As summer temperatures rise, so do the risks for heat-related illnesses—especially for workers in the material handling and warehouse industries, where physical exertion and limited airflow are part of the daily routine. Whether employees are loading trucks outdoors, managing logistics in open-air yards, or working in non-climate-controlled warehouses, staying cool isn’t just a matter of comfort—it’s a matter of safety. Employers have a responsibility to protect their teams from heat stress and related hazards. This article offers practical, proven tips to help keep your workforce safe, cool, and productive throughout the hottest months of the year.

1. Hydration Strategies

• Water stations: Place multiple shaded water stations with coolers or dispensers filled with ice water.

• Electrolyte options: Offer sports drinks or electrolyte powders to replenish salts lost through sweat.

• Hydration reminders: Use signs, mobile app reminders, or supervisors to prompt workers to drink water every 15–20 minutes.

2. Shade & Rest Breaks

• Pop-up tents or canopies: Provide shaded areas at regular intervals.

• Portable misting tents or fans: Use cooling fans or misting systems in rest areas.

• Mandatory cool-down breaks: Schedule 5–10 minute breaks in the shade every hour, more frequently if temps are above 90°F.

3. Clothing & Gear

• Lightweight, breathable fabrics: Encourage moisture-wicking clothing in light colors.

• Cooling gear:

  • Cooling vests (ice-pack or evaporative)

  • Neck wraps or towels soaked in cold water

  • Wide-brimmed hats or brim extensions on helmets for sun protection

• UV-protective gear to prevent sunburn and overheating.

4. Work Schedule Adjustments

• Start earlier or split shifts: Begin work at sunrise and pause during peak heat hours (typically 12–4 p.m.).

• Rotate tasks: Alternate between physically intense and less demanding tasks.

• Use buddy systems to monitor for signs of heat illness.

5. Cooling Equipment

• Battery-operated fans: Personal wearable fans for hard-to-reach sites.

• Portable misting fans: For job trailers or staging areas.

• Ice chest/coolers: Keep cold towels or drinks handy.

6. Training & Awareness

• Heat illness prevention training:

  • Teach symptoms of heat exhaustion and heat stroke.

  • Emphasize the importance of acclimatization.

• Post safety signs in common areas with visual cues for heat illness symptoms and first aid steps.

7. Technology Solutions

• Wearable sensors: Monitor core body temp or heart rate (ideal for high-risk environments).

• Weather alert apps: Notify crews when heat advisories are issued.

8. Environmental Enhancements

• Temporary shade structures near worksites.

• Pavement wetting (for road crews) to reduce ambient surface temperature.

• Tree planting (long-term) or use of artificial vertical shade barriers where possible.

Pro Tips

• Use OSHA’s Heat Safety Tool app for personalized alerts and recommendations.

• Gradually acclimate new or returning workers to heat over 1–2 weeks.

• Create a heat emergency response plan, including access to cold packs, cooling areas, and emergency contact protocols.

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. 
• How well do you know your operators? Download our Forklift Operator Questionnaire to get to know their experience operating lift equipment.
• 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. 
  • Download our Electric Forklift Inspection Form
  • Download our IC Forklift Inspection Form
• 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.
• Learn more about our Planned Maintenance Program.
• Learn the Five Main Benefits of Planned Maintenance.
• 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.