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Forklift Health and Safety Best Practices Guideline (BP015) PDF
Forklift Health and Safety Best Practices Guideline (BP015) PDF
Best
Practices
Guideline
SECTION 1: Introduction
Copyright and disclaimer
This material may be used, reproduced, stored or transmitted for non-commercial purposes. The source of this material
must be acknowledged when publishing or issuing it to others. This material is not to be used, reproduced, stored or
transmitted for commercial purposes without written permission from the Government of Alberta.
The information provided in this document is solely for the user’s information and convenience and, while thought
to be accurate and functional, it is provided without warranty of any kind. The Crown, its agents, employees or
contractors will not be liable to you for any damages, direct or indirect, arising out of your use of the information
contained in this document.
This document may be applicable to assist in establishing a forklift health and safety program at your worksite. However,
it is critical that you evaluate your own unique circumstances to ensure that an appropriate program is established for
your work site. It is strongly recommended that you consult relevant professionals (including, but not limited to, lawyers
and health and safety specialists) to assist in the development of your own program. Further, this document does not
replace the need for employers to ensure their workers are trained and competent in the safe use of forklift trucks.
It is important to note that adherence to this document does not absolve you from potential liability under the legislation
in cases where you are determined to be in non-compliance with the legislation. In case of any inconsistency between
this document and the Occupational Health and Safety Act, Regulation or Code, the legislation will always prevail.
This document is current to September 15, 2014. The law changes from time to time with new legislation, amendments
to existing legislation, and decisions from the courts. It is important that you keep up with these changes and keep
yourself informed of the current law.
8 SECTION 2
Legislation
14 SECTION 3
Key elements of a health and
safety program for forklifts
16 SECTION 4
Hazard assessment
21 SECTION 5
Worker training and competency
34 SECTION 6
Management, supervision
and internal responsibility
36 SECTION 7
Safe operating procedures
40 SECTION 8
Equipment maintenance
and modification
42 SECTION 9
Facility design
43 SECTION 10
Preventing injuries to muscles, joints
and bones
Acknowledgements
This best practices guideline was created with the help
of a multi-stakeholder advisory committee that drew
on its experience in forklift truck health and safety. The
advisory committee included representatives from:
Alberta Construction Safety Association
Alberta Jobs, Skills, Training and Labour
Alberta Federation of Labour
Health and Safety Association Network
International Union of Painters & Allied Trades
Manufacturers’ Health & Safety Association
Oil Sands Safety Association
Wajax Industries
Alberta Jobs, Skills, Training and Labour wishes to
acknowledge and thank the Ontario Ministry of Labour
for permission to adapt its Guideline for Safe Operation
of Powered Lift Trucks, July 1999 and Manitoba Labour
and Immigration for permission to adapt its Code of
Practice For the Safe Operation of Powered Lift Trucks,
November 2006.
SECTION 1: Introduction 5
Powered forklifts covered in this guideline include
self-propelled vehicles of Class 1 to 7 as defined by the
Industrial Truck Association:
CLASS 1: Electric motor rider trucks CLASS 3: Electric motor driven hand trucks
Counterbalanced
rider, pneumatic
Low lift platform
tire, sit down.
CLASS 2: Electric motor narrow aisle trucks CLASS 4 and 5: Internal combustion
engine lift trucks, cushion or pneumatic tires
Fork, counterbalanced,
Order picker pneumatic tire
Variable reach
rough terrain
fork lift truck
SECTION 1: Introduction 7
Legislation
Alberta’s Occupational Health and Safety (OHS)
Act, Regulation and Code have general and specific
requirements related to the operation of forklifts.
In many instances the legislation sets out requirements
for the safe use of “equipment” or “powered mobile
equipment.” All forklifts meet the definition of
“equipment” and all powered forklifts meet the
definition of “powered mobile equipment.” Hence,
requirements relating to “equipment” and “powered
mobile equipment” apply to forklifts.
