Forklift Pit

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1910.178 (l)

1915.120 (a)

1917.1 (a)(2)(xiv)

1918.1 (b)(10)

1926.602 (d)

OSHAX.orgThe Unofficial Guide To the OSHA


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Disclaimer

This presentation is intended as a resource forproviding training on OSHAs revised poweredindustrial truck operator standards. It is not asubstitute for any of the provisions of theOccupational Safety and Health Act of 1970, or

for any standards issued by the U.S.Department of Labors Occupational Safetyand Health Administration (OSHA). It is alsonot a substitute for a powered industrialtruck operator training program.



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Acknowledgment OSHAs Office of Training and Education wishes

to acknowledge the following for contributing

some of the graphics used in this presentation: Caterpillar Lift Trucks Mason Contractors Association of America

Industrial Truck Association State of Utah Labor Commission - Occupational Safety &

Health Division Steamship Trade Association of Baltimore Taylor Machine Works, Inc. UAW - Ford National Joint Committee on Health and Safety

Appearance of products does not imply

endorsement by the U.S. Department of Labor.



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Powered IndustrialTruck - Definition

A mobile, power-propelled truck used to carry, push,

pull, lift, stack or tier materials. [American Society of

Mechanical Engineers (ASME) definition]

Excluded are vehicles used for earth moving andover-the-road hauling.

Commonly known as forklifts, pallet trucks, rider

trucks, forktrucks, or lifttrucks.

Can be powered through electric or combustionengines.



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Scope of Standard

The scope provisions of 1910.178(a), which arebased on ANSI B56.1 - 1969, remain in effect andcover: ... fork trucks, tractors, platform lift trucks, motorized

hand trucks, and other specialized industrial truckspowered by electric motors or internal combustion

engines. It does not apply to compressed air or nonflammablecompressed gas-operated industrial trucks, farmvehicles, nor vehicles intended primarily for earthmoving or over-the-road hauling.

This scope covers general industry, construction and

shipyards.



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Scope of Standard (continued)

For marine terminal and longshoringindustries, all powered industrial trucks are

covered, no matter what specialized name

they are given.

This includes, but is not limited to, straddle

carriers, hustlers, toploaders, container

reach stackers, and other vehicles that carry,

push, pull, lift, or tier loads.



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Reasons for New Standard

Powered industrial truck accidents causeapproximately 100 fatalities and 36,340

serious injuries in general industry and

construction annually.

It is estimated that 20 - 25% of the accidents

are, at least in part, caused by inadequate

training.



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Additional Reasons for NewStandard

Updated consensus standards have beenpublished.

OSHA has been petitioned to improve the

requirements for industrial truck training. Advisory Committee on Construction Safety and

Health has recommended improving the standard.

Resolutions have been introduced in the Senate

and House urging OSHA to revise its outdatedstandard.



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Forklift Fatalities, 1992-1996

Source: Bureau of Labor Statistics, Job Related Fatalities Involving Forklifts

86 89

120

95

114

1992 1993 1994 1995 1996



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Forklift Fatalities by Age Group1992 -1996

3%

10%

22%

21%

12%

5%

27%

Under 20

20 - 24

25 - 34

35 - 44

45 - 54

56 - 64

65 & over

Source: Bureau of Labor Statistics



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Industries Where Powered Industrial TruckAccidents Occurred

Source: OSHA Fatality/Catastrophe Reports, complied by OSHA Office of Electrical/Electronic and

Mechanical Engineering Safety Standards.


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Nonfatal Occupational Injuries andIllnesses by Source, 1996

Source: Bureau of Labor Statistics, Job Related Fatalities by Selected Characteristics, 1996.


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Background

The previous OSHA standards, whilerequiring operator training, did not define the

type of training or authorization required.

March 15, 1988 - Industrial Truck Association

(ITA) petitioned OSHA for specific training

requirements.



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Background (continued)

American National Standards Institute(ANSI), in cooperation with ASME, has

revised its standard 4 times, including

current lifttruck technology and specific

training topics.



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Background (continued)

OSHA published a proposed ruling on March 14,1995 for General Industry, Shipyard, MarineTerminals, and Longshoring regulations, addingspecific training requirements.

On January 30, 1996, OSHA proposed a revisionof the construction standards, mandating thedevelopment of an operator training programbased on the prior knowledge and skills of thetrainee and requiring a periodic evaluation.



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Final Rule

OSHA published the final rule for PoweredIndustrial Truck Operator Training on December1, 1998.

The effective date is March 1, 1999. Start-up

dates are included in paragraph (l)(7). It applies to all industries except agricultural

operations.

OSHA estimates that the new rule will prevent 11deaths and 9,422 injuries per year.



