Forklifts Injuring

7/30/2019 Forklifts Injuring

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Preventing forkli

people during lounloading of truc

A guide to effective pr

VWA5

32/02/04

.02

WorkSafe Victoria is a division of the Vic torian WorkCover Authority


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Contents

Introduction 1

Legal obligations 1

How to use this guide 1

Key elements of effective forklift traffic management systems

Comparative chart of tasks and issues 2

Key elements of effective forklift traffic management systems

Dos and Donts 9

1. Example of an effective forklift traffic management system for loading

and unloading vehicles 10

2. Example of an implemented effective forklift traffic management system

for loading and unloading vehicles 11

Some other important facts to consider 12

WorkSafe Victoria Offices 13

WorkSafe Victoria O

WorkSafe Victoria offers a complete

range of health and safety services:

Emergency response

Advice, information and education

Inspections

Licencing and certification

Publications

Head Office

Victorian WorkCover Authority

Level 24, 222 Exhibition Street

Melbourne Victoria 3000

GPO Box 4306

Melbourne Victoria 3001

Telephone 9641 1555

Fax 9641 1222

Toll-free 1800 136 089

Local offices

Ballarat 5337 1400

Bendigo 5443 8866

Dandenong 8792 9000

Geelong 5226 1200

Melbourne 9628 8115

Mildura 5021 4001

Mulgrave 9565 9444

Preston 9485 4555

Shepparton 5831 8260

Traralgon 5174 8900

Wangaratta 5721 8588

Warrnambool 5562 5600


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Introduction

In Victoria, a worker dies on average every week and over half of the forklift related fatalities

have been caused by people being hit by a moving forklift. This impact is felt by everyonearound them. Families, loved ones, work colleagues, employers and mates. The reality is that

almost every one of these deaths could have been prevented if proper forklift operating safety

procedures like those outlined in this guide were implemented and followed.

No one should die at work.

The purpose of this guide is to help employers implement safe and effective forklift traffic

management systems, and in doing so to comply with the relevant aspects of the Victorian

Occupational Health and Safety Act 1985 and the Occupational Health and Safety (Plant)

Regulations 1995.

This booklet helps to identify some of the potential risks and provides solutions and tips to help

reduce injuries and fatalities resulting from unsafe forklift operations during the loading and

unloading of heavy goods vehicles.

Legal obligations

The employers main duty under the Victorian Occupational Health and Safety Act 1985 (OHS

Act) is contained in Section 21(1). This section provides that employers (including contractors)

are required to:

provide and maintain so far as is practicable for employees a working environment that

is safe and without risks to health

Employers and employees responsible for the safe use of forklifts must be familiar and meet the

requirements of the OHS Act along with the Occupational Health & Safety (Plant) Regulations

1995 (particularly regulation 711 714).

How to use this guide

This guide lists effective ways to reduce risks to safety when vehicles are being loaded or

unloaded by forklifts. This will help you identify dangerous work practices and provide clear

advice on safer work practices.

As you read this guide, take a walk around your workplace to look for potential hazards.

Then find ways to fix the problem in the short term while you work at long term solutions.

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Key elements of effective forklift trafficmanagement systems

Comparative chart of tasks and issues

A comparative chart has been developed to help you. The practices in the green column should

be regarded as the target for all workplaces. The practices in the amber column are less

effective in reducing risk and should only be treated as an interim solution. Whilst the practices

in the red column involve high risk and should not be used in workplaces; an employer who

allows high risk practices to be used is almost invariably going to be in breach of Occupational

Health & Safety Legislation.

High Risk- Unacceptable Work Practices

Medium Risk- Interim solution only

Low Risk- Target for all workplaces

Find long term solutions

Find ways to fix the problem in the short term

Only acceptable aspermanent practices if its

clearly not PRACTICABLE to

implement higher standardpractices in your workplace

Breach of OHSLegislation

Please Note:

The OHS Act does not allow a person to avoid putting a risk control measure in place purely

on the basis of the cost of the control measure.

The term forklift, as used in this guide, applies to counterbalanced industrial trucks that are

designed to lift and move loads and typically used to load and unload vehicles.

