A 1-2 hour forklift presentation. Johnanewquist@gmail.com

1. Material
Handling Safety
Draft 6 28 2020

2. Materials Handling & Storage
[1910.176 – 184]
2
SUBPARTN
257
305
339
418
590
178(q)(7)
178(p)(1)
178(l)(6)
178(l)(4)(iii)
178(l)(1)(i)
POWERED INDUSTRIAL TRUCKS – COMPETENCY TRAINING
POWERED INDUSTRIAL TRUCKS – REFRESHER TRAINING IN RELEVANT TO
POWERED INDUSTRIAL TRUCKS – CERTIFICATION OF TRAINING
POWERED INDUSTRIAL TRUCKS – SAFE OPERATING CONDITION
POWERED INDUSTRIAL TRUCKS – EXAMINATION FOR DEFECTS

3. Struck By OSHA Reg 5

4. 2018

5. Aug
2019

6. May 2018
• Alfred Lee, owner of Good View Roofing and
Building Supply Corp., and his manager, 44-year-
old Alan Chan, were charged May 1 by the San
Francisco district attorney’s office in the death of
60-year-old forklift operator Hua Quing Ruan.
• Lee, 65, and Chan each face one count of
involuntary manslaughter and three counts of
causing an unsafe work environment resulting in
death.
• Ruan was killed just before 2 p.m. on Nov. 21,
2016, when his forklift tipped over at the bottom of
a ramp leading from the company’s loading dock.
He had been descending the ramp with a bag of
mortar mix on a wooden pallet to load into a
customer’s car, when the bag fell off and blocked
his front wheel, according to state workplace
safety regulators at Cal/OSHA.
• Ruan was not wearing a seat belt, which
investigators determined was a factor in his
death. He was also not certified to operate the
forklift, according to Cal/OSHA.
• Officials said the ramp was in violation of state
workplace safety regulations because it should
have had a curb to prevent the forklift from going
over the side.

7. Objectives
• Explain common
forklift and
motorized
equipment
hazards
• Describe methods
to prevent prior
fatalities and
lawsuits.
• Photo by Joe
Keenan

8. Apr 2018

9. May 2017
• A Menards worker was
killed Friday in what the
Hennepin County Medical
Examiner is calling a
"forklift mishap" while
working at the Burnsville
MN store.
• 27-year-old Alec
Saunders on Tuesday.
• Witnesses say the worker
was trying to move two-
by-fours when the forklift
started to flip over. They
say he tried to jump off
the equipment and that's
when it landed on top of
him.

10. May 2017

11. May 2016

12. Feb 2018
• Police say James Davio, 57,
of Newport, had just
arrived for work at
Pleasant Valley Farms in
Berkshire around 6 a.m.
when he was run over by a
bucket loader.
• Authorities say the
operator of the machine,
Jamie St. Pierre, 22, didn't
see Davio.
Front end loader

13. Storage

14. Storage

15. Storage

16. Sleep
• Individuals who sleep fewer than six hours a
night on average have a 13 per cent higher
mortality risk than people who sleep at least
seven hours.
• U.S. sustains by far the highest economic
losses up to $411 billion a year or 2.26% GDP
• U.S. loses an equivalent of around 1.2 million
working days due to insufficient sleep.
• Individuals could: Set consistent wake-up
times; limit the use of electronic items before
bedtime; and exercise.
• Employers could: Recognize the importance
of sleep and the employer’s role in its
promotion; design and build brighter
workspaces; combat workplace psychosocial
risks; and discourage the extended use of
electronic devices.
Est. Incidence Rate per
Chronobiology 2010
Less than 5 hours – 7.89
5-6 hours – 5.21
6-7 hours – 3.62
7-8 hours - 2.27
8-9 hours - 2.50

17. October 2016
• February 16, 1999
OSHA Interpretation
on Temps
• “Some training on site
regarding specific
factors of the new
operator's workplace
is likely always to be
necessary.”

18. September 2016
On September 24, 2017, Employee
#1, a maintenance technician, was
performing preventive maintenance
on powered industrial truck.
The forks of the order picker came
down on him, killing Employee #1
Lockout?

19. Dec 2015
• $1.7 Million
• Atlanta GA
• May 2012, Jones, then 40, was shopping at the
Atlanta Restaurant Depot outlet.
• Jones noticed store employee Mark Plaza
standing by a forklift moving a pallet.
• Jones stopped his cart between seven and 15
feet from the forklift and was facing away from it,
perusing the shelves, when he heard a beep.
• "As he turned to look over his right shoulder, the
forklift backed into him," said Williams. "He fell
over the shopping cart and hit his neck on the
steel shelving, which is where we contended that
he hurt his neck."
• Jones "immediately felt numbness in his arms and
legs."
• May 2014 Jones underwent spinal fusion surgery.