Some sections of the legislation applicable to forklifts
are simplified and generalized below. For ease of
understanding, the word “forklift” has been substituted
for “equipment” where applicable. Refer to the actual
legislation for the complete rules. The legislation can be
viewed online at worksafe.alberta.ca or ordered from
the Alberta Queen’s Printer at qp.alberta.ca.
The OHS Act sets out general duties for employers,
workers and suppliers:
• Employers must ensure the health and safety of
all workers at a work site. OHS ACT, SECTION 2
• Workers must take reasonable care and cooperate
with their employer to protect their health and
safety, and the health and safety of other workers at
a work site. OHS ACT, SECTION 2
• Suppliers must ensure that forklifts supplied are
in safe operating condition. OHS ACT, SECTION 2
The OHS Act requires that all forklifts sold by a
supplier, and being used by an employer, be in safe
operating condition and comply with the OHS
Code. The employer must not rely on the supplier
to ensure compliance. OHS ACT, SECTION 11
SECTION 2: Legislation 9
• Danger from movement and securing of • Seat belts and control Where powered forklifts
materials Employers must ensure that workers are equipped with a seat belt, employers must
are protected from any danger related to the ensure that the seat belt is present and in useable
movement of a powered forklift or the movement condition, and workers must wear the seat belt.
or dislodgement of a load on or near a forklift. If Workers must operate forklifts safely and maintain
a worker could be injured by dislodged materials, full control of the forklift at all times, which
or movement of an elevated forklift undergoing includes keeping the cab, floor and deck of powered
repairs, for example, reasonable steps must forklifts free of materials, tools or other objects
be taken to ensure the material, or forklift, is that could interfere with the operation or create
restrained to eliminate the potential danger. other hazards. OHS CODE, SECTIONS 256 & 284
OHS CODE, SECTIONS 189 & 258 The employer must ensure that forklifts have
• Pedestrian traffic Employers must ensure that seats or other installations sufficient to ensure the
workers on foot are protected from powered forklift safety of the operator and other workers who may
traffic. An employer must ensure pedestrians wear be in or on the equipment while it is in motion. All
a piece of highly visible clothing, that walkways forklifts fitted with a rollover protective structure
are designated to separate pedestrian traffic manufactured on or after July 1, 2009, must have
from areas where powered forklifts are operating seat belts for the operator and passengers that
and that workers use the designated walkways. comply with either SAE Standard J386 (2006),
Where designated walkways are not practicable, Operator Restraint System for Off-Road Work
employers must ensure that safe work procedures Machines, or SAE Information Report J2292
are used to protect workers. OHS CODE, SECTIONS (2006), Combination Pelvic/Upper Torso (Type
194 & 259 2) Operator Restraint Systems for Off-Road Work
• Lifting and handling loads Employers Machines. If the work process makes the wearing
must provide, where reasonably practicable, of seat belts in the forklift impracticable, the
appropriate equipment for lifting, lowering, employer may permit workers to wear shoulder
carrying, handling or transporting heavy or awkward belts or use bars, screens or other restraining
loads. OHS CODE, SECTION 208 devices designed to prevent the operator or a
passenger from being thrown out of the rollover
• Training and competence Workers must not
protective structure. OHS CODE, SECTION 266 & 271
operate powered forklifts unless they are trained
and have demonstrated competence to safely • Visual inspection Forklift operators must
operate the forklift, or are under the direct complete a visual inspection of a powered forklift
supervision of a competent worker. Employers and the surrounding area to ensure that the forklift
must also ensure that workers who may be exposed is in safe operating condition and that no worker,
to the possibility of musculoskeletal injury are including the operator, is endangered when the
trained in specific measures to eliminate or reduce forklift is started up. OHS CODE, SECTION 257
that possibility. OHS CODE, SECTIONS 211.1 & 256
SECTION 2: Legislation 11
• Load rating chart Employers must ensure that • Workplace Hazardous Materials
forklifts have a durable and legible load rating Information System (WHMIS) Employers
chart (capacity plate) that is readily available to must ensure that controlled products (e.g., propane
the operator. OHS CODE, SECTION 283 or natural gas used to fuel a powered forklift’s
• Aerial fork-mounted work platform internal combustion engine) are used, stored, and
Employers must ensure that work platforms handled in accordance with Part 29 of the OHS
(or cages) mounted on a powered forklift’s forks Code. Workers who refuel forklifts must be trained
are securely attached to the forklift, and that in WHMIS, including the theory plus practical
a work platform used to support a worker is aspects of refueling. “Generic” WHMIS training,
commercially manufactured or designed and on its own, might not be sufficient to meet the full
certified by a professional engineer. Employers training requirement because generic training
must also ensure that workers on a forklift’s fork- might not include the practical worksite-specific
mounted work platform use a personal fall arrest component.
