cages.

A basket made for lifting personnel on a forklift's forks
If you must use a forklift to elevate workers, do so with an approved lifting cage

Personnel can enter the cage, secure themselves, and be safely lifted to their work height.

Just make sure that you follow a few rules when working with forklift safety cages:

  • Use only approved lifting cages
  • Secure the cage to the carriage or forks
  • Use restraining devices like body harnesses to secure workers to the cage
  • Never drive with the cage elevated

19. Ascend and Descend Ramps Properly

Navigating ramps is one of the most dangerous activities for forklift operators.

The reason is that even slight grades can cause the forklift to become unstable.

An illustration of two forklifts going up and down a ramp with the load upgrade both ways
Travel with your load upgrade when travel forward or reverse on ramps

And this is magnified if the operator turns while on the ramp.

Because doing so can easily cause the fork truck to tip over.

To minimize the chances of this happening, operators should:

  • Drive slowly up and down ramps
  • Drive with the load upgrade to minimize the chances of it falling off the forks
  • Never turn on a ramp if at all possible
Relevant OSHA Standards Expand
  • 1910.178(n)(7): Grades shall be ascended or descended slowly.
  • 1910.178(n)(7)(i): When ascending or descending grades in excess of 10 percent, loaded trucks shall be driven with the load upgrade.
  • 1910.178(n)(7)(iii): On all grades the load and load engaging means shall be tilted back if applicable, and raised only as far as necessary to clear the road surface.

20. Secure Unattended Forklifts

It’s not uncommon for some lift truck operators to spend their entire shift on their forklift.

But more often than not, operators are on and off their lift trucks throughout their day.

A forklift parked in a yard
If leaving a forklift unattended, make sure you secure it

If that’s the case, it’s necessary to take proper precautions when leaving a lift truck unattended.

Now, you might be wondering: At what distance is a forklift considered to be unattended?

Fortunately, OSHA provides an answer to this question:

A powered industrial truck is unattended when the operator is 25 ft. or more away from the vehicle which remains in his view, or whenever the operator leaves the vehicle and it is not in his view.

OSHA Standard 1910.178(m)(5)(ii)

In that case, the operator has a responsibility to secure their lift truck by:

  • Lowering the forks completely
  • Turning off the power
  • Setting the parking brake

This brings up another popular question: Can you leave keys in a forklift?

A forklift ignition turned to the "off" position
Remove your keys from unattended forklifts to prevent unauthorized people from using it

We couldn’t find where OSHA specifically addresses this.

But the answer should be “No.”

Why should you remove the key from your forklift?

Because it’s simply a best practice to prevent unauthorized people from powering up the lift truck.

Relevant OSHA Standards Expand
  • 1910.178(m)(5)(i): When a powered industrial truck is left unattended, load engaging means shall be fully lowered, controls shall be neutralized, power shall be shut off, and brakes set. Wheels shall be blocked if the truck is parked on an incline.
  • 1910.178(m)(5)(ii): A powered industrial truck is unattended when the operator is 25 ft. or more away from the vehicle which remains in his view, or whenever the operator leaves the vehicle and it is not in his view.
  • 1910.178(m)(5)(iii): When the operator of an industrial truck is dismounted and within 25 ft. of the truck still in his view, the load engaging means shall be fully lowered, controls neutralized, and the brakes set to prevent movement.

21. Keep Your Equipment Clean

Fork trucks should regularly be cleaned to ensure they operate efficiently.

After all, many lift trucks are used in extremely dirty environments.

A dirty forklift parked in a machine shop
Wash your lift trucks frequently to improve safety

And in those environments, debris and dirt accumulation can interfere with the mechanical components of the truck and limit its performance.

But another reason to keep your lift trucks clean is for safety purposes.

If the truck has grease and grim on the steering wheel, pedals, or control levers, the operator’s grip won’t be as secure.

Without a secure hold, the operator won’t have total control over their lift truck.

And that can result in serious accidents.

Relevant OSHA Standards Expand
  • 1910.178(q)(10): Industrial trucks shall be kept in a clean condition, free of lint, excess oil, and grease. Noncombustible agents should be used for cleaning trucks. Low flash point (below 100 °F.) solvents shall not be used. High flash point (at or above 100 °F.) solvents may be used. Precautions regarding toxicity, ventilation, and fire hazard shall be consonant with the agent or solvent used.

22. Follow Safe Refueling Procedures

Most fork trucks run on either LPG, gasoline, diesel, or electricity.

And each of these fuel sources poses risks when it comes time to refuel.

A forklift operator removing an empty LP tank
Propane tanks are heavy. Make sure to use proper lifting techniques when replacing them

So, operators should be aware of the safety procedures when refueling and ensure they follow them closely.

Some forklift propane safety tips include:

  • Turning off the engine on internal combustion (IC) lift trucks before refueling
  • Eliminating ignition sources (like smoking) when near fuel sources
  • Following safe lifting procedures as a full LPG tank can weigh over 84 lbs.
  • Wearing proper personal protective equipment like a face mask and gloves when handling propane

And some forklift battery safety tips include:

  • Charging batteries for electric lift trucks only in designated areas
  • Using proper material handling equipment for removing batteries
  • Not smoking in the charging areas
  • Opening the hood when charging to ventilate and dissipate heat
Relevant OSHA Standards Expand
  • 1910.178(m)(2): No person shall be allowed to stand or pass under the elevated portion of any truck, whether loaded or empty.

23. Never Walk Under Elevated Forks

This tip is for pedestrians.

