The wide use of forklifts and other motorized vehicles in the workplace has led to large numbers of injuries. This has been true despite an existing regulation by the Occupational Safety and Health Administration (OSHA). This regulation governs the use in the workplace of forklifts, platform lift trucks, motorized hand trucks and other specialized industrial trucks powered by electric motors and internal combustion engines. OSHA classifies all such vehicles as Powered Industrial Trucks.

OSHA determined that its Powered Industrial Trucks regulation needed to be strengthened to respond to the high number of injuries. In 1999, OSHA finalized a change in the regulation which clarified and expanded the employer's duty to train and certify operators of powered industrial trucks. Below are the basic requirements of the revised regulation (also called a standard), information about dangers associated with powered industrial trucks and ideas to help ensure that employers are complying with this regulation.

The Law

OSHA, a federal agency with jurisdiction over private-sector workers, issued this regulation. However, public sector workers covered by state OSHA plans (such as PESH in New York State) are also covered by this regulation. The only difference is that enforcement is handled by the state, rather than the federal agency. The OSHA standard for powered industrial trucks used by general industry can be found in the Code of Federal Regulations under 29 CFR 1910.178. Here are some of the specific requirements of the standard:

• Hazard Evaluation: Employers are required to determine which kind of powered industrial truck is required to do a job safely. They must consider load capacity, terrain, and potentially hazardous situations, such as the presence of flammable liquids and gases, or explosive dust. The standard contains a chart that instructs employers which class of powered industrial truck to use in particular situations.
• Maintenance: Any powered industrial truck that is defective, in need of repair, or in any way unsafe, must be taken out of service until it has been restored to safe operating condition. All repairs must be made by authorized personnel and then re-examined before they are returned to service. Safety examinations must be conducted at least daily and if trucks are used on a round-the-clock basis, examinations must be conducted after each shift. Defects found must be immediately reported and corrected. There are a number of specific maintenance requirements in the regulation as well.
• Loads: They must be stable, safely arranged and within the rated capacity of the truck.
• Fire Safety: Fire aisles, access to stairways and fire equipment must be kept clear.
• Guarding: An overhead guard must be used as protection against falling objects. A load backrest extension must be used if the possibility exists that the load may fall backward.
• Traveling: The driver must slow down and sound the horn when crossing aisles and at locations where vision is obstructed. Speed must be reduced on wet and slippery floors. If the load being carried obstructs forward view, the driver is required to travel with the load trailing.
• Fueling: Fuel tanks may not be filled while the engine is running. Any spills must be cleaned up before restarting the engine.
• Batteries: Battery charging installations must be located in areas designated for that purpose. Facilities must be provided for flushing and neutralizing spilled electrolyte, for fire protection, for protecting charging apparatus from damage by trucks, and for adequate ventilation for dispersal of fumes from batteries.

Training

Before operating a powered industrial truck, employees must receive proper training in safe loading, driving, and other issues. Forklift operators must be trained in the following topics:

Truck-related topics

• operating instructions, warnings and precautions for the specific type of truck that will be operated
• differences between trucks and automobiles (for example, forklifts are heavier, less stable, usually steered by back wheels, designed with a three-point suspension system, and use different foot controls)
• truck controls & instrumentation (where they are located, what they do, how they work)
• engine or motor operation
• steering and maneuvering
• visibility (including restrictions due to loading)
• fork and attachment adaptation
• vehicle capacity and stability
• inspection and maintenance that the operator will be expected to perform
• refueling and or charging/recharging batteries

Workplace-related topics

• surface conditions where vehicle will be operated
  composition of loads, load stacking & unstacking
  pedestrian traffic
• narrow aisles and other restricted places where vehicle will operate
• hazardous conditions
• ramps and other sloped surfaces that could affect vehicle stability
  enclosed areas where carbon monoxide or diesel exhaust could build up

Training methods

Training must be conducted in three ways:

• lecture, discussion, computer learning, video tape, written information,
• practical training (demonstrations by the trainer and practice performed by trainee), and
• evaluation of the workers' performance in the workplace.
  

Trainers

OSHA says that employers must provide instructors who have the knowledge, training, and experience to train powered industrial truck operators and evaluate their competence.