The term loading refers to both the unloading and loading of vehicles unless otherwise

specified.


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Key elements of effective forklift trafficmanagement systems

Comparative chart of tasks and issues

Trafficmanagement

plan

There is no trafficmanagement plan. Trafficmanagement is dealt within an ad hoc way. Nosafe work procedures arein place.

Traffic is managed byindividual safe workprocedures at each areaof the workplace.

A comprehensive trafficmanagement plan, dealingwith all likely traffic controlissues, has been preparedand documented. Everyoneaffected by the planunderstands and applies

the traffic managementprinciples. The effectivenessof the plan is regularlyreviewed in collaborationwith workers.

High Risk Medium Risk Low Risk

Signage forfrequently

usedpedestrianroutes and

forkliftoperating

areas

No signs or if there aresigns they are not inprominent areas or whereforklifts are operating.Signs and markings areinconsistent across theworkplace and provideinsufficient informationabout intended use.

Signs prominentlydisplayed at entrance toworkplace and forkliftareas warning ofpresence of forklifts: Forexample Forkliftsoperating in thisarea. There are nosigns specific to theworkplaces own trafficmanagement system.Pedestrian walkways andforklift operating areasare marked to show theirintended use.

Signs conforming toAustralian Standard AS1319 are prominentlydisplayed at entrance toworkplace and in forkliftoperating areasreminding pedestriansand forklifts drivers aboutcritical parts of theworkplaces trafficmanagement system. Forexample

Pedestrian Prohibited Forklift OperatingArea;

Speed Limited Area.Pedestrian walkways,roadways and forklift

operating areas areclearly marked with highvisibility self evidentlines and signs

Speed limits No speed limits enforcedor speed limits fail toconsider load stability andstopping distance factors.

Speed limits have beendetermined through acomprehensive riskassessment taking accountof stability under brakingand stopping distances.Speed limits are enforcedthrough supervision or

speed monitoring.

Speed limits have beendetermined through acomprehensive riskassessment takingaccount of stability underbraking and stoppingdistances. Forklifts arefitted with speed limiting

devices.


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No information isprovided to visiting driverson safe loading

procedures.

Staff not trained inloading operations.

All visiting transportdrivers are fully briefedand provided with written

information/instructionsregarding the loadingprocedures used at work.

Staff involved in loadingoperations are trained inthe workplaces loadingprocedures only.

All visiting transportdrivers are fully briefedand provided with written

information/instructionsregarding the loadingprocedures used at work.

Everyone involved inloading operations aretrained in safe loadingoperations including:

the use of correctequipment to performthe task safely;

the use of alternative

load shifting equipmentand methods; and

knowing when use of aforklift is notappropriate for the task.

The training aims toimprove skills to allow staffto make contributions toenhancing safe workpractices.


No systems in place forpedestrian crossing areas.

A priority or give wayprocedure applies to

pedestrian crossings.Prominent signs specifywho must give way.

Forklift proximity warningdevices only.

Pedestrian crossings arecarefully planned, clearly

marked, clear ofobstructions and speedsare limited to suit requiredstopping distances andload stability.

A priority or give wayprocedure applies topedestrian crossings.Prominent signs specifywho must give way.

Forklift proximity warningsystems incorporating

temporary pedestrianbarriers such as boomgates etc. at crossings.

No physical barriers at

high risk areas. Noproper risk assessmentcarried out.

Physical barriers at high

risk areas e.g. blindcorners or places whereforklifts are close topedestrian areas.

Physical barriers protect

all marked pedestrianwalkways.

In addition to physicalbarriers in areas wherepedestrian traffic iscommon there are largefixed bollards set out fromblind corners to protectpedestrians in all areas.

Informingvisitingdrivers

Forklift

barriers

Pedestriancrossings


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No markings, bollards, orsafety zones for the driveror loading crew.

A clearly defined safetyzone protected by largeportable bollards/barriers

is provided so that thedriver or loading crewcan supervise loading ata safe distance frommoving forklifts.

There are specifiedexclusion zones aroundvehicle trailers and forkliftoperating areas.