system connected to an anchor specified by the In the event of an injury, an employer must comply
manufacturer of the work platform or forklift, with section 18 the OHS Act regarding the reporting
and if practical, the lanyard is short enough to and investigation of injuries and accidents. For more
prevent the worker from being ejected from the information, refer to the bulletin Reporting and
work platform. Forklift operators must remain at Investigating Injuries and Incidents (LI016) available at
the forklift’s controls while a worker is on a fork- worksafe.alberta.ca.
mounted elevated work platform, and may not
move the forklift horizontally when a worker is on The above is a simplified summary of some parts of the
the work platform. OHS CODE, SECTIONS 156 & 349 relevant OHS legislation that pertains to forklifts and is
• Chemical hazards Employers must ensure not the legislation itself. Refer to the actual legislation for
that a worker’s exposure to any harmful the actual and complete rules.
substance (e.g., carbon monoxide or carbon
dioxide produced by a powered forklift’s internal
combustion engine) is kept as low as reasonably
achievable and does not exceed its occupational
exposure limit. OHS CODE, SECTION 16
SECTION 2: Legislation 13
Key elements
of a health
and safety
program
for forklifts
Employers whose work involves the use of forklifts
are encouraged to implement a comprehensive forklift
health and safety program, which includes the following
key elements:
• Hazard assessment;
• Training and information;
• Management, supervision and internal
responsibility (includes forklift selection);
• Safe operating procedures;
• Forklift maintenance and modification;
• Facility design; and
• Preventing injuries to muscles, joints and bones.
Management, supervision
and internal responsibility
Effective management and supervision begins by
appointing competent managers and supervisors.
Section 6 of this guideline provides a description of
considerations for effective management, supervision
and internal responsibility. Forklift selection is also
covered in this section.
Shifting of boxes or
loads being lifted by forklift
Company: Date:
Shifting of boxes or
loads being lifted by forklift
HAZARD
PRIORITY TO
IMPLEMENT
Low Low Low Low
CONTROL Medium Medium Medium Medium
High High High High
FOLLOW-UP
ACTION(S)
FOR CONTROLS
NOT IN PLACE
DUE DATE
PERSON
RESPONSIBLE
21
• Knows how to protect him/herself and others from any necessary corrective actions regarding pre-use
the hazards. inspection, startup and operation of the forklift.
• Has demonstrated to a designated skilled and Employers may choose to have training conducted
experienced person that the skills and knowledge by external trainers such as an industry health and
identified as final outcomes for operator safety association or a training company. Alternatively,
competency have been learned. training may be done in-house if there is an adequately
The employer should develop an evaluation system to qualified trainer. In-house trainers, in addition to being
ensure ongoing competency of operators. This should fully competent in training of workers and operating
include, but not be limited to, testing on operation of the forklifts, must keep current on legislation, equipment
forklift, knowledge and skill level regarding the forklift changes, etc.
and company policy and procedures relating to forklift A forklift operator’s training should be documented and
operations. This evaluation should assess the need for records made available to a government occupational
further training, training updates or refresher courses. health and safety officer whenever requested. All
Employers may consult a safety association or the operator training and evaluation should be conducted
forklift manufacturer for information on institutions, by individuals who have the appropriate knowledge,
agencies or people with expert knowledge of forklifts. training and experience to train forklift operators and
evaluate their competence.