20. Dec 2015

21. Oct 2015

22. Aug 2015
• Army vet hurt in
McCormick Place
forklift accident
awarded $15.2 million
• Ankle degloved when
hit by untrained forklift
operator.

23. Aug 2015
• The worker was operating a
forklift machine and removing
bundles of steel from 24-foot
shelving in the warehouse.
• The worker had removed one
bundle, and in the process,
inadvertently dislodged a
second bundle, causing it to jut
out into the aisle.
• The worker turned his forklift
around to proceed down the
narrow aisle and apparently
didn't see the second bundle
sticking out.
• Three sections of flat steel
bars penetrated his chest.

24. July 2015
• 63-year-old Albert Brooks of
Metairie was working on a
1992 Peterbilt dump truck
owned by Bennet.
• Brooks’ body was positioned
between the raised bed of the
truck and the frame.
• During the work, a support
broke, causing the raised bed
to fall on Brooks, crushing
him.

25. July 2015

26. January 2015
• Kevin Voyles was
killed in a GA factory
by falling marble
slabs.

27. Feb 2014
• Two men were killed in an
industrial accident at a granite
company facility in San
Francisco
• Two men were trapped after at
least one large slab of granite
fell on them as they unloaded
a container truck,

28. Dec 2013
• $281 Million award
• Osorio was driving a
Heckmann tractor-trailer on FM
133 in TX and the drive shaft
broke off from under the truck.
• The part plowed through the
windshield of a pickup that
Aguilar was a passenger in
• The lawsuit alleged that the
drive shaft broke because the
defendants did not properly
maintain the tractor-trailer.
2014 reduced to $163.8 million by the
Dimmit County court
Subsequently further reduced to
$105.2 million when the judgment
was amended by the Dimmit County
court on April 1, 2014
Company paid $5.5 million. The
insurance company paid the rest.
Legal bills were $1.3 million a quarter.

29. Nov 2013
Cont

30. Nov 2013 cont

31. May 2015
• Federal OSHA does not
specifically require employers
to equip forklifts with portable
fire extinguishers.
• However, if the manufacturer
equips its forklifts with fire
extinguishers, the employer
must maintain the
extinguishers
• Also, the Liquefied Petroleum
Gas standard 2006 edition
addresses their use in Chapter
9, which states that where
either the "authority having
jurisdiction" or the end user
requires an industrial truck to
be equipped with a portable
extinguisher
• The NFPA standard also says
that industrial trucks can only
be equipped with portable
extinguishers if operators have
been trained in their safe
operation and use.

32. Storage
• Piles of lumber that have become
unstable must be immediately
made safe, or, the area into
which they might fall must be
fenced or barricaded and
employees must be prohibited
from entering it.
1910.265(c)(27)(iii)
These is safe. Rest
are unsafe.

33. July 2019

34. July 2013
• Billy Johnston, 48, was killed in an industrial
accident in West Allis was lowering a 24,000
pound dust collector when a chain broke. He
was either hit in the head by the chain and
thrown 30 feet from the piece of equipment, or
he hit his head as a result of the fall

35. July 2013
• Rack on the right
• Slid forks in
• Tilted forks up
• Heard a pop
• Stuck hand in to see if
product damaged
• Rack back bar had
popped loose
trapping arm

36. July 2013
• $82,600
• An unapproved C-clamp
slid off a 2,600-pound
press brake ram as it was
lifted, causing the ram to
fall to the ground and pin
the worker pinning him to
the ground and resulting
in amputation at the knee.

37. May 2013
• Workers were lifting a bag of
processed powdered
chemicals.
• The bag, which weighed 3,675
pounds, was hoisted by
several straps designed to
bear the load.
• During the operation, one of
the straps failed, causing the
bag to drop.
• A worker’s arm and head were
wedged underneath the bag
while others worked to free
him.

38. Dekalb accident 1997
• Protect sling from sharp surfaces
• Employees were positioning a
22,000 pound generator with the
use of a truck-mounted crane and
four synthetic web slings.
• While the employees were moving
the generator, the slings contacted
a steel purlin and were cut.
• The generator fell and rolled onto
the employees.
• Employee #1 suffered fatal
internal injuries.
• Employee #2 suffered back
injuries and was hospitalized.
• Photo is an example

39. Falls
• Getting on a pallet
has lead to many
deaths and is not
acceptable.
• Employees use what
is available.

40. Struck-by
• What should be
done?
• Many foot crushing by
people too close.
• How close is too
close?’

41. Struck By
• Loads falling off kill
people.
• Loads improperly
stored kill people.
• What can be done?

42. Struck-by
• What should be done
when backing out?

43. May 2014

44. Overturned
• Curbs
• Seat belts
• Excessive weight
lifted

45. Training
• The Standard also requires
that operators receive training
in the topics which are
applicable to the safe
operation of the truck in the
employer’s workplace.
• Employees must be trained
separately for each different
type of forklift they will be
using, but they do not need to
complete separate training for
the same type of forklift made
by a different manufacturer.
For classroom training element, the
employer may demonstrate the
employee's successful completion by
a written or oral test or other
appropriate means, such as an
evaluation by the instructor

46. Certification
OSHA also requires initial
certification and recertification
of forklift drivers every three
years.
• The employer must provide a
certificate stating the
employee has completed the
training.