If there is no risk of thecabin being damaged bya load or the forklift, thedriver remains in the truckcabin during loading andunloading operations.

A clearly defined safetyzone protected by largefixed bollards/barriers is

provided so that the driveror loading crew cansupervise loading at asafe distance frommoving forklifts andfalling loads; or

Loading supervision isachieved via remotemeans such as closedcircuit TV and/or radiocommunications; or

The loading supervisorsobservation post iselevated and visible to theforklift operator at alltimes.

If there is no risk of thecabin being damaged bya load or the forklift, thedriver remains in the truckcabin during loading andunloading operations.


Pedestrian

ExclusionZones

Loading crew or other

pedestrians are permittedto move in close proximityto working forklifts or thevehicle loading activity.

There is no acceptable

interim alternative.

A clearly defined

pedestrian exclusion zoneis designated around thevehicle being loaded. Theextent of the exclusionzone is determined from acomprehensive riskassessment of all loadingoperations. A minimumexclusion zone size shouldbe established for adistance equal to theheight of the load fromthe ground plus anadditional allowance forthe nature of the load e.g.potential to bounce, rollor splash contents.

Lines or large bollardsdelineate the exclusionzone.

All forklift movements arestopped if pedestrians e.g.loading crew need toenter the exclusion zone.

Safety zonesfor drivers of

trucks and

loading crew


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Number ofloading crew

and

monitoringof their

location

Large number of peoplein the loading crewaround the loading area

and there is no system tomonitor their presence.

There is no acceptableinterim alternative.

Loading crew is limited tominimal numbers to keepcommunications simple

and make it easier tomonitor where the crew islocated.

Where there has to be alarge number of people inthe loading crew, specificmonitoring systems are inplace so that forkliftoperator is certain of thelocation of any memberof the crew while theforklift is in operation.


Loading crew Personnel are permittedon the vehicle tray whenthe forklift is moving theload.


No personnel are on thevehicle tray during anymovement of the load bya forklift.

Visibility ofpeople near

workingforklifts

No procedure in placerelated to visibility ofpeople near workingforklifts. Loading crewmay not always be inview of forklift operator.High visibility clothing is

not worn or is ineffective.


The forklift driver checksthat loading crew and thetruck driver are in the safetyzone before entering thepedestrian exclusion zone.Forklift drivers stop workimmediately if the location

of the truck driver or anymember of the loadingcrew cannot be confirmedor any pedestrian enters theexclusion zone.

High visibility clothing isworn by anyone required tomove or work in the vicinityof forklifts or other traffic.

No special arrangementsin place when more than

one vehicle is beingloaded.

Portable physical barriersused around forklift

operating zones wheremore than one vehicle isbeing loaded.

Warning systems are usedto alert forklift drivers ifthey have moved intoanother exclusion zone.

Fixed physical barriers orscheduling of operations

make it impossible for aforklift that is notsupposed to be involvedin a loading operation tointrude into anotherdesignated exclusion zonewhile loading operationsare underway.

Loading operations arenot supervised orplanned.

Supervision of loadingoperation occurs on aneeds only basis.

Loading operators areunder constantsupervision and loadingprocedures are enforced.

Parking areasfor multiple

vehicles

Supervision


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Trainingforklift

operators

Forklift operators are notlicensed and trainees arenot constantly and directly

supervised.

Operators have not beenspecifically trained in allactivities undertaken.


Forklift operators arelicensed or they are traineesunder constant direct

supervision. Competenciesare regularly reviewed andupdated.

Task (workplace) specifictraining is provided on allactivities to be undertaken.

Using aforklift to lift

people

People are lifted on thetynes of a forklift withouta safety cage.

Forklifts are only used tolift people where no othermethod is practicable.People are only lifted insafety cages that comply

with the AustralianStandard.

Forklifts (other thanspecialised order pickingforklifts) are not used tolift people.

Controllingwho uses

forklifts

There is no specificprocedure or control ofwho operates the forklift.

A key control procedureis implemented to ensurethat only competentforklift operators haveaccess to the keys andforklift. This procedure ismanaged by the forkliftoperators.