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Fatalities/Injuries Potentially Averted Annually byNew Standard

Source: U.S. Department of Labor, OSHA, Office of Regulatory Analysis, 1997


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Performance-Oriented

Requirements

The powered industrial truck operatortraining requirements are performance-

oriented to permit employers to tailor a

training program to the characteristics of

their workplaces and the particular types ofpowered industrial trucks operated.



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Revised Operator TrainingRequirements

General Industry:1910.178 is amended by revisingparagraph (l) and adding Appendix A.

Shipyard Employment:New section 1915.120 andAppendix A are added.

Marine Terminals:Section 1917.1 is amended byadding new paragraph (a)(2)(xiv) and Appendix A.

Longshoring:Section 1918.1 is amended by addingnew paragraph (b)(10) and Appendix A.

Construction:1926.602 is amended by adding newparagraph (d) and Appendix A.



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Operator Training Safe operations

The employer shall ensure that each poweredindustrial truck operator is competent to operate apowered industrial truck safely, as demonstrated bysuccessful completion of the training and evaluatiospecified in the OSHA standard.

Prior to permitting an employee to operate apowered industrial truck (except for trainingpurposes), the employer shall ensure that eachoperator has successfully completed the requiredtraining (or previously received appropriatetraining).



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Training Program Implementation

Trainees may operate a powered industrial

truck only:

Under direct supervision of a person who has

the knowledge, training, and experience totrain operators and evaluate their

competence; and,

Where such operation does not endanger the

trainee or other employees.



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Training Program Implementation(continued)

Training shall consist of a combination of:

Formal instruction (e.g., lecture, discussion,interactive computer learning, written material),

Practical training (demonstrations and exercisesperformed by the trainee), and

Evaluation of the operators performance in theworkplace



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Training Program Implementation(continued)

Training andevaluation shall beconducted by aperson with the

knowledge, trainingand experience totrain poweredindustrial truckoperators and

evaluate theircompetence.



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Training Program Content

Operators shall receive initial training in the

following topics, except in topics which the

employer can demonstrate are not applicable

to safe operation in the employers workplace.

Truck-related topics

Workplace-related topics

The requirements of the standard



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Training Program Content(continued)

Operating instructions,warnings and precautions

Differences fromautomobile

Controls andinstrumentation

Engine or motor operation

Steering and maneuvering

Visibility

Fork and attachmentadaptation, operation, use

Vehicle capacity and stability

Vehicle inspection andmaintenance that theoperator will be required toperform

Refueling/Charging/Recharging batteries

Operating limitations

Other instructions, etc.

Truck-related topics



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Training Program Content(continued)

Surface conditions

Composition and stabilityof loads

Load manipulation,

stacking, unstacking Pedestrian traffic

Narrow aisles andrestricted areas

Operating in hazardous

(classified) locations

Operating on ramps andsloped surfaces

Potentially hazardousenvironmental conditions

Operating in closedenvironments or other areaswhere poor ventilation ormaintenance could causecarbon monoxide or dieselexhaust buildup

Workplace-related topics



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Training Program Content (continued)

The requirements of the OSHA standard onpowered industrial trucks must also be

included in the initial operator training

program.



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Refresher Training and

Evaluation

Refresher training, including an evaluation of theeffectiveness of that training, shall be conducted toensure that the operator has the knowledge and skillsneeded to operate the powered industrial truck safely

Refresher training required when: Unsafe operation Accident or near-miss

Evaluation indicates need

Different type of equipment introduced

Workplace condition changes



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Refresher Training and Evaluation(continued)

An evaluation of each powered industrialtruck operators performance must be

conducted:

After initial training,

After refresher training, and

At least once every three years



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Avoidance of Duplicative

Training If an operator has previously received

training in a topic specified in this section,

and the training is appropriate to the truck

and working conditions encountered,

additional training in that topic is not requiredif the operator has been evaluated and found

competent to operate the truck safely.



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Certification

The employer shall certify that each operatorhas been trained and evaluated as requiredby the standard.

Certification shall include:

Name of operator

Date of training

Date of evaluation

Identity of person(s) performing the training or

evaluation



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Dates The employer shall ensure that operators of

powered industrial trucks are trained, asappropriate, by the dates shown in the followingtable.

If the employee washired:

The initial training andevaluation of that

employee must becompleted:

Before December 1, 1999 By December 1, 1999

After December 1, 1999

Before the employee is

assigned to operate apowered industrial truck.



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Appendix A - Stability of Powered

Industrial Trucks

Appendix A provides non-mandatory guidance

to assist employers in implementing the

standard.

This appendix does not add to, alter, or reduce

the requirements of this section.