Employers should maintain in the workplace a record
of workers competent to operate forklifts. For each Even though training can be acquired from outside
worker, the record should indicate the skills and agencies, employers are still responsible to ensure
knowledge demonstrated, the class or classes of forklift forklift operators are competent in their work
on which the operator was trained and assessed, the environment with the forklifts they operate.
name and affiliation of the trainer/assessor, the date the Some examples of when a refresher course should be
training/assessment took place, and training certificate given to operators are:
expiry dates if applicable. Employers may provide
operators with certificates of competency. • Operator has been observed operating the forklift
in an unsafe manner.
Forklift operator training courses should typically be
• Operator has been involved in an incident.
full day in duration, i.e., at least seven hours of actual
training time, and consisting of a balance between • Operator receives an evaluation that indicates he
classroom theory and hands-on practical training. or she has operated the forklift unsafely.
• Operator is assigned a different type or class of
While operators of forklifts must always be competent
forklift.
to work safely, as required by the OHS legislation, it
is a best practice that operators of forklifts receive • Environmental conditions in the workplace
retraining at intervals not exceeding three years. change, which may affect the safe operation of
Workers should also be retrained when equipment is the forklift. Examples include introduction of a
modified, new equipment is introduced, when there flammable environment, introduction of additional
are changes to the environment, and when there are forklifts or other equipment, etc.
changes to applicable legislation. Retraining should be A sample performance test for forklift operators
consistent with the employer’s forklift safety program is included on page 22.
and applicable legislation.
If a medical condition affects a worker’s ability to
Eighteen months after training or retraining, a mid- operate a forklift safely, the worker should not be
term skills evaluation should be conducted to re-assess assigned to operate a forklift.
the operator’s practical skills. The goal of this mid-
term evaluation is to give the operator feedback for
NOT NEEDS
TASK OK APPLICABLE TRAINING
Planned route ahead, checked doorways. Kept a clear view of direction of travel.
Yielded to pedestrians.
Drove straight up and straight down inclined surfaces, with and without loads.
Approached load properly. Forks under load all the way, and centered.
Placed load within marked area. Stacked load evenly and neatly.
Model/serial number
Capacity rating at a given load
centre at a given height
Dangerous activities
OBJECTIVE
INSTRUCTIONAL
Operating with restricted visibility Not tilting the mast back enough Operating with restrictions such
(blind spots, corners, inspections) to stabilize the load as overhead equipment or other
obstructions, e.g., stationary
Operating without using a seat belt Increasing the capacity of the
or other restraining device building structures
forklift or overloading the forklift
(circle check)
a competent operator:
Uses the correct mounting Fastens seat belt (or uses
Carries out a visual inspection procedures other restraining device)
of the forklift and its attachments before operating the forklift
Assumes the appropriate driving
to ensure that the equipment
position Starts and stops safely with
is in good operating condition,
and without a load
using a checklist provided by Ensures transmission/directional
the employer control lever is in neutral Allows sufficient room for
turning corners
Follows recommended procedures Ensures parking brakes
for daily inspections of fluid levels are applied Operates at low speed
when turning
Activates start button/switch
Ensures warning system Uses appropriate steering
techniques when turning in
is operating
confined and limited spaces
Brings the forklift to a complete Keeps all parts of the body inside the operator’s compartment at all times
stop, sets the parking brake and
Ensures clear visibility in the intended direction of travel
returns transmission/directional
control lever to neutral If visibility is restricted by the load being carried, drives the forklift in reverse
or asks to be guided by another worker
Lowers forks to the ground and
tilts them forward Keeps the load-engaging means or the load itself low (usually within 10 cm
of the floor/surface and tilted backward)
Uses appropriate shut-down
