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A great presentation provided by John Newquist, Assistant Regional Administrator at DOL-OSHA (Region V)
Citation preview
Forklift Safety
Draft 7 27 2011
July 13, 2011
• One person died Wednesday after a forklift accident in Fluvanna County. The incident happened shortly after 5 p.m. in front of the Tapscott Brothers Lumber Company. (NC)
• The Will County Coroner's line reports that a 35 year old Aurora man was pronounced deceased at Silver Cross Hospital at 7:22 AM Wednesday morning, after a forklift accident in Mokena. The Coroner's line stated that Jose R Barrera-Ruiz died of multiple injuries.
These Deaths Were Preventable• These were not isolated
incidents.
• There were 1000+ deaths in 10 Years 2000-2010.
• Workers have a right to a safe workplace.
• In the operation of forklifts these are the FIVE largest risks among many:– Falls – Hit by Falling or moving
Load– Hit by Forklift– Equipment overturning– Amputation
• All of these are preventable
2010 Injury Causation Statistics• 32 falls: includes 12 pallet, platform or forks, 10 forklift went off dock, 1 ejected
from forklift, 5 fall from load lifted, 1 fall through hole, 1 order picker platform, 2 mezzanine
• 46 struck by falling/moving object or load
• 36 struck by forklift
• 15 forklift overturned
• 29 crushed or caught in forklift/load and an object
• 10 caught in amputation
• 5 burns / fire
• 3 CO, 1 Ammonia
• Type of forklift not included - many not identifying the type
Injury Prevention Basics• Management Leadership
• Employee Participation
• Hazard Prevention and Control
• Education and Training
• Program Evaluation and Improvement
• Communication and coordination on multi-employer sites
• These principles are adopted and recognized by…– 2100 VPP Companies– 1600 SHARPs– 1926.20, 1926.21 – 1910.119– ANSI Z9.10– OHSAS 18001– States AR, CA, LA,
HI, MN, MT NV, NH, NY, OR, WA
Falls
• Pallets used as elevating platforms has lead to many deaths and is not acceptable
• Employees use what is available
• Use proper platforms designed per ANSI/ITSDF B56.1-2005
Elevating/Order Picker Truck
•Fall protection is required when the operator rides up with the load
•Use ANSI Z359 fall arrest equipment
Struck-by
• What should be done?
• Many a foot have been crushed by people getting too close.
• How close is too close?
Struck By
• Leaving forklift trucks without brakes or chocks
• Truck Moves
Struck By
• Falling Loads KILL• Loads improperly
stored kill people.• What can be done?
Struck-by
What should be done
when backing out?
Accidents – Forklift Leaves Dock
• November 1, 2000• An employee was driving
a forklift truck in reverse • She backed off of the
receiving dock and was pinned under the forklift
• Operator was not wearing seatbelt and the forklift didn't have a overhead guard
Overturned• Uneven surfaces
– Curbs– Potholes– Change in grade– Low tire pressure
• Seat belts• Excessive weight
lifted
Is a Forklift a Crane?
Qualified rigger?• OSHA’s Construction
Crane standard may apply in construction.
• Many injuries result from dropped loads when using slings for rigging.
Caught In-Between
Guarding Needed!
SHIB http://www.osha.gov/dts/shib/shib072709.html
There have been fatalities where standup type fork trucks crush the operator under cross bar of a rack system.
Body part outside frame of forklift is dangerous!
Lifting/Moving the Forklift
• Is there a procedure to get forklift off?
• What is the procedure to free a stuck forklift?
Truck Unloading
• Is material palletized?• Will the load stay stable
as straps are loosened? • Many times a person
adjacent to the load being removed is hit.
• Where do people stand?
Lockout or Guarding?
• The person who works on the forklift must know the OSHA lockout standards.
• Any body part can be cut or crushed if caught in a scissor point.
• Forklift maintenance fatalities – employees were crushed after jack failure, or crushed between mast and frame of truck because they didn’t block it.