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Appendix A - Stability of PoweredIndustrial Trucks

Definitions

General

Basic Principles

Stability Triangle

Longitudinal Stability

Lateral Stability

Dynamic Stability



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Load CG

Vertical

Stability

Line(Line of Action)

Combined CG

Truck CG

Load CG

Combined CG

Vertical

Stability

Line

(Line of Action)

Truck CG

The vehicle is stable This vehicle is unstable and

will continue to tip over

Stability Triangle - Figure 2


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Effective Powered Industrial TruckOperator Training Program

Four major areas of concern must beaddressed:

The general hazards that apply to the operation

of all or most powered industrial trucks;

The hazards associated with the operation ofparticular types of trucks;

The hazards of workplaces generally; and,

The hazards of the particular workplace where

the vehicle operates.


T f P d I d i l


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Types of Powered Industrial

Trucks There are many different types of powered

industrial trucks covered by the OSHA standard. Commonly used types include:

High lift trucks, counterbalanced trucks, cantilever trucks,rider trucks, forklift trucks, high lift trucks, high lift platformtrucks, low lift trucks, motorized hand trucks, pallet trucks,

straddle trucks, reach rider trucks, high lift order picker trucks,motorized hand/rider trucks, and counterbalanced front/sideloader lift trucks.

A single type of truck can only be described bycalling it by all of its characteristics, (e.g., a highlift, counterbalanced, sit down rider truck).



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Unique Characteristics of PoweredIndustrial Trucks

Each type of powered industrial truck has itsown unique characteristics and some

inherent hazards.

To be effective, training must address the

unique characteristics of the type of vehicle

the employee is being trained to operate.


C t f F klift


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Components of a ForkliftTruck*

*One of the most common types of powered industrial trucks


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Classes of Commonly-Used Powered

Industrial Trucks*

The Industrial Truck Association has placed poweredindustrial trucks into 7 classes. Class I - Electric motor rider trucks

Class II - Electric motor narrow aisle trucks

Class III - Electric motor hand trucks or hand/rider trucks

Class IV - Internal combustion engine trucks (solid/cushiontires)

Class V - Internal combustion engine trucks (pneumatictires)

Class VI - Electric and internal combustion engine tractors

Class VII - Rough terrain forklift trucks

*Note that this classification refers to commonly-used vehicles and does notinclude all powered industrial trucks covered by the OSHA standard.

C


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Class I - Electric Motor Rider

Trucks

Counterbalanced rider type, stand up Three wheel electric trucks, sit-down

Counterbalanced rider type, cushion tires,

sit-down (high and low platform)

Counterbalanced rider, pneumatic tire, sit-

down (high and low platform)


Cl I El i M Rid


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Class I - Electric Motor Rider

Trucks


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Class I - Electric Motor Rider Trucks

Counterbalanced

Rider Type, Stand-Up


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Class II - Electric Motor Narrow AisleTrucks

High lift straddle Order picker

Reach type outrigger

Side loaders, turret trucks, swing mast andconvertible turret/stock pickers

Low lift pallet and platform (rider)



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Class II - Electric Motor Narrow Aisle Trucks



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Class II - Narrow Aisle Trucks



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Class III - Electric Motor Hand orHand/Rider Trucks

Low lift platform Low lift walkie pallet

Reach type outrigger

High lift straddle High lift counterbalanced

Low lift walkie/rider pallet



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Class III - Electric Motor Hand orHand/Rider Trucks



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Class IV - Internal Combustion EngineTrucks - Cushion (Solid) Tires

Fork, counterbalanced (cushion/solid tires)

Class IV - Internal Combustion


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Class IV - Internal CombustionEngine Trucks - Cushion (Solid)Tires

Cl V I l C b i


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Class V - Internal CombustionEngine Trucks - Pneumatic Tires

Fork, counterbalanced (pneumatic tires)

Cl V I t l C b ti E i


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Class V - Internal Combustion EngineTrucks (Pneumatic Tires)


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Class VI - Electric & Internal CombustionEngine Tractors

Sit-down rider



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Rough Terrain Straight Mast Forklifts


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Some Types of Powered IndustrialTrucks Used in Maritime

Container top handlers

Container reach stackers

Straddle carriers

Semi-tractors/ Utility

vehicles

Sidehandlers

Combination vacuum lifts

Yard tractors

The following types of vehicles are

covered by the OSHA standard if the

vehicles carry, push, pull, lift, or tier loads.


P d I d t i l T k U d i


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Powered Industrial Trucks Used inMaritime

Container HandlersOSHAX.orgThe Unofficial Guide To the OSHA

Powered Industrial Trucks Used in


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Empty-Container Handler



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Container Reach Stacker




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Straddle Carriers




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Yard Tractor

Documents

Forklift Pit