procedures and turns off power Keeps safe operating distance from other lifting devices, pedestrians,
supply structures and machinery
competent operator:
When not carrying a load, travels Always faces the direction
forward down an incline and travels of travel Assesses the weight distribution
in reverse up an incline of the load and identifies
When turning, ensures no
limitations of the structures where
When carrying a load, travels in personnel are within the forklift’s
the load is to be placed
reverse down an incline and travels danger zone
forward up an incline
Observes employer’s policy for Ensures that the load is within
the rated capacity for the forklift,
Ensures that there is sufficient ensuring the safety of pedestrians
taking into account the job to be
clearance for the forklift and load
If stopped at an intersection, done
prior to travelling on an incline or
does not move until eye contact
uneven terrain
is made with any personnel or Checks forks/attachments to
ensure that they are safe to use
Does not turn the forklift around operators of other vehicles at the
with respect to the equipment’s
on a ramp or incline intersection
capacity rating
Drives at an appropriate speed Maintains a safe distance from
taking into consideration the pedestrians
effects of the slope of the driving
surface on the forklift and load
security
Load pick up and placement Load security and integrity Personnel lifting, lowering
and supporting
Checks overhead clearance Observes the limits for Ensures forklift meets prescribed
freestanding stack height requirements
Ensures safe distance from any
live power source Ensures the load is secure and Uses only a platform specifically
balanced before lifting designed for use with a forklift and
Engages at least two-thirds of
equipped with a guardrail
the load length to be lifted and
centres load evenly on forks Ensures that the platform is
secured to the mast as prescribed
Adjusts the tilting angle of the
mast, height of fork arms and Raises and lowers the platform
reach extension to stabilize load to test its operation before
allowing a worker on it
Ensures no unsecured articles are
lying on top of the load Ensures that the person on the
platform dons the necessary
Does not drag the forks when
personal protective equipment
inserting or withdrawing them
and is secured as prescribed
from a load
FORK-MOUNTED
WORK PLATFORM:
Basic Safety Features Load capacity rating.
Guardrails to protect
workers from falling. Screen to protect
workers from
forklift’s mast.
Platform securely
attaches to forklift.
Manufacturer or engineer-approved
anchor point(s) to attach CSA approved
shock-absorbing safety lanyard and full
body harness for fall arrest and restraint.
Make: Shift:
MAINTENANCE
OK REQUIRED
Check lift chains for equal tension, broken pins and extra wear.
Check for loose bolts and cracks on overhead guard, back rest and tilt cylinders.
Check tires for cracks or other signs of wear. If inflatable tires, does air pressure
meet the manufacturer’s specifications?
Check that the seat is in good condition and the seat belt is working properly.
Check the fluid levels for the brake fluid, engine oil, hydraulic tank and coolant.
Start the engine and check the dashboard gauges for proper readings.
Hold the brake pedal down for 10 seconds. Is there any noticeable
drift with the pressure?
43
Reducing non-neutral postures will reduce the risk of Control measures
injury and can be achieved by:
Control measures to reduce the likelihood of injury are
• Adjusting the forklift’s operator’s seat, to ensure generally categorized into:
workers are not straining to do everyday activities.
• Engineering controls;
• Bringing movements closer to the centerline of the
worker’s body to increase the worker’s control over • Administrative controls; and
body movement. • Personal protective equipment (PPE).
• Installing mirrors or other equipment to reduce the With respect to forklift operations, the controls that
amount of head movement required. have the greatest likelihood of reducing the risk of
injury are engineering and administrative controls.
Forceful exertions occur when the operator adopts
It is preferable to use a combination of these controls
actions that have the potential to physically overload his
when considering the best method to reduce the risk of
or her body, such as when a forklift operator jumps out
injury. Controls should be used in such a manner that
of the forklift and manually pushes heavy items to line
the physical demands of work are kept within a worker’s
them up on a pallet.
physical capabilities to work without injury.
