If you search on the Internet for “forklift safety", the results that appear first are often articles about common forklift accidents and how to prevent them. This advice is important, but what if we apply prevention measures further back in the process, before a truck-mounted forklift is purchased? 

When shopping for equipment, it is easy to get caught up in the immediate promises of power and lift range instead of digging into any safety-related features. In the long term, however, the two most critical elements of the forklift’s longevity and performance are the safety features and the operator. 

Here we review important safety considerations for truck-mounted forklifts - equipment that is critical for a variety of industries, especially construction, materials handling, lumber and warehouse/distribution centres. We also discuss how operators can maintain injury- and accident-free records when operating forklifts. 

Why is all of this important to you and your operators? Consider the following: for fiscal year 2023, the US Occupational Safety and Health Administration (OSHA) reports that forklifts are fifth on the list of the top 10 most frequently cited standards. OSHA also estimates that each year in North America, there are an average of 87 fatalities and 35,000 to 62,000 forklift-related injuries. 

The safety of operators and those who work around forklifts is dependent on a team effort from the purchase of the forklift to the last load of the day. Ensuring everyone is adhering to accepted safety-related practices is an important operational consideration.

Forklift must-haves for safety:

Ground control – Anecdotally, insurance professionals working with industries utilising truck-mounted forklifts will tell you that operators slipping and falling, especially in rainy or snowy conditions when the forklift is elevated, is a major cause of claims. Actions like climbing up and down the rig and checking fluids become less hazardous at ground level.
Service and support – Regular and specific maintenance of your truck-mounted forklift helps avoid potential problems. By implementing a maintenance schedule along with a daily pre-trip inspection per the operator manual guidelines, you can minimise downtime and reduce the risk of accidents. If you are in the market for a truck-mounted forklift, check out the service and support options available by the authorised dealer for the manufacturer in your area. Ensure your operators follow a thorough pre- and post-trip checklist and encourage them to report and/or address any issues immediately. A “we can take care of that later” approach can be hazardous to everyone and lead to avoidable accidents or issues. Likewise, if you rely on a partner to provide maintenance and service, consider the number and reach of mobile service trucks it deploys, as you don’t want to be faced with significant downtime if something needs fixing. 
All-wheel brakes – The industry standard for truck-mounted forklifts has long been a single brake on the steering wheel. Look for brakes on all three wheels for two-thirds more stopping power.
Operator ergonomic comfort – A comfortable operator is a safe operator. Given this, look for features like ample foot room with motion and engine accelerator pedals ergonomically level with one another, no steering wheel column to obstruct feet, and an overall spacious operator cabin with great 360-degree panoramic views. In short, even the slightest variations (or modifications) can help operators perform at the highest, most efficient levels possible.
Fuel tank refill – Refuelling equipment can offer additional hazards for operators. This is particularly the case if operators must climb or drag a heavy diesel fuel hose and nozzle over the forklift or raise the fuel nozzle above their shoulders to refuel at the station when it’s mounted on the back of the transport. When sourcing equipment, look for models that have a fuel fill cap that is approximately waist high, located on the left, driver side of the forklift and transport truck, for optimal operator use.  
Fork carriage – For operator safety and work efficiency, see-through visibility is important and is often overlooked when it comes to fork carriages. At a minimum, look for equipment that offers a Class IV opening with Class III ITA Boards, as this combination offers the operator excellent visibility of both the forks and load. 
Seatbelt - A high visibility seatbelt creates visual accountability. 

Operator must-haves for safety:

Proper PPE—Ensure your operators have the proper personal protection equipment (PPE) to meet your requirements and those of the worksites they will be on. Common PPE includes hard hats, reflective vests, safety gloves and safety-toed footwear. 
Informed co-workers – An operator can follow all procedures, but a distracted pedestrian ignoring a blind spot or wandering into the path of a forklift can spell disaster. Ensure that all employees or contractors are trained in forklift safety and aware of possible operational hazards. In addition, we recommend your equipment incorporates as much safety-related lighting as possible.
Respect the load – Proper distribution and handling of the load, including management of starts, speed and stops, are essential to avoiding mishaps that can damage equipment, property and/or people. Everyone needs to know and adhere to the limits of the machine. That is why your operator must be trained and OSHA-certified to operate a Class VII rough-terrain forklift in order to understand, among other things, the forklift stability triangle in addition to all the safety aspects that come along with operating a truck-mounted forklift on uneven ground and unimproved surfaces. 
This is not an exhaustive list of safety tips, but the most common areas of concern and potential oversight are been covered. 

There are many performance considerations when purchasing a truck-mounted forklift, as productivity and uptime are also critical to your operation. So, as you are testing equipment and comparing features and benefits, be sure to also ask about service and support, safety features and operator ergonomics to ensure the long-term functionality of your forklift.