Evaluation and Refresher Training

Prior to December 1, 1999, employers must evaluate workers who currently operate powered industrial trucks to determine the workers' competence to drive the truck. This evaluation must be based on OSHA's training program. Operators found competent to drive the truck safely need not be trained in any parts of OSHA's training program about which they have previously received training. Anyone hired after Dec. 1, 1999 must receive the training before they operate a powered industrial truck.

Workers must be evaluated at least every three years after initial training.

Refresher training must be given when:

• workers operate powered industrial trucks unsafely
• an accident or near miss has occurred
• workers are assigned to drive a different type of truck
• a change in workplace conditions occurs.

Certification

The employer must certify in writing each employee who operates a forklift has been evaluated and/or trained according to OSHA's requirements. The certification must include the name of the employee, the date of the training and/or evaluation and the name of the person who performed the training or evaluation.

Hazards of Powered Industrial Trucks

Vehicle exhaust

Exhaust from internal combustion powered trucks contains carbon monoxide fumes. Carbon monoxide is an odorless, colorless, and tasteless gas. Symptoms of overexposure include headache, reddening of the skin, dizziness, roaring in the ears, nausea, weakness, rapid breathing, chest tightness, mental confusion, poor coordination, and sleepiness leading to unconsciousness. These symptoms may come on very rapidly, within a matter of minutes. Carbon monoxide exposure can be fatal.

Over the long term, low-level carbon monoxide exposure can cause a loss of appetite, impaired vision and hearing, and irregular menstrual and ovulation cycles. It can also slow down reaction time, affect judgment, and cause personality changes. Workers with existing heart conditions are particularly susceptible to additional heart damage from carbon monoxide exposure.

OSHA's legal limit (referred to as the permissible exposure limit or PEL) for exposure to carbon monoxide is 50 parts per million (ppm) averaged over an 8-hour workday. (Parts per million is a measure of the concentration of a chemical in the air. 50 ppm means that there are 50 parts of carbon monoxide in every million similarly sized parts of surrounding air.) For New York State public employees who are covered by PESH, the PEL is 35ppm.

Forklift operators exposed to diesel exhaust in the work environment may also be at risk for health problems. The composition of diesel exhaust varies depending on engine type, operating conditions, lubricating oil, and whether an emissions control system is present. Diesel exhaust can cause eye irritation and respiratory problems, and has the potential to cause cancer. There is no OSHA standard for diesel exhaust.

Acids

Strong acids (such as sulfuric acid) are used in batteries. Make sure you are properly protected if you are required to work with acids. To prevent injury:

• Wear protective clothing--such as rubber boots, a rubber apron, chemical goggles, face shields, and rubber gloves--to guard against chemical splashes and burns.
• When charging batteries, acid should be poured into water; water should not be poured into acid. (This may result in an explosion.)

Maintenance and Operation of Propane Trucks

Extra precautions need to be taken with trucks powered by propane or liquefied petroleum gas (all of which are discussed in the regulation):
Always check for gas leaks. Never start the motor if there is a leak.
Don't store the truck near intense heat or explosive materials.
If the truck is to be left standing for any length of time, shut off the hand valve and let the fuel system run dry.

Tips for forklift operators

• In stockrooms, double-acting doors should have windows installed to minimize the possibility of employees being struck by a powered industrial truck, particularly forklifts.
• Whether loaded or empty, carry forks and platforms on lift trucks as low as possible. This reduces the possibility of overturning the truck or dumping the load.
• Loads should not be raised or lowered during travel.
  Internal combustion-powered trucks should never be used in small buildings or areas where there is inadequate ventilation.
• Wheels, high-lift platform rollers, chain sprockets and other moving parts should be guarded if they can potentially injure the operator or others.

What can unions do to protect truck operators?

Hazard Assessment: Health and safety committees can help employers evaluate the work environment and work tasks when deciding which type of powered industrial trucks to use. Committees can also monitor the environment to make sure that hazardous conditions are corrected. In addition, the union should be involved in investigating any accidents or near misses that occur with powered industrial truck operation.

Training: Unions can negotiate with employers about who provides training to make sure that:

• training is adequate and complies with OSHA requirements
• standard criteria are established to measure operator performance
• evaluation of operator performance is done in a fair and impartial manner.