A key control procedure isimplemented to ensurethat only competentforklift operators haveaccess to the keys andforklift. Managers orsupervisors are in controlover access to keys to theforklift.

Maintenanceof forklifts

There is no regularmaintenance performedby suitably qualified orcompetent persons andno documentation is kept.

Forklifts are wellmaintained by competentstaff but information inmaintenance records andlogbooks are notintegrated into a riskcontrol system.

There is a daily pre-startup maintenance checkdone by the driver.Suitably qualified orcompetent personsperform regularinspections andmaintenance.Comprehensive record ofmaintenance is kept andis available to operators.Logbooks are maintainedby operators. Alldocumentation isregularly monitored andthe information from thedocuments is integratedinto a risk control system.

Fitting andwearing of

seat belts orother forms of

driverrestraint

Seat belts are not worn orare not fitted to forklifts,there is no driver restraintand no relatedsupervision.

Seat belts are fitted tonew forklifts but not toolder units.

Supervision isinconsistent.

Wearing of seat belts iscompulsory on new forkliftsbut not on older units.

Seat belts are fitted to newforklift vehicles and retro-fitted to older units.Wearing of seat belts iscompulsory and thepractice is supervised.


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Use ofalternativeload liftingequipment

Attachments

Appropriate loadshifting/handlingequipment is notavailable.


Load shifting or handlingequipment is provided foruse as an alternativewhere the use of a forkliftmay be particularlyhazardous.

Appropriate load liftingattachments are notavailable for forkliftoperations or they are notengineered to appropriatestandards.

Purpose built liftingattachments are used andthese are marked with thesafe working load, anengineers report isavailable and theattachments are regularlyinspected for damage or

wear.

Only attachmentsconfirmed by themanufacturer as suitable forthe particular forklift andtasks are used. Safeworking load and radiuscharts for the forklift andattachment combination

are displayed on the forklift.The attachments areregularly inspected fordamage or wear.


Incidentreporting

Forklift related incidentsare not reported orinvestigated.


All forklift relatedincidents are reported,investigated and actedupon to prevent futureincidents. Reporting andresponse involves healthand safety representatives.

Loadingdocks

Loading ramps aremanufactured without

obvious regard to loadingforces, necessary width oredge guarding.

Loading ramp notsecured to loading dockor trailer.

Trailer movementprevented only by parkingbrakes.

No edge marking ondocks or ramps.

Loading ramps (bridgingplates) properly

engineered, full width ofvehicle being loaded andfitted with raised edgeguarding having highvisibility markings.

Loading ramps locked toloading dock trailerbrakes applied andwheels chocked againstmovement.

Edges of loading docksclearly defined with high

visibility markings.

Automatic dock levellersused at all loading points.

Edges of loading docksclearly defined with highvisibility markings.

Automatic trailer brakingchocks and parkingbrakes used.

Dock designed to allowvehicle to drive throughrather than reverse in.

Use ofengineeringsolutions forcritical safety

controls

No use of engineering ortechnological safetyoriented systems.

Minimum engineeringand technology toimprove safety but not allavailable systems areexploited. e.g. onlyreversing warning systemsused.

Use of smart forkliftvehicles that utiliseengineering andtechnology to improvesafety e.g. use ofautomatic pedestrianproximity warning devicesand speed limiting devices.


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Key elements of effective forklift trafficmanagement systems Dos and Donts

Do

develop and implement traffic

management plans for both forklift and

heavy vehicle movements.

provide specified pedestrian exclusion

zones around vehicle tray or trailer and

forklift operating areas.

require the forklift driver to stop workimmediately if they lose sight of the

truck driver or any member of the

loading crew.

supervise work to ensure that

procedures are followed.

have specific workplace training in

competency in safe forklift operation,

use of attachments and safe loading

practice.

report and investigate all forklift related

incidents.

provide safety areas where pedestrians

involved in the loading activity are

clearly visible to the forklift driver.

instruct and brief all visitors, including

visiting truck drivers, on companyprocedures.

