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There’s a lot to keep track of when administering employees’ time off, especially when it falls under the Family and Medical Leave Act (FMLA).

Employers might wonder if they need to tell employees when their FMLA leave is running out. And the simple answer is “not really.”

Neither the statute nor the regulations specifically require you to notify or remind employees that their FMLA leave exhausted or is close to it. If you know how much time FMLA leave an employee is taking, you are, however, required to include that information on the designation notice. But, otherwise, there isn’t any other form or required document to tell an employee, “Hey, you’re running low on FMLA leave.”

Does this mean you may not give employees such a reminder?

Again, the simple answer is “no.” Employers may even have good arguments for doing so.

Why a gentle reminder can be helpful

When employees are on FMLA leave, the reason behind the need for leave will probably be of great importance to the employee. It could be because a baby was born or because a family member has a serious health condition. In any case, the employees most likely have a lot on their mind. They might not be constantly thinking about when they will return to work or when they will run out of FMLA leave.

Providing a gentle reminder can show employees that you’re thinking of them, and that you expect them to return on a particular date. Employees generally appreciate knowing what is expected of them. Giving them such a reminder can also help allay any questions about whether they knew they were expected back on such a date.

This could also be a good opportunity to remind employees that if they cannot return to work because of continued issues with their own serious health condition, they should let the employer know. In cases like this, an employer then can engage in an interactive process (dialogue) with the employee regarding possible reasonable accommodations under the Americans with Disabilities Act. One accommodation, for example, might be more leave time.

Providing employees with reminders about how much leave time they have left can also address the consequences for any absences after FMLA protections expire. This is especially important in terms of maintaining employee benefits.

Designation notice changes

If the information in the designation notice changes, such as if the employee exhausts FMLA leave then requests more leave, you must provide a written notice of the change. Like with the original designation notice, a change notice must be given to the employee within five business days of receipt of the employee’s first notice of need for additional leave.

Therefore, if, after an employee exhausts all 12 weeks of FMLA leave, the employee asks for more leave, you are to notify the employee of the changes to the designation notice. You may use another designation notice if you wish, but you are not required to do so. You could simply indicate to the employee that there is no more FMLA leave available, so the additional leave will not be designated as FMLA leave.

Key to remember: Keeping the lines of communication open between you and employees who are on FMLA leave can benefit both employers and employees, even if all types of communication aren’t necessarily required.

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Most Recent Highlights In Environmental

Hazardous waste manifests: Hybrid vs. fully electronic
2026-04-28T05:00:00Z

Hazardous waste manifests: Hybrid vs. fully electronic

More industries are embracing the exclusive use of electronic platforms. For example, digital payments are replacing cash, news sites are going fully online, and cloud storage is eclipsing external computer storage. And, based on recent proposed rulemaking, hazardous waste manifests may join the list.

The Environmental Protection Agency (EPA) proposed the Paper Manifest Sunset Rule in March 2026, planning to shift to electronic-only manifests for tracking hazardous waste that’s regulated by the Resource Conservation and Recovery Act (RCRA).

If the proposed rule is finalized, regulated entities will have to track all hazardous waste shipments electronically. Specifically, generators, transporters, and receiving facilities could only use hybrid or fully electronic manifests on the Hazardous Waste Electronic Manifest System (e-Manifest).

So, what are the differences between hybrid and fully electronic manifests? Let’s compare the distinctions and explore some of the benefits that electronic manifests can offer.

What’s a hybrid manifest?

EPA initially established the hybrid manifest for generators that couldn’t fully participate in electronic manifests when the e-Manifest launched in 2018. The hybrid manifest combines paper and electronic manifests, allowing generators that aren’t registered in e-Manifest or don’t have an EPA identification (ID) number to sign printed copies of electronic manifests.

Here’s the general hybrid manifest process:

  • The first transporter initiates an electronic manifest in e-Manifest. A hard copy of the electronic manifest is printed out, and the generator and initial transporter sign the paper copy.
  • The generator keeps a signed paper copy on-site. The transporter keeps a signed paper copy with the shipment until it’s delivered to the receiving facility.
  • From that point forward, the initial transporter and all subsequent waste handlers track the shipment in e-Manifest (using electronic signatures and electronic transmissions).
  • The manifest is complete when the receiving facility or exporter electronically signs it on e-Manifest.

What’s a fully electronic manifest?

The fully electronic manifest is tracked completely online. All handlers — generators, transporters, and receiving facilities or exporters — must have an EPA ID number and be registered in e-Manifest to use the fully electronic manifest.

The entire process is conducted on e-Manifest:

  • The manifest is created electronically in e-Manifest.
  • All handlers electronically sign the manifest in e-Manifest.
  • The manifest is complete when the receiving facility or exporter electronically signs it on e-Manifest.

What benefits do electronic manifests offer?

Regardless of whether EPA’s rule is finalized as is, electronic manifests offer hazardous waste handlers a range of benefits. Consider the following potential perks.

Compliance with existing regulations

Many handlers are already required to embrace electronic manifesting. In July 2024, EPA finalized the e-Manifest Third Rule, which requires:

  • Large quantity generators and small quantity generators to register for e-Manifest,
  • Exporters to submit manifests and continuation sheets to e-Manifest (and pay the associated fees), and
  • Waste handlers to submit manifest-related reports and data corrections to e-Manifest.

Streamlined recordkeeping for generators

Hazardous waste handlers using e-Manifest automatically meet the recordkeeping requirements to maintain records of manifests (paper or electronic) since the manifests are retained electronically in the system.

This eliminates the need to keep hard copies. It also provides a centralized place where handlers can access these documents at any time.

However, the provision doesn’t apply to generators using hybrid manifests; they must keep the initial paper copies of the electronic manifest for 3 years.

Reduced costs

Embracing electronic manifesting removes the costs associated with printing paper manifests from EPA-approved sources.

Keep in mind, there’s an unavoidable cost for receiving facilities and exporters. These entities have to pay user fees for each manifest they submit to e-Manifest.

Proactive preparation

EPA’s proposed Paper Manifest Sunset Rule would prohibit the use of paper manifests 2 years after the publication of a final rule. Hazardous waste handlers who transition to using only electronic manifests now will be better prepared to comply with future regulations. It gives businesses time to coordinate resources and address any unexpected issues.

Key to remember: Do you know the differences between hybrid and fully electronic hazardous waste manifests? The distinctions could be the difference between compliance and noncompliance.

EPA publishes first round of expiring TSCA CBI claims
2026-04