Forklift Amputation Hazard
• Maintenance hazards:– Scissor point between
lifting carriage and mast.
– Pinch point between overhead guard and mast
• Chain and sprocket can amputate fingers.
•http://www.cdc.gov/niosh/face/stateface/ca/04ca012.html
Electrical
• When working around electrical wires be aware of any potential contact (electrocution).– 20ft. safe distance from overhead lines is required by
OSHA’s crane standard (1926.1400).
• If you must use the lift closer, this must be preplanned and elements of the crane standard must be addressed in the planning.
• Triple Fatality in Illinois when a forklift contacted overhead lines in a yard. ~2003
Fire / Burns
• The employee and the forklift were dowsed in toluene.
• The toluene ignited from an unknown source prior to the employee leaving the lift seat.
• The employee was severely burned. • The truck was a destroyed. • What could be done to prevent this?
Forklift strikes overhead pipe containing Toluene.
Many people trust these machines
Sample Safety Rules
• Follow Manufacturer’s instructions and OSHA regulations. Use ANSI/ITSDF B56 standards on forklifts if you cannot get the manufacturer’s rules.
• Follow CAUTION WARNING DANGER Labels. • Prohibit untrained personnel from operating all
forklifts.• A trained person must inspect each forklift at
least daily before use.• And many more!
Training• Hands on training is
necessary. A forklift is not a car.
• The worker must be able to demonstrate – safe operation in their
workplace – follow each forklift
manufacturers’ usage instructions.
BEFORE CERTIFICATION
•Initially
•Every 3 years
•Near Miss
Certification and Re-certification
Evaluation
•Date of Certification
•Operator’s name
•Trainer’s Name
Inspections
Per manufacturer’s guidelines. • At least daily before use.• Check all working components and safety
device.• Address all leakage of fluids.• Search for defective hydraulic/pneumatic
hoses.• Look for quickfix signs (not acceptable)
i.e. electrical tape, rags tied on hoses…
Inspections
Why is this inspection form weak?
Manufactured Attachment
NOTE: Use of such an attachment changes the load capacity of the PIV
DANGER: Manufacturer’s Written Approval Required
• Barrel lifter (liquid = inertia)
• Capacity plate update required?
• Don’t forget unapproved attachments can overload the trucks.
DANGER: Manufacturer’s Written Approval Required
Manufactured Attachment
Lifting Slabs
• Many injuries have occurred while lifting large flat objects
• Use lifting attachments designed and approved for each specific job.
• ANSI B30.20
Seatbelts
• Must be worn when equipped.
• Prevent the operator from being pinned by the truck or overhead guard.
Click for rollover video
Inspection
Labels• Ensure that
capacities for attachments are listed
Inspection
• Load Backrest Extension is damaged
Inspection
• How much wear is acceptable?
Forklift Inspections
• Overhead guard improperly welded
Forklift Inspection
• Broken Fiberglass Housing is a Laceration Hazard
Inspection
• Leaking Hydraulic Fluid
• Can lead to: – Low pressure– Air bubbles– Erratic operation– Slippery surfaces
Personnel Elevating Platforms
• Good Platform must include guardrails
• Secure the platform to the forklift.
• Screen at forklift side
Personnel Elevating PlatformsOSHA 5(a)(1) Violations
– ANSI/ITSDF B56.1-2005:
• No screen (scissor point)• Cannot be secured to
forks or backrest
Emergency Response
• What is the response if the drum contains flammable or toxic liquid?
Fire
• Cylinder gases ignited by forklift.
• What can be done?
Carbon Monoxide
0222 HCOOHC xx
Perfect World:
Real World:
xxxxx HCNOCOOHCONOHC 2222
Acute Exposure
• Headache• Nausea• Weakness• Irritability• Chest Pain • Unconsciousness
Chronic Exposure
• Headache• Dizziness• Anorexia• Ataxia• Confusion
Best Practice and Required in MNGeneral industry: Minnesota Rules § 5205.0116 Carbon Monoxide Monitoring
• Subpart 1. Internal combustion engine powered industrial trucks. The employer shall monitor environmental exposure of employees to carbon monoxide whenever internal combustion engine powered industrial trucks as defined in Code of Federal Regulations, Title 29, section 1910.178(a)(1) are operated indoors to ensure that carbon monoxide levels do not exceed those given in Code of Federal Regulations, Title 29, section 1910.1000, Table Z-1-A.
