View all topics

Avoiding Struck-By Hazards When Operating Forklifts

Struck By | OSHA Fatal Four

The Problem

Forklifts are an essential part of many workplaces, but they also present significant struck-by hazards. Each year, hundreds of workers are injured or killed in forklift-related incidents. Most of these accidents occur because of poor visibility, improper operation, or failure to follow safety protocols. Today, we’ll focus on identifying these hazards and discussing how to operate forklifts safely to prevent struck-by incidents.

Identify the Hazards

  • Blind Spots: Limited visibility can prevent operators from seeing pedestrians or other obstacles.
  • Unsecured Loads: Improperly loaded or unstable cargo can shift or fall, striking workers nearby.
  • Excessive Speed: Driving too fast reduces reaction time and increases the likelihood of collisions.
  • Pedestrian Proximity: Workers walking near forklifts are at risk of being struck, especially in tight or busy areas.‍
  • Improper Backing: Forklift operators backing up without checking their surroundings can hit other workers or objects.

Safety Practices and Preventative Measures

To reduce struck-by hazards, follow these critical steps:

  1. Maintain Clear Visibility:

    • Always ensure the path ahead and around the forklift is clear.
    • Use mirrors and spotters in areas with blind spots.
    • Avoid carrying loads that block your line of sight; drive in reverse if necessary.

  2. Secure and Balance Loads:

    • Make sure loads are stable and evenly distributed before moving.
    • Do not exceed the forklift's rated capacity.
    • Use proper securing tools like straps or nets for loose items.

  3. Control Speed:

    • Operate the forklift at safe speeds, especially in crowded or confined spaces.
    • Slow down when turning, and avoid sudden stops to prevent load shifts.

  4. Warn and Communicate:

    • Use warning horns, lights, and alarms to alert pedestrians of your presence.
    • Establish eye contact with pedestrians to ensure they’re aware of your position.

  5. Create Safe Pedestrian Zones:

    • Separate forklift pathways from pedestrian walkways whenever possible.
    • Use barriers, floor markings, or signs to designate forklift-only areas.
    • Avoid operating forklifts in areas with high pedestrian traffic unless absolutely necessary.

  6. Safe Backing Procedures:

    • Always check your surroundings before backing up.
    • Use spotters when reversing in tight spaces or around pedestrians.
    • Never assume the path behind you is clear—always confirm visually.

  7. Training and Certification:

    • Only certified and trained operators should use forklifts.
    • Regularly refresh training to ensure compliance with OSHA standards.

Real-Life Case or Scenario

Where possible, use an actual incident that you have experienced or been involved in.

E.g. In one incident, a worker was struck and injured by a forklift because the operator was carrying a load that blocked their view. The worker didn’t see the forklift approaching, and the operator couldn’t see the worker in their blind spot. Proper use of a spotter and better communication could have prevented this accident.

Employee Responsibilities

  • Always follow forklift safety protocols, including speed limits and load limits.
  • Be aware of your surroundings, especially when working near forklifts.
  • Communicate with forklift operators to ensure clear visibility and understanding.
  • Report any unsafe conditions, such as broken alarms or unclear walkways, to your supervisor.

Employer Responsibilities

  • Provide proper training and certification for all forklift operators.
  • Maintain forklifts to ensure safety features like lights, alarms, and mirrors are functioning.
  • Establish clear forklift pathways and pedestrian zones to minimize risks.
  • Conduct regular safety audits to identify and address hazards.

Discussion & Questions

  • "What are some common forklift hazards you’ve noticed on our job site?"
  • "How can we improve communication between operators and pedestrians?"
  • Allow workers to share their experiences and suggest safety improvements.

‍

Commitment/Action Plan

Let’s commit to practicing safe forklift operation starting today. This includes slowing down in tight spaces, ensuring clear visibility, and prioritizing communication with pedestrians. Everyone has a role in preventing struck-by incidents.

Wrap-Up

Struck-by hazards involving forklifts are preventable. By following these safety practices and staying alert, we can protect ourselves and our coworkers from serious injuries. Thank you for your attention and commitment to safety.

Standards Overview

  • OSHA Standard 1910.178 regulates forklift operation, requiring proper training and certification for operators.
  • Employers must ensure that forklift safety practices are followed and that equipment is properly maintained.
  • OSHA emphasizes the need for clear visibility, controlled speeds, and the use of warning systems to protect pedestrians and operators.
OSHA Occupational Safety and Health Administration

Legal Disclaimer

This toolbox talk is provided for informational and educational purposes only. It is not intended to be a substitute for professional legal, safety, or regulatory advice. The information presented is based on best practices and general industry standards but may not apply to all workplace situations.
‍
It is the responsibility of the employer, supervisors, and workers to ensure compliance with applicable federal, state, and local laws, regulations, and standards. The authors, presenters, and distributors of this toolbox talk assume no liability for the use or application of the information provided.
‍
Participants are encouraged to consult appropriate legal, safety, or regulatory professionals to address specific concerns or questions. Always follow your organization's policies and procedures for workplace safety and hazard mitigation.

All Rights Reserved Site App Pro 2024