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Warehouses pose various risks to workers’ safety and well-being, especially when forklifts are added to the mix. Navigating tight spaces and handling heavy loads without understanding the potential hazards can lead to accidents, injuries and property damage. This blog will explore common forklift hazards that employers and workers should know about to maintain a safe working environment. By understanding these forklift hazards and implementing control measures, we can spot and reduce the risk of accidents, keeping your workplace safe and secure.

1. Improper Use of Forklifts 

Even though OSHA has a formal training program for forklift operators, some people still misuse these machines. From racing to taking dangerously sharp turns, the improper use of these machines can lead to severe injuries. To ensure forklift safety, it’s crucial that operators have proper training according to OSHA standards. Anyone getting behind the wheel of a forklift should have a certificate proving they know how to handle the machinery safely. 

2. Lack of Forklift Maintenance and Inspection 

Like any other type of machinery, forklifts need proper maintenance and inspection to ensure safety. Without regular upkeep, forklifts can experience brake failures, steering issues, or tire blowouts, all of which increase the risk of accidents. Performing regular forklift maintenance is crucial to identify and fix potential problems before they become serious hazards. Always inspect your forklift after a few uses, and if you notice any issues, do not use it until those problems are resolved. 

3. Blind Spots 

When a forklift is carrying a large and heavy load, the operator’s view is often blocked, making it difficult to see directly ahead. In these cases, it’s safest for the operator to drive the forklift in reverse so long as the operator is comfortable in doing so. To limit forklift dangers, pedestrians should be aware of the forklift’s blind spots and avoid the area while the forklift is in use. To further promote forklift safety, visibility can be improved with mirrors, cameras or proximity sensors to provide operators a clear view of their surroundings. 

4. Pedestrians 

When there is no clear separation between pedestrian walkways and forklift traffic areas, the risk of collisions increases. Inadequate signage, poorly marked floors and insufficient pedestrian safety training contribute to this forklift safety hazard. To reduce this risk, it’s essential to set clear guidelines and procedures for pedestrian safety in areas where forklifts operate. 

5. Overhead Obstructions 

Low ceilings or hanging objects can create dangerous situations for forklift operators. If a forklift’s load is high, it could collide with overhead obstacles, or the forklift may not fit into certain spaces, causing additional problems. To minimize this risk, mark the height of any low ceilings for forklift operators. Operators are usually aware of their forklift’s size and can use these markings to adjust their load and height accordingly. 

6. Overloading and Unsecured Loads

Overloading a forklift can lead to instability and poor handling, posing a major safety risk. When forklifts carry loads beyond their capacity, they become harder to control, increasing the chance of tip-overs and dropped loads. Additionally, overloading strains the forklift’s components, leading to other forklift dangers like mechanical failures and accidents. To prevent overloading, operators must be trained to assess the weight and dimensions of the loads they handle and understand their forklift’s capacity limits as specified by the manufacturer. Forklift operators should consider factors like load distribution, load centre and the height at which the load is lifted. Using visual aids like load capacity charts and weight indicators can help operators make informed decisions. Another potential risk is unsecured loads. Every forklift has individual attachments like clasps and backrests that should be used to secure loads. Upon loading, check to make sure nothing feels loose or wobbly. If you feel it give too much, good sign it needs ot be tightened to avoid your load falling and injuring someone. To prevent this, everyone on the team should know how to secure a load with straps.

7. Improper Unloading Procedures 

Inadequate unloading procedures can lead to accidents and damage. If you frequently receive shipments, you likely rely on forklifts to transport items from the truck to your warehouse. All operators should understand forklift health and safety and lift truck safety. Improper techniques can cause falls, tip-overs or collisions. The ramps and lift on trucks need to be operated correctly. If the docks or ramps are not set up properly, it could be dangerous. Training should cover proper angles, positioning and loading dock or trailer alignment. Operators should ensure the forklift is securely parked or choked before loading or unloading. Communication is key. Forklift operators and workers must remain in constant communication to ensure safe and efficient operations. Using standardized hand signals, communication devices or visual aids can help improve communication and coordination. 

8. Floor Conditions 

Uneven or poorly paved floors can cause issues for forklift operators. They may damage the forklift and lead to accidents. Wet, slippery or debris-cluttered surfaces pose additional risks. Before allowing forklifts to operate, ensure the floors in your warehouse are clear and clean. 

9. Lack of Forklift Operator Training 

Forklift operators without proper training pose serious risks to themselves and others, leading to accidents and injuries. Operating a forklift demands specialized skills to navigate tight spaces, handle loads safely and adapt to diverse work environments. Without adequate training, operators may overlook crucial safety procedures like load limits, braking techniques and safe driving practices. Training programs must cover everything from pre-operational checks and handling loads to maneuvering in confined areas and responding to emergencies. Operators should also be educated about specific workplace hazards such as ramps and inclines. Comprehensive training ensures operators develop and maintain safe operating practices, addressing any gaps in knowledge or skills. Beyond forklift training, consider additional training for workers like fall protection, incident investigation and aerial lift operations, depending on your workplace needs. Remember, continuous training is crucial to keep operators updated on industry standards and safety protocols. 

10. Speeding and Reckless Driving 

Excessive speeding and reckless driving should always be avoided. Forklifts are heavy machines that can pose risks even at slow speeds if operated carelessly. Operators must be trained in safe driving practices, emphasizing the need for appropriate speeds, especially in crowded areas or when handling unstable or elevated loads. Here are some safe driving techniques for forklift operators:

• Use horns and lights to signal the forklift’s presence.
• Yield to pedestrians.
• Follow designated traffic lanes and adhere to speed limits.

Encouraging a culture of accountability and urging operators to report incidents or near-misses involving speed or reckless driving can further enhance forklift safety. 

11. Improper Fueling and Charging 

Improperly charging or fuelling a forklift can lead to accidents, fires or equipment damage. Proper training for forklift operators is essential in handling and storing fuel safely and following correct procedures for refuelling or recharging forklift batteries, whether electric or fuel-powered. Training should cover safe battery handling and maintenance, storage of flammable fuels, correct use of charging equipment inspection of battery connections and adherence to charging schedules. Designated fuelling or charging areas should have proper ventilation and safety measures to reduce the risk of fires or explosions. By enforcing these procedures, the risk of accidents and fires can be minimized, ensuring the safety of forklift operators and those working nearby.

The Role of Forklift Truck Risk Assessments 

As you can see managing a large fleet of forklifts comes with inherent risks that can have serious consequences. This is where forklift truck risk assessments can help, offering protection against accidents, injuries and costly downtime. For example: a forklift tip-over can damage equipment, injure an employee and halt production for hours. The effects can be extensive, impacting everything from employee morale and customer satisfaction. A forklift truck assessment could have prevented it all by identifying existing hazards in the warehouse, such as uneven floor surfaces, and prompting corrective actions. Accidents like tip-overs can lead to hefty costs, but a risk assessment can offer significant savings. Taking a systematic approach helps identify and address potential forklift dangers before they escalate into costly incidents. Workplaces with implemented safety programs have been shown to experience fewer accidents altogether. Investing in forklift risk assessments is about more than just compliance; it safeguards your workers, protects your assets and streamlines your operations.

Keep Your Warehouse Efficient with Tailift Canada 

Now that you’re aware of the potential dangers associated with forklifts that may be lurking in your warehouse, you can approach safety with confidence. Explore our selection of Tailift forklifts by connecting with us today and learn more about how we can support your operations. Stay tuned for further insights and updates on enhancing forklift safety and efficiency with Tailift Canada.