Forklift Safety: A Guide to Safer Material Handling

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Forklift Safety: A Guide to Safer Material Handling

Forklift Safety: A Guide to Safer Material Handling

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Aug 27,26

Hemant Sethi, Managing Director, British Safety Council India, outlines essential forklift safety practices to reduce workplace risks, prevent accidents and promote safer material handling.

Forklift Safety: A Guide to Safer Material Handling

Forklifts are indispensable in the transport of heavy material over short distances such as from one site to another within a factory or warehouse. The hydraulic valves can be controlled either electrically with or manually through a set of levers.

A forklift must be controlled and operated by a skilled forklift operator. Due to its rear-wheel steering, operation of a forklift is different from driving a regular vehicle. Forklifts are potentially dangerous vehicles to operate, and can even be involved in fatal accidents. Occupational safety regulations need to be followed when operating a forklift. It is recommended that operators go through a certified training course in order to be deemed fit to operate a forklift vehicle.

Although forklift trucks are not subject to an MOT, as Heavy Goods Vehicles (HGV) are, they do require a Thorough Examination under both Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) and Provision and Use of Work Equipment Regulations 1998 (PUWER) requirements, so the importance of carrying out this examination to the highest standard is critical to the industry and all those working in it.

The lack of clarity surrounding how often lift truck examinations are carried out and documented can leave managers confused – potentially placing employees at risk.

Nevertheless, there are certain common-sense precautions that must be followed, and these should be taken seriously not only by the operators but even by their supervisors.

1. Demarcation of zones

The zones where a forklift operates should be clearly demarcated so that people do not stray into its path. The vehicle itself should have anti-slip surfaces especially on footholds where the operator has to transfer weight from one foot to the other. Grab handles must be designed so that the operator gets a firm grip on them while mounting and dismounting the vehicle.

2. Alertness of operators

A forklift operator must be extremely alert and focussed. He should be well composed and drive the vehicle slowly, always looking out for potential hazards. He should be thoroughly familiar with the vehicle and its salient features. It goes without saying that forklift operators should avoid consuming alcohol or any substance that is likely to interfere with their alertness before operating a forklift.

3. Blades position

The angle of the blades should be adjusted so that if the load slides, it slides backwards towards the forklift and not onto the road ahead. Yet, care has to be taken that the load merely slides backwards and does not bang into the vehicle. The height of the load should be adjusted so that the operator can see where he is driving. A low load also brings stability to the vehicle.

4. Proper exits

Before moving the forklift, the operator should ensure that there are no obstructions in his path. Exits should be wide enough to allow for passage of the vehicle and the protruding load. The height and width of the load should be well below any overhead obstacles such as the beam of the gate or bulky storage items.

Loads should not be stacked loosely on the blades. They should be tightly strapped to avoid tumbling off the vehicle when it is in motion. It is important to set the emergency brakes when stopping. All personnel should be away from the vehicle when the load is being lowered.

But even when companies comply with all aspects of safety and risk assessment, forklift accidents take place.

5. Regular audits

Internal communication within the organisation is very important. All employees should be familiar with the organisation's occupational health and safety policy. Periodic safety audits should be undertaken and corrective action taken to address any anomalies.

Occupational health and safety should be a top-down approach. Line managers should ensure that the safety policy of the company gets translated into action on the ground. There should be a clear chain of responsibility and accountability.

6. Safety training

Safety training should not be a requirement for the operators alone. Line managers may not drive the trucks, but they are key enablers, and have bearing on the behaviour of the workforce. They should be trained to identify potential dangers and impose corrective action. Regular monitoring of safety compliance should be part of a line manager's job description.

Companies should be proactive in investing time and resources in staff training. It may not always be possible to recruit staff with the right skills; but existing staff can be equipped with these skills so that they are well prepared to meet the challenges head on. Moreover, skilling of staff can be a great motivator for employees and can help retain talent within the company.

7. Clear standard operating practices

The company should have clear standard operating practices and all staff should be familiar with them. Staff should be encouraged to challenge each other and point out instances of careless behaviour. Peer pressure is a good way for employees to internalise best practices.

Often, senior management is so target-driven that deadlines become all-important and health and safety tend to get overlooked by 'overzealous' employees. This should be seen as a major transgression of company regulations. It is better to take action against an errant employee before any damage is done than to have to face long-standing legal issues if an accident does occur.

8. Move at the appropriate speed

Operate the forklift while adhering to specified speed limits. Avoid abrupt stops, sharp turns, sudden changes in direction, or excessive speed during manoeuvres, as these behaviours can result in the tipping of the forklift. In the event that the forklift begins to tilt, it is strongly advised not to attempt to exit the vehicle hastily. Instead, experts suggest remaining inside the vehicle, firmly grasping the steering wheel, and stabilising your footing.

9. Refuel and recharge the forklift

Maintaining equipment in a fully charged and fueled state is of paramount importance. Ensure proper recharging and refueling procedures are carried out at designated locations, typically characterised by good ventilation and being free from any potential sources of ignition. Exercise vigilance by consistently powering off the equipment during refueling operations.

10. Maintain a safe operating distance

Maintain constant awareness of the equipment in the vicinity of the worksite. Refrain from operating a forklift in close proximity to other machinery unless it is an absolute necessity. Ensure you maintain a safe distance that provides ample space for a secure stop and the ability to maneuver away from other machines that might exhibit unpredictable movement patterns.

11. Park the forklift at the end of the shift

Concluding your shift, it is imperative to consistently park the equipment within the designated and authorised zones. The construction company must ensure that these parking areas do not impede pathways, hinder entrances/exits, or create obstructions. Lower the forks completely until they rest on the floor, engage the parking brake, power down the engine, and remove the ignition key.

The Indian acceptance standard for forklift trucks specifies guidelines on the basis of which forklift trucks should be tested. In the preparation of this standard, assistance has been taken from relevant British Standards issued by the British Standards Institution.

About the author:

Hemant Sethi is the Managing Director of British Safety Council India, he has played an integral part in managing the successful launch of the British Safety Council’s India operation. Some of his key contributions during this time include the recruitment and onboarding of a local team, growing the British Safety Council’s presence in the market and identifying the critical areas of impact (campaigning) for the British Safety Council moving forward.