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Forklifts can be very dangerous pieces of equipment, so all forklift operators must be trained and hold a relevant certificate of competency. They must also be given site-specific forklift training to address issues such as pallet racking configuration. In addition, you should consider the following factors that affect forklift safety.

Overturning and tipping

Overturning poses the greatest risk to forklift operators. When an operator jumps or is thrown from a forklift, they usually end up trapped underneath it.

Forklifts overturn most often when they are being operated without a load and the forks are elevated.

Other factors that can increase the risk of a forklift tipping include:

• turning sharply
• travelling across an incline or uneven ground
• travelling with a raised load
• carrying a load forwards down a slope
• carrying an unevenly balanced load
• braking hard while the forklift is loaded

Speed and stopping distances

Forklifts that are moving too fast have trouble stopping and this can cause the forklift to tip over or the load to fall off.

You should calculate the safe stopping distances for your forklifts when being operated at various speeds. As a guide, a forklift needs at least three metres to stop when traveling at 6km/hour (walking pace).

Speed limits must be appropriate for the area and task. Set speed limits that take into account:

• pedestrian flow
• potential areas of poor vision for forklift operators
• operating environment (e.g. inclines and lighting)
• types of loads being carried
• factors that could affect the forklift’s traction (e.g. oily, wet or dirty ground surfaces).

Getting on and off

Around a third of forklift-related injuries occur when an operator gets on or off a forklift. Slipping or falling from forklifts often results in serious strains and sprains. Make sure that forklifts have anti-slip steps and vertical grab handles so that operators have at least three points in contact with the forklift when they are getting on and off of it (e.g. two feet and one hand or two hands and one foot). Review your work practices and consider whether you can reduce the number of times operators need to get on and off their forklift.

Forklift operators can also suffer neck and back strains from continually looking up when stacking and looking behind when driving in reverse. Aids that limit the need for operators to crane their necks can assist in reducing these types of injuries.

In some cases, driving on uneven surfaces can contribute to back strains. At workplaces where these injuries are common, the quality and condition of forklift seats, together with road surfaces, should be reviewed and upgraded.

Handling loads

Overloaded forklifts are more likely to tip or lose their loads. When this happens, the forklift operator and pedestrians are at risk of injuries.

Each forklift has a ‘load capacity data plate’. These plates detail the load each forklift is able to safely lift. These limits must never be exceeded.

The shape and size of a load also affects the way it should be lifted. When a load is raised, the forklift is less stable. Driving with a raised load can easily lead to overturning, particularly if the forklift is being driven quickly, around a corner or over an uneven surface.

Dangerous environments

Operating petrol, diesel and liquid petroleum gas (LPG) powered forklift trucks in poorly ventilated spaces such as cool storage or freezer rooms is dangerous because hazardous exhaust fumes can build up and kill people. Carbon monoxide is an especially dangerous emission because it is odourless and so people exposed to high levels may have little or no warning before they collapse.

There are also significant risks involved when forklifts are being used to handle flammable dangerous goods.

Pedestrians

Pedestrians and forklifts need to be kept separate. The first step is to identify the places where a collision could occur and take into account floor surfaces, exits and driveways. Your workers will often be the best source of information, so they should be consulted and involved in the process.