An illustration of a worker walking under an elevated forklift load, with a box falling on them
No one should ever walk under an elevated load

Now, why is it important not to walk under the forks of a lift truck?

  • The operator may not see and inadvertently lower the load on the pedestrian
  • An unstable load may fall off the forks and onto the pedestrian
  • The lifting mechanism can malfunction and come down on the pedestrian

Whichever scenario it is, it’s not a result that anyone wants.

So, if you see an elevated forklift mast, maintain plenty of space and walk around it.

Relevant OSHA Standards Expand
  • 1910.178(g)(1): Battery charging installations shall be located in areas designated for that purpose.
  • 1910.178(g)(2): Facilities shall be provided for flushing and neutralizing spilled electrolyte, for fire protection, for protecting charging apparatus from damage by trucks, and for adequate ventilation for dispersal of fumes from gassing batteries.
  • 1910.178(g)(4): A conveyor, overhead hoist, or equivalent material handling equipment shall be provided for handling batteries.
  • 1910.178(g)(5): Reinstalled batteries shall be properly positioned and secured in the truck.
  • 1910.178(g)(8): Trucks shall be properly positioned and brake applied before attempting to change or charge batteries.
  • 1910.178(g)(10): Smoking shall be prohibited in the charging area.
  • 1910.178(g)(11): Precautions shall be taken to prevent open flames, sparks, or electric arcs in battery charging areas.
  • 1910.178(g)(12): Tools and other metallic objects shall be kept away from the top of uncovered batteries.
  • 1910.178(p)(2): Fuel tanks shall not be filled while the engine is running. Spillage shall be avoided.

24. Keep Your Work Environment Clean, Clear, and In Good Repair

Without a clean and safe work environment, the chances of a forklift accident go up.

A well-organized, clean warehouse
Dirty work environments compromise forklift safety. Keep yours clean!

To reduce this, employers should:

  • Conduct regular walk-throughs to identify obstructions and clutter that pose a risk and make plans to correct them
  • Keep stairways and escape routes free of obstructions
  • Inspect and repair any cracks or damage to key areas like loading docks and pallet racking

Forklift operators can do their part by first walking any routes that may be obstructed.

Then, they should clear the obstructions before proceeding.

Relevant OSHA Standards Expand
  • 1910.141(a)(3)(i): All places of employment shall be kept clean to the extent that the nature of the work allows.

25. Do Not Run Over Debris

If you follow the previous safety tip, you can do a lot to eliminate this hazard.

Still, especially tough work environments will never be totally free of debris.

A cluttered warehouse
Running over debris can cause forklift instability and lead to accidents

In that case, forklift operators should do everything they can to avoid running it over.

Why?

Debris can chunk out tires, cause damage to critical forklift components, and introduce instability.

When that happens, the risk of a forklift accident goes up.

And so does the cost of maintenance and repairs.

Relevant OSHA Standards Expand
  • 1910.178(n)(14): Running over loose objects on the roadway surface shall be avoided.

26. Be Mindful of the Hazards of Your Fork Truck

One of the most dangerous components of a lift truck is the mast.

If you’re unfamiliar, this is the mechanism that allows the forks and load to travel up and down.

Because of its design, the mast can cause serious injury to anyone who places a body part within it.

A forklift mast pointed out on a Toyota 8FGCU25 forklift
Never place any body part within the mast. Doing so can cause serious injury like amputation

So, always keep fingers, hands, and limbs away from the chains, the rails, and the pulleys.

Furthermore, operators should never ride with their arms or legs outside the operator compartment.

That includes the common practice of putting your hand on the rear overhead guard post when backing.

A forklift operator putting their hand on the outside of an overhead guard post
Putting your hand on the overhead guard post when backing up is a major crushing hazard

If an operator does so, they can easily crush their hands against a fixed object like a wall.

And that can cause serious injury.

Relevant OSHA Standards Expand
  • 1910.178(m)(4): The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck.

27. Never Exceed the Rated Capacity

Forklift trucks are usually referred to by their nominal capacity.

For instance, a 5,000 lbs. forklift is rated to lift 5,000 lbs. at a specified height.

This can be misleading, however.

That’s because attachments like side shifters can reduce the actual lifting capacity of the lift truck.

So, you must understand the true weight lifting ability of your fork truck.

How do you do that?

A forklift data plate showing the rated capacities
Check your forklift’s data plate for the actual lifting capacity

By checking the data plate.

It will list any attachments and show exactly how much weight the truck can lift at specified heights.

Once you know that information, never lift anything that exceeds that limit.

Doing so can cause a whole host of problems, like tip-overs, falling loads, and loss of control.

Relevant OSHA Standards Expand
  • 1910.178(o)(2): Only loads within the rated capacity of the truck shall be handled.
  • 1910.178(a)(6): The user shall see that all nameplates and markings are in place and are maintained in a legible condition.

28. Don't Talk and Operate

Distracted driving isn’t just a problem on the open road.

It’s also a huge issue for facilities that operate forklifts.

And among the main problems is the use of cell phones.

A forklift operator using a smart phone
Forklift operators shouldn’t talk or text while operating

Operators should never talk or text while operating their forklift.

And pedestrians should take extra care when using their phones while in proximity to lift trucks.

Relevant OSHA Standards Expand
  • OSHA's General Duty Clause:
    • (a) Each employer -- shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees

Conclusion

There you have it: 28 forklift safety tips.

Now we’d like to hear from you.

Were you surprised by any of the tips we covered?

Do you have additional tips that we should add?

Let us know in the comments below!

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54304

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