To reduce the risk of injury, consider decreasing the
Engineering controls Since injuries are more likely
physical effort required to perform work by either
to occur when the physical capabilities of a worker are
getting assistance from another worker or using
exceeded, physical changes to the work environment
equipment to move material.
are the most effective way to reduce the risk of injury.
Repetitive motions occur when a worker physically Engineering controls should focus on reducing force
performs the same sequence of actions for extended and exposure to awkward postures.
periods of time with little or no variation in the muscles
With respect to forklifts, it is important to:
used. With repeated exposure, micro-injuries may
accumulate and develop into a serious injury. • Use the correct type of forklift for the job at hand.
To reduce the risk of injury, consider rest breaks for the • Use a forklift with sufficient operator space and
forklift operator or job rotation between competently comfort features including well-located hand and
trained workers throughout the work shift. foot controls, clear control panel displays, and
allowance for a good stance of the operator.
Exposure to vibration occurs when there is a direct
• Use a forklift that has seat belts installed, or other
transfer of repetitive movements of a machine or tool to a
restraining device if the forklift is equipped with
person’s body, such as when a hand tool or heavy machine
ROPS.
shakes repeatedly. When exposed to vibration, the body’s
muscles tighten and blood circulation decreases. When a forklift overturns, the safest place for the
operator is in the cab with his or her seat belt fastened.
To reduce the risk of injury related to vibration,
There are ergonomic factors to consider regarding seat
consider providing forklifts designed to withstand
belts, as they may affect the comfort of an operator if
vibration and that reduce the amount of vibration
they are improperly fitted.
the operator is exposed to, and ensure the forklift is
maintained to reduce vibration. Also consider keeping Properly fitted seat belts are crucial to safe forklift
floor surfaces smooth to avoid a bumpy ride for the operation. If the seat belt does not fit the operator
forklift operator. properly, it will either be rendered useless, or affect the
operator’s ability to move within the seat. Preventing
For additional information, refer to Workplace Health
normal operator movement while seated could result in
and Safety Bulletin: All Shook Up—Understanding
strain injuries from working against the placement of
Vibration, ERG026, employment.alberta.ca/
the seat belt.
documents/WHS/WHS-PUB_erg026.pdf
Rack work to include Facing load sideways Constant gripping over Prolonged looking Prolonged seating.
OF INJURY
SOURCE
lifting, inserting, while extracting load. long periods of forklift upwards to workers
extracting, and operation. elevated within the
Neck is rotated
lowering pallets. fork-mounted work
with potential tilting
platform.
while looking up to
manipulate the load.
entire body
Over-tilt of neck - Risk for soft tissue, Muscle strain, Neck strain, Reduced blood to
INJURIES
POSSIBLE
potential strain tendon and cervical tingling of hands back injury legs, varicose veins
spine damage
Use of ‘Universal Stand facing the load Provide additional Consider using Provide foot rest,
SOLUTIONS
POSSIBLE
Stance’ forklift as using the appropriate soft-pads, apply rest different type of apply rest beaks
opposed to ‘Sit type of forklift breaks, stretching equipment instead and stretching
Down Counterbalance’ of forklift
forklift
Hand grip on Exposure to vibration Looking for Turning on corners Handling cold items
steering wheel pedestrians/objects in cold storage/
while reversing forklift freezer environment
Tendonitis Spine shock Neck and lower Bent wrist causing Numbness
back twisting pain and discomfort
Maintain proper Use equipment Use correct type of Grip hand wheels Wear appropriate
positioning designed for rough forklift for the job, and maintain posture clothing, use forklift
terrain, consider air ride utilize swivel seats keeping the wrist designed for cold
seats, and a quality as part of engineering straight environment
seat cushion. Observe controls, keep
proper equipment shoulders in line with
maintenance. Use the hips
vibration-absorbing
material to isolate
vibration from the
hands. Periodic ground
plowing to smooth the
surface. Rest breaks
and stretching
Notes 49
Notes
Notes 51
ISBN 978-1-4601-1961-7 (print)
ISBN 978-1-4601-1962-4 (online)