The air monitoring shall be done at least quarterly and represent exposures during a day of highest usage in the areas where employee carbon monoxide exposure is most likely.
• Subpart 2. Tailpipe exhaust gas analysis. The employer shall ensure that powered industrial truck engine exhaust gases do not contain more than one percent carbon monoxide for propane fueled trucks or two percent carbon monoxide for gasoline fueled measured at idle and at three-fourths throttle during final engine tuning in a regular maintenance program.
Exposure Limits
• OSHA 50 ppm 8-hour Time Weighted Average (TWA)
• NIOSH 35 ppm 8-hour TWA
• 200 ppm Ceiling by NIOSH
• ACGIH Threshold Limit Value is 25 ppm 8-hour TWA; 40-hour work week
PPM CO Time Symptoms
200 2-3 hours Headache, fatigue, nausea.
400 1-2 hours Symptoms intensify. Life threatening after 3 hours.
800 45 minutes
Dizziness, nausea, convulsions. Death after
2-3 hours.
1600 20 minutes
Dizziness, nausea, convulsions. Death within
1 hour.
ACGIH Recommendations
• Limit CO concentration to 1% or less for propane fueled trucks
• Limit CO concentration to 2% or less for gasoline fueled trucks.
Forklift Exhaust Test
• No Violation – Forklift emits low
level of CO
Prevention of CO Poisoning
• Maintain equipment in good working order
• Provide periodic tune-ups for forklifts to ensure that they run “lean”
• Periodic CO analysis of exhaust gases to determine emission concentrations
• Provide adequate ventilation• Install CO monitors
Storage
• What is the problem and solution?
Storage
• No Violation– Material stored
properly in racks
Material Handling
• Rack was hit by forklift and tagged out and pallets removed.
Material Handling
• No Violation– Aisle properly
marked
– Smooth Clean lanes
Struck By
• No Violation– Corner marked so
forklift operation can see around corner
Cautions
• Watch for any holes. These will flip some forklifts. These should be identified in advance and plans to prevent a forklift from going into one is necessary.
• Watch for aerial lifts and other mobile equipment. Barricade the equipment to prevent contact with each other.
Quiz
• How often does a forklift driver have to be re-evaluated/certified? __________
• Forklifts must be inspected every ________ before use.
• OSHA’s limit for Carbon Monoxide in an 8 hour shift is ____ ppm.
Resources
• www.osha.gov• Compliance Assistance Specialists in OSHA
offices• On-site Consultation• Quick Takes
http://www.osha.gov/as/opa/quicktakes• www.aiag.org Pedestrian & Vehicle Safety
Guidelines Comments or Corrections go to John Newquist
What is the pending hazard?
Summary
Training
Job Hazard Analysis
Written procedures
Manufacturer rules
Inspections
Further
• This ppt was prepared by John Newquist as a preliminary aid for people required to evaluate forklifts.
• Thanks to Misette Kobler, Carlos Gallegos and Janet S., for corrections and suggestions.
• Thanks to Joe Schwarz, Marc Snitzer, Walter Visage, Rick Dvorak, Cynthia Evans, Aaron Priddy, for previous work on the topic.
• This is not an official OSHA publication. Those will be on the OSHA.gov website.
• [email protected] is my email if you see any errors. This is just a draft as of the cover date.
• 312-353-5977
Wage & Hour Referral
• No one under 18 allowed on a PIT
“Order 7 of Hazardous Occupations” prohibits employees under 18 years of age from operating forklifts, employers must make certain that workers under 18 years of age are not permitted to use PIT’s.