47. Certification
• The employee must be
retrained and recertified
every three years, at a
minimum, or after an
accident or “near miss” which
resulted from an unsafe act.

48. Evaluation
Date of Certification
Operator’s name
Trainer’s Name
Employers must conduct
classroom-type training and
actually observe the employee
operating the equipment under
the physical conditions at the
workplace, such as aisles,
ramps, and loading docks.

49. Refresher Training
• Observe the powered
industrial truck operator
during normal operations
to determine if the
operator is performing
safely, and
• Ask pertinent questions to
ensure that the operator
has the knowledge or
experience needed to
operate a truck safely.

50. Is a Forklift a Crane?
• Slings use
• Qualified rigger?
• What can go wrong?

51. Pushing Loads
• Operators were
allowed to
“bulldoze” double
high pallets
• Issues are
obstructed view

52. 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.

53. Caught in
• Several under rack
caught in fatalities
• Driving into fixed
object
• Body part outside
frame of forklift

54. Seatbelts
• Seatbelts prevent the
operator from being
pinned by the truck or
overhead guard.

55. Inspection
• OSHA prohibits operation
of forklifts if they are not
in safe operating
condition
• Barrel lifter with no
capacity plate
• Don’t forget unapproved
attachments that overload
the attachment

56. Decal I put on forktrucks … requiring a 2 person lift.

57. Forklift Amputation Hazard
• The mast has open
gears and scissor
points.

58. Fork Lift Platforms
• 5(a)(1) under
ANSI/ASME B56.1-
2000
• No screen on right.

59. Forklift Platforms
• Good Platform must
be guardrails
• Secureable
• Screen at forklift side

60. Slabs
• Several death
happening when
lifting large flat
objects

61. Operation
• Reverse travel if
operator cannot see
in front
• Seat belts
• Traffic control if in
road

62. June 2019

63. Maintenance
• When working on any
vehicle/forklift,
cribbing or blocking
needs to be
performed in case of
hydraulic failure.

64. Riding on Forks
• Not allowed

65. Sample Safety Rules
• Follow Manufacturer’s
instructions and
OSHA regulations.
• Use ANSI B56
standards on forklifts
if you cannot get the
manufacturer’s rules..

66. Safety Rules
• Follow Warning
Labels.
• Only trained
personnel can
operate the lifts.
• A trained person must
inspect the machine
before each shift.
• And many more!

67. Training
• Hands on training is
necessary. An forklift
lift is not a car.
• The worker should be
able to demonstrate
all predicted uses of
the lift and
compliance with
manufacturers
instructions.

68. Cautions
• Watch for any holes.
These will flip some
forklift.
• These should be
identified in advanced
and plans to prevent
a forklift from going
into one is necessary.

69. Electrical
• 1/12/1999
• An employee was operating a
side loader, loading and
unloading rail car containers in
a terminal yard.
• A 7200-volt overhead power
line ran nearby, about 8.8
meters above the ground.
• The mast on the loader
reached up to about 9.1
meters.
• The employee brought the
mast of the loader into contact
with the power line.
• Three employees at the site
were electrocuted

70. Emergency Response
• What is your plan?

71. Fire
• Cylinder gases ignited
by forklift.
• What can be done?

72. Inspections
Why is this inspection form weak?

73. Forklift Inspections
• Overhead guard
improperly welded

74. Inspection
• Labels

75. Inspection
• Load Extension
Backrest

76. Inspection
• How much wear is
acceptable?

77. Forklift Inspection
• Broken Fiberglass
Housing is a
laceration Hazard

78. Inspection
• Leaking Hydraulic
Fluid

79. Carbon Monoxide
0222 HCOOHC xx 
Perfect World:
Real World:
xxxxx HCNOCOOHCONOHC  2222

80. 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

81. Forklift Exhaust
• No Violation.
• This forklift emits low
level of CO.

82. Storage
• What is the problem
and solution?

83. Storage
• No Violation.
• Material stored
properly in racks.

84. Storage
• Cylinders must be
secured from
falling down.

85. Material Handling
• Rack was hit by
forklift and tagged out
and pallets removed.

86. Material Handling
• No Violation
• Aisle properly marked
• Clean lanes

87. Aisles Not Marked

88. Struck By
• No Violation.
• Corner marked so
forklift operation can
see around corner.

89. Raised Dump Truck Bed
• Event Date: 01/05/2010
• Employee # 1 was attempting
to lower the bed of a detached
dump trailer which had
become stuck in the upright
position.
• The employee was working in
between the trailer bed and
frame when the bed fell
crushing the employee.
• Employee # 2 who assisted
employee # 1 but was standing
outside the caught between
area was also struck by the
falling trailer bed but sustained
only minor injuries.
• 34 M Fatality
Use physical stops to hold up in case of failure.

