The Industrial Truck Association (ITA) will soon be celebrating increasing awareness to the importance of forklift safety. Forklift Safety Day is a great opportunity to review your forklift safety program and/or plan. And if you don’t have a program or plan, this would be a great opportunity to create one! Here's a link to the events taking place in Washington on June 10 and 11.
Start with Training
Are all of your forklift operators up-to-date on their training. Remember, forklift operators must receive refresher training every three years, and be evaluated on the equipment that they operate.
Learn more about Operator Training and our classes at our Training Page.
Inspections and Maintenance
We know that pre-shift inspections of all equipment are required by OSHA. But did you know that by taking a few minutes to inspect equipment not only improves safety, it helps you identify small issues before they blossom into giant repair or injury and damage headaches.
Planned Maintenance – This is a great opportunity to review your current PM program. Is it being executed properly according to intervals you require? Is the Planned Maintenance complete and thorough? A thorough and robust Planned Maintenance program is key to maintaining safety and productivity of your forklifts.
CLICK HERE to get a quote on a Planned Maintenance Program tailored to your fleet’s requirements.
Forklift Safety is No Accident
We’re here to help you maintain safety in your forklift operations by ensuring all your employees that might operate a forklift, know the limitations and dangers of forklifts AND to ensure they are all operating a peak efficiency and safety. To speak to one of our professional about any aspects of your forklift fleet’s safety or performance, just give us a call at 804-233-0051.
Your forklift’s forks bear the brunt of your loading and unloading operations. Wear and tear, or damage to either component can create a dangerous situation for your employees and anyone working around your fleet. And a 10% wear on your forks can reduce your safe lifting capacity by 20%, making your 5,000lb. forklift, a 4,000lb. forklift.
Inspecting your forklift forks regularly is essential for safety and efficiency. Here’s a step-by-step guide to inspecting your forks properly:
1. Visual Inspection
Check for Cracks & Damage – Look closely for cracks, bends, or other signs of damage. Pay special attention to welds and stress points.
Inspect for Bending or Warping – Lay a straight edge along the fork blade to check for any bending. Even slight bends can reduce lifting capacity.
Look for Wear on the Heel – The fork heel (where the blade meets the shank) is a high-stress area. If it’s worn down by 10% or more, replace the fork.
Check for Surface Damage – Rust, deep scratches, and chipped paint could indicate hidden damage or weak spots.
2. Measure Fork Thickness
Use calipers to measure the thickness of the fork heel.
Compare it to the original thickness. If it has worn down by 10% or more, replace the fork (this reduces load capacity by about 20%).
3. Check Fork Hooks & Mounting Points
Ensure the hooks are not cracked or excessively worn.
Verify that the locking pins are functional and secure.
Make sure the forks are properly mounted and not loose.
4. Confirm Even Fork Height
Set the forks on a level surface and check if the tips are even.
A difference of more than 3% of fork length means one fork is more worn than the other and should be replaced.
5. Inspect Load Markings
Make sure the load capacity markings on the forks are visible and legible.
If they are missing or unreadable, you may need to replace the forks or have them re-marked.
6. Test Fork Operation
Engage and disengage the forks to ensure smooth movement.
Look for signs of unusual resistance, sticking, or instability.
7. Follow OSHA or Manufacturer Guidelines
OSHA and forklift manufacturers typically recommend daily pre-shift inspections and full inspections at least once per year (or more in high-use environments).
Learn more about the types and classes of forkls available for your forklift. If any defects or wear exceed safety limits, replace the forks immediately rather than attempting repairs. Forklifts depend on strong, reliable forks to operate safely. Contact us at 804-233-0051 and we will help you select the proper forks for your forklift and operational requirements.
Proper forklift operator training to meet OSHA requirements consists of classroom instruction by a credible source, hands-on evaluation and equipment- and facility- specific training. Most companies have a handle on the first two components. In many cases, employers also follow up with specific training using the equipment in their facilities. However, all too often, companies ignore the final aspect of ensuring full compliance with OSHA requirements.
Each facility, be it warehousing, assembly or manufacturing, is unique and has its own set of potential hazards. These potential hazards must be addressed in terms of operating the lift equipment in them. To ignore this is to put your operation and finances in jeopardy, because an accident can occur as a result of one of these hazards. OSHA offers specific guidelines to help guide you through your facility inspection and to identify these potential hazards.
Workplace Layout & Hazards
Aisle Width & Traffic Patterns – Ensure operators are trained on navigating tight spaces and avoiding collisions.
Pedestrian Safety – Identify high-traffic pedestrian areas and enforce safety protocols.
Loading Dock Safety – Train operators on loading/unloading techniques and dock-specific hazards (e.g., dock edges, trailer creep).
Ramps & Inclines – Address safe travel on slopes, including weight distribution and braking techniques.
Blind Spots & Mirrors – Ensure operators are aware of areas with limited visibility.
Overhead Clearances – Are there low-hanging items that an upright could damage, or doorways. Be sure your operators are aware of these.
Equipment-Specific Training
Type of Forklifts Used – Cover differences in controls, stability, and lifting capacity for various forklift types (counterbalance, reach truck, order picker, etc.).
Attachments – Train operators on attachments like clamps, rotators, or extensions and how they affect load handling and stability.
Pre-Use Inspections – Ensure daily checklists include site-specific concerns, such as dust, debris, or temperature extremes.
Load Handling & Material Storage
Types of Loads – Address how to handle materials specific to your site (e.g., pallets, bulk materials, fragile items).
Storage Racking & Stacking Rules – Train operators on proper stacking height, weight limits, and load stability.
Hazardous Materials – If applicable, cover handling and storage of hazardous materials per OSHA regulations.
Floor Loading Limits – Be sure your operators do not take heavy loads on to floors not rated to handle them.
Environmental & Seasonal Considerations
Floor Conditions – Address potential hazards like wet floors, debris, or uneven surfaces.
Regulatory Compliance – Training must align with OSHA’s Powered Industrial Truck standard (29 CFR 1910.178) and any local safety laws.
Hands-On Training & Evaluation
Practical Demonstration – Have operators practice on-site tasks under supervision.
Site-Specific Evaluations – Conduct hands-on skill assessments in the real work environment.
Refresher Training – Provide ongoing training for new hazards, equipment, or changes in workflow.
Visit our Training Page to learn more about our Forklift Operator Training and Train the Trainer training programs, and see our Training Schedule. There you will also find useful downloads like IC and Electric forklift inspection forms as well as a Forklift Operator Questionnaire. For more information on our training, or to schedule, please contact us at 804-233-0051.
