In 2013, we published an article in BIC on the huge increase in forklift-related fatalities that were occurring in the Houston area. In the years since, forklift-related fatalities have fallen, and in fiscal year 2015 there was one compared to five each fiscal year 2011 through 2013. Since January 2015, serious incidents resulting in amputation, hospitalization or loss of an eye have been required to be reported to OSHA. Looking at a full calendar year of those reports, we can see forklifts still represent a significant hazard in the workplace. In calendar year 2015, we had 29 reports of serious incidents ranging from a severe finger laceration to a hospitalization after a worker was crushed by a rollover protective structure (ROPS) during a tip-over. The fatality we had last year involved contacting an overhead powerline with a rough-terrain forklift while moving an oil water separator. The serious incidents can be categorized as:
- Struck-by (SB) incidents include SB-powered vehicle (seven); SB falling object or equipment (six); and SB shifting, rolling or moving object or equipment (three). Loads move, shift and fall. Workers should stay clear of the area where the load and other materials that may be bumped may shift or fall. Workers need to remain aware of forklift movements and stay out of travel paths including the area a load may fall while in transit. Operators need to ensure their travel paths are free of pedestrians and move cautiously where a worker may be obscured from vision.
- Caught-between (CB) incidents include CB stationary and moving objects/equipment (eight) and CB moving objects/equipment (one). Operators should ensure feet and hands remain within the forklift cab and seat belts are always worn. Maintenance and hydraulic fluid related to the mast system seems to show up frequently, even in previous forklift fatalities. The mast may move, especially when hydraulic fluid is drained, and should be blocked to prevent falling. Hands should be kept out of potential pinch points.
- Fall incidents include fall lower-level nonmoving equipment (one) and fall lower-level structure or equipment (one). Maintaining a three-point contact when climbing into a vehicle, whether it is a forklift or a truck, prevents serious injuries. Though only one injury was related to forklifts, in the category of vehicles overall there were a number of serious injuries including fractures from falling while climbing in or out of a vehicle. When working at height, a properly designed and secured work platform must be used. A pal-let is not an acceptable work platform.
- Other incidents include fire vapors, gases or liquids (one) and injection (one). Propane used for fuel is flammable, and caution must be used wherever gas may build up and create a flammable atmosphere. Again, mast maintenance and hydraulics shows up and a severe injury occurred when the pressured fluid was injected into a worker’s hand. An energy control program addressing forklift maintenance would prevent many serious injuries.
Lessons learned include the importance of operator training and implementing and enforcing safe operating procedures in the facility. The OSHA standard under 1910.178(l) requires powered industrial truck (P.I.T.) operators be trained and competent, with provisions for refresher training and evaluation every three years. If the operator is involved in an accident or near miss, is observed operating in an unsafe manner, an evaluation reveals the operator is not operating in a safe manner, they are assigned a different type of truck or conditions in the workplace change, then he/she also needs refresher training and evaluation. If you use or operate forklifts, review 1910.178 Powered Industrial Trucks for the full OSHA requirements. It would be prudent to also instruct other workers in areas where forklifts operate on hazards such as the dangers and limitations of forklifts and the hazards of falling loads.
OSHA’s website www.osha.gov has a P.I.T. page under the “Safety and Health Topics” link with helpful information and tools. The compliance assistance specialist is a non-enforcement position responsible for outreach and assistance.
For more information, contact Jim Shelton at shelton.james@dol.gov.
