 Forklift batteries are extremely heavy. PHOTO OM Carrelli Elevatori |
Jay Bruscato is vice president, first aid & safety at Cintas Corporation, a leader in first aid and personal protective products.
Introduced nearly a century ago, forklifts today are used in construction, manufacturing, warehousing and materials handling environments. According to the Occupational Safety and Health Administration (OSHA), they are also the cause of approximately 34,900 serious injuries a year. To help organisations promote workplace safety, we have identified seven facts about forklifts and their risks.
 Jay Bruscato |
With the proper precautions and training in place, forklifts are safe, efficient and necessary machines. While general forklift operation might be part of a safety program, safety managers must regularly communicate with operators so that they can understand the hazards associated with the equipment and eliminate unsafe practices from the workplace.
Seven key forklift facts that can improve worker safety include:
- Forklift batteries expose workers to dangerous chemicals. Lead-acid and nickel-iron rechargeable batteries contain corrosive chemicals, which harm skin if a worker is not wearing personal protective equipment (PPE). Gloves, aprons, and face and eye protection are essential when handling batteries. Employees should also know how to properly clean up chemical spills.
- OSHA requires businesses with battery-operated forklifts to install eyewash stations and showers. Businesses must provide an eyewash station and, in some cases, an emergency shower within a 10-second reach of battery-operated forklifts. This helps minimise the impact of injuries caused by battery acid splashes or dust and flying debris. Organisations should partner with a safety provider that can maintain the eyewash station and regularly check fluid levels.
- Forklift batteries are extremely heavy and can weigh as much as 2,000 lb. (910 Kg). A forklift battery is much larger than a standard-sized battery. To ensure employees don't strain themselves while handling batteries, special equipment such as a battery cart should be used when recharging batteries. Protective footwear should also be worn by employees.
- OSHA requires training for forklift operators. Each operator must complete formal training that includes classroom instruction, trainer demonstrations, exercises and practical evaluation of individual operator performance. Utilising instructor-led training, DVD programs and online courses offers a balanced approach to teaching employees. Organisations should also reinforce training with safety floor signs and wall posters.
- Some forklifts have a load capacity of up to 50 tons - the weight of about seven elephants. Although most forklifts haul only around one to five tons of materials, the weight of this cargo is still heavy. Erratic driving and improper braking, accelerating and turning can cause forklifts to crash, along with the materials they are transporting. Employees must undergo training before being permitted to operate forklifts and handle batteries. Formal training will encourage safe behaviours, such as proper driving techniques and how to keep the work area free of obstructions that can create hazards for drivers.
- One in four workplace transport-related accidents involves a forklift truck.
Given the frequency of forklift accidents, workers should understand what steps to take in the event of an accident, such as how to call emergency personnel for help. Organisations can teach employees emergency response during training sessions.
- Forklift batteries can emit toxic gases while charging. While charging, batteries release oxygen and hydrogen gases, which can be highly explosive if the workplace is not properly ventilated. Organisations should use fume hoods or exhaust fans to keep emissions from reaching volatile levels.