90. Semi-trailers
• Two fatals getting
caught between truck
and object.
• Trailer often is not
level causing load to
roll off
• Load straps release
improperly stacked
loads.

91. Skid Steer
• Two fatals from being
struck by moving
Skidsteer
• One death from caught in
frame and bucket arm
• Aug 2013 Matthew
Mallett was riding in the
skid loader driven by his
great-aunt, Gail
Henderson, 49, when he
fell out.

92. Jan 2014
• 43-year-old Ronald L.
Meier, of Maria Stein,
Ohio, was working on
a skid loader when
the bucket fell,
pinning him between
the loader and the
bucket

93.  Lock-Out Tag-Out Considerations:
1. Review requirements for the individual crane.
2. Integrate lock out and maintenance requirements.
3. Ensure training in adequate for level of maintenance.
4. Ensure written programs are established and reviewed.
5. Carefully select lockout devices, ask the manufacturer for
recommendations.
6. Do not necessarily assume devices are interchangeable
between different types of cranes.
REVIEW THE MANUFACTURERS SPECIFIC INSPECTION REQUIREMENTS!
LOCKED
OUT
This Lock/Tag may
only be removed by
NAME: __________
DEPT : __________
COMPLETION
DATE: ___________
TIME: ____________
DON’T OPERATE
DANGER

94. 2
TON
ACME
CRANE
ALWAYS CHECK LOAD RATING
10
TON
10
TON CAP.
10 TON CAPACITY
KNOW THE RATED LOAD OF THE CRANE
BASICS OF CRANE SAFETYBASICS OF CRANE SAFETY

95. BASICS OF CRANE SAFETY
5 TON
ALWAYS ENSURE
THE LIFTING
DEVICE AND ALL
SUPPORTING
COMPONENTS ARE
RATED FOR THE
LOAD TO BE
LIFTED!
2
TON
10 TON LOAD
KNOW THE RATED LOAD OF THE CRANE
BASICS OF CRANE SAFETY

96. BASICS OF CRANE SAFETY
NEVER ALLOW A COWORKER
BETWEEN A FIXED OBJECT AND
A LOAD!
ACME
CRANE
2
TON
DANGER
WORKING
CRANES
BASICS OF CRANE SAFETY

97. BASICS OF CRANE SAFETY
2
TON
ACME
CRANE ALWAYS POSITION
LIFTING DEVICE
DIRECTLY OVER
LOAD BEFORE
LIFTING!
THINK BEFORE YOU LIFT
BASICS OF CRANE SAFETY

98. BASICS OF CRANE SAFETY
DISSIPATE ALL HAZARDOUS ENERGY
DANGER
HIGH
VOLTAGE
Always Ensure Energy
Sources Are Dissipated
Before Initiating Any
Maintenance Activity.
2
TON
ACME
CRANE
BASICS OF CRANE SAFETY

99. Accident
• 5/6/08
• No bridge stops
for pendant
controlled crane
• Crane ran off rails
and the lifting
device and crane
hit employee
•

100. Accident
• 03/19/2008
• Bridge Crane
employee was
servicing bridge
crane and fell
approximately 58 feet.

101. Accident
• 12/20/2007
• One of the four man
ground crew working
with a mobile
underhung bridge
crane got too close to
the wheel of the
crane and was ran
over.

102. Accident
• March 14, 2008
• A 1,868 pound plate fell
from the C-clamp and
onto the employee.
• These devices must be
designed and rated for
lifting steel plates.

103. Oct 2015

104. Accident
• Tuscaloosa AL
• “Where passageways or
walkways were provided,
obstructions were so placed
that the safety of personnel
was jeopardized by
movements of cranes,”
• “employee was using a crane
to move a sheet of steel to the
hot bed when one of the
wheels of the crane's floor rail
system ran over Korey Ryan's
foot.”
Typical rail gantry crane

105. Quiz
• How often does a forklift driver have to be re-
evaluated/certified? __________
• OSHA’s limit for Carbon Monoxide in an 8 hour
shift is ____ ppm.

106. Summary
• Training
• Job Hazard Analysis
• Written procedures
• Manufacturer rules
• Inspections

107. Questions?