NewsIndustry NewsSafety & HealthForklifts and Powered TrucksGeneral Industry SafetyForklifts and Powered TrucksIn-Depth ArticleEnglishFocus AreaUSA
To improve forklift safety, train material handlers
2023-07-13T05:00:00Z
Forklift operators should not carry unstable loads, but other workers (not the operator) usually stack items on pallets. Those material handlers play a role in forklift safety. Many problems could result from stacking loads improperly, but every problem has a solution.
Problem | Solution |
Stacking bags or boxes on a pallet unevenly, creating instability that could get worse if the forklift goes over bumps (like dock plates) or rough ground (outdoors). | Training to explain how stacked items can shift during transport, to stack items properly such as interlocking, and/or wrapping the load with plastic for stability. |
Stacking items on a damaged pallet, or one with broken slats that fall into the area where forklift tines go. Missing slats could allow product to fall through, where the forklift tines may damage product when picking up the load. | Provide readily available replacement pallets, and remove damaged pallets for repair or replacement. Deliver training on the type of damage that disqualifies a pallet from use. Consider damage that affects whether pallets can be safely stacked in tiers. |
Stacking items too high (on pallets or otherwise) contributes to instability (especially with heavier items) or may exceed the forklift backrest height. | Unsecured loads should not extend above the forklift backrest because items may fall behind the mast. Provide a measuring stick or similar item showing the height limit of stacked materials. |
Forklift operators must recognize unstable loads and refuse to handle them. They must also avoid actions that could damage pallets such as bulldozing. However, workers stacking materials bear some responsibility as well. They must understand the consequences of creating unstable loads or using damaged pallets.