Fork lift truck safety

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Fork lift truck safety
An lpb toolbox talk
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Fork lift truck safety

• Fork lift trucks (FLTs) are used in a wide
  variety of industries including commerce,
  warehousing, retail, agriculture and
  construction.
• Their safe operation depends on a range of
  factors common to all these establishments.
• This toolbox talk discusses these safety factors
  and the hazards of ignoring them.

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Fork lift truck safety

• Always use trained and accredited FLT drivers.
  Remember there are many different types of FLT.
• FLT driving and operation is a specialised skill.
  It is not the same as driving a car.
• Contact ROSPA and other safety organisations for
  further details on specific training courses.

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Always have clear FLT/ people demarcations Case
study 1

• A man was driving his own car along a works road.
• A FLT was driven out of a plant area from behind
  a stack of drums.
• Its forks, which were slightly raised, went
  straight through the rear drivers-side door of
  the car.
• Fortunately, there were no injuries.

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Lessons learnedCase study 1

• Have clearly marked priority routes for FLTs
  and keep pedestrians out of them except where
  absolutely unavoidable.
• Take extra care when crossing demarcation lines
  (FLTs and people or other vehicles bicycles are
  particularly at risk).
• Be especially vigilant when emerging from areas
  where you cant be seen.
• Always travel with the forks at the lowest level.

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Never climb or ride on the forks Case study 2

• A man assisting the FLT driver stood on the
  forks, which were then raised to give him a view
  of something above his head.
• His foot became trapped between the forks and one
  of the fork masts.
• His foot sustained crush injuries which took
  months to recover.
• There are safe, approved techniques for lifting
  people. Again, consult ROSPA.

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Never indulge in horseplay with FLTs

• Do not drive FLTs too fast. They can easily go
  out of control.
• Do not race with other FLT drivers.
• If an accident happened, other people could be
  hurt or killed and property damaged.
• FLTs are very heavy and can go quite fast (up to
  30mph). Always travel at a safe speed.

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Other key safe behaviours

• Always carry out prescribed pre-use checks.
• Never exceed the safe working load of the FLT
  this is usually clearly printed on the truck
  masts. Make sure loads are well balanced and
  distributed.
• Always ensure a clear view when driving the FLT.
  If the load on the forks is high, it may be safer
  to reverse than go forward.
• Make sure that other people in the area, are not
  in danger of being trapped behind or between
  items being moved.

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More key safe behaviours

• Always stack and de-stack in an orderly fashion
  to prevent items falling. Ensure that items are
  placed firmly on the forks before lifting or
  lowering.
• It is normal to lift items on pallets or in boxes
  that have permanent legs to facilitate even
  distribution of the load on the forks and
  minimise the risk of things dropping off.
• Use a specific driver/FLT ignition key security
  system.
• Work with a standby person.

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A very unsafe practice

• Never do anything like this

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The power gameCase study 3

• Most FLTs are powered by electric batteries or
  gas cylinders. Recharging batteries or
  changing/filling cylinders are frequent
  requirements. Hydrogen is generated.
• A man was cleaning the top of a FLT battery
  whilst it was being recharged.
• He was using a screwdriver wrapped in a cloth.
• The screwdriver blade bridged two battery
  terminals causing an arc which ignited an
  explosive mixture containing hydrogen in a
  battery cell.
• Flying debris from the cell caused the man
  serious eye injuries.

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Lessons learnedCase study 3

• FLT batteries are large and powerful. They should
  be cleaned and maintained by use of
  non-conducting tools.
• Goggles should be worn when working on them.
• FLT battery terminals should have insulating caps.

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The power gameCase study 4

• Flammable gas escaped from the filling line due
  to the seal being missing from the filler nozzle
  while a FLT gas tank was being refilled.
• Considerable plant damage and minor injuries to
  the FLT driver occurred.
• Check that all vital components are in place
  before starting to use the flammable gas.

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Further information

• LPB articles
• Explosion when refuelling a liquid gas-driven
  stacker, LPB 087
• Things not what they seem to be - a fork lift
  truck accident, LPB178
• Other information
• HSE Booklet HS(G)6 Safety in working with lift
  trucks. ISBN 071761 781 5
• HSE Guidance Note PM28 Working Platforms
  (non-integrated on fork lift trucks)
• HSE Specialist Inspector Reports No60, Safety of
  Industrial Lift Trucks
• Fork Lift Truck Association

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Disclaimer
Whilst the Institution of Chemical Engineers has
made every effort to ensure the accuracy of the
information contained in this training
presentation, it remains the responsibility of
those responsible for the operations to ensure
that the regulations and guidance issued by the
authorities are consulted, that an appropriate
risk assessment is carried out and that
appropriate procedures are stipulated and
followed.