Dont

allow pedestrians in forklift operating

areas.

allow drivers to supervise the loading

process while standing in the forklift

truck operating zone, including on the

opposite side of the vehicle and on the

tray.

lift people on the tynes of a forklift.

access pedestrian exclusion zones while

a forklift is moving in the area or moving

a load.

stand beside a vehicle on the opposite

side to where a forklift is moving or

adjusting a load.

stand on the tray of a vehicle while a

forklift is moving or adjusting a load.


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1. Example of an effective forklift trafficmanagement system for loading and unloading

vehiclesThe following example will assist you with developing an effective forklift traffic management

system.

Remember, keeping pedestrians and truck drivers at a safe distance from operating forklifts is

the only way to prevent death and injury.

Safety Zone for DriverThe driver must be in full view to a forklift operator. Allloading or unloading activity must stop if the drivercannot be seen or needs to enter exclusion zone toinspect load. Alternatively, if it is safe to do so, the

system of work can provide for the driver to stay in thetruck cabin during loading and unloading.

One way traffic is safer. Removable bollards in front ofthe truck enable it to move forward after being loading.

Bollards/Witches Hats/Paint marking the Pedestrian

Exclusion Zone.

Pedestrian Exclusion ZoneA minimum exclusion zone should beestablished for a distance equal to theheight of the load from the ground plus anadditional allowance for the nature of theload e.g. potential to bounce, roll or splashcontents. All forklift movements within thezone must be stopped before pedestriansenter this area.

Forklift

Truck loading/unloading - Exclusion Zones

Truckcabin

Trucktrailer

This is a total exclusionzone during loading or

unloading activity.


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2. Example of an implemented effective forklifttraffic management system for loading and

unloading vehiclesAs outlined in this guide the key to effective forklift traffic management systems is to separate

pedestrians and operating forklifts and to keep drivers in a safety zone.

The following is an example of how one operator has adapted the principles outlined in this

guide and implemented the following traffic management system. This system has significantly

reduced the level of risk and increased productivity.

Safety Zone for Driver

Pedestrian Exclusion Zone

Pedestrian Exclusion ZoneA pedestrian exclusion zone has been established for a distance equal to the height of the load from the ground plus anadditional allowance for the nature of the load. Forklift movements within this zone are stopped before pedestrians enter.

Forklift runners takepallets from edge ofexclusion zone totheir destinations.

Pallets are takento the edge ofexclusion zoneby a singleforklift.

Truckcabin

Trucktrailer

This is a total

exclusion zoneduring loadingor unloading

activity.

Forklift

Bollards/Witches Hats/PaintBollards marking the perimeter of the pedestrian exclusion zone have been installed.

Safety Zone for DriverThe driver must be in full view to a forklift operator. All loading or unloading activity must stop if the driver cannot be seen orneeds to enter exclusion zone to inspect load. Alternatively, if it is safe to do so, the system of work can provide for the driver tostay in the truck cabin during loading and unloading.

ForkliftsOnly one forklift operates in the pedestrian exclusion zone.


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Some other important facts to consider

Forklifts and the loads they carry are heavy; a laden forklift travelling at 15km/hr may take

12 metres or more to stop in an emergency.

Rear wheel steering can cause the rear of the forklift to swing out unexpectedly and crush or

run over the feet of bystanders.

Forklift wheels carry very high loads and will inflict serious injuries to feet.

Forklifts are designed to lift only palletised loads or equipment that has purpose-built slots

to engage the tynes. Talk to your supplier about special purpose attachments for safely lifting

other loads e.g. drum lifters, wide load spreader tynes. Loads that have steel to steel contact

with the tynes are especially dangerous as they slip unexpectedly during movement.

Forklifts can become unstable and roll over when turning or braking at speed, particularly if

travelling with the load raised.

Seatbelts or operator restraints should always be used. Drivers being thrown from the seat

and crushed by the forklift in a rollover has been the cause of many fatal injuries.

Forklifts placing or removing loads from other vehicles or material stacks can disturb

adjacent material causing these to fall on bystanders.

Remember keeping pedestrians at a safe distance from operating forklifts is the

only way to prevent death & injury.

Documents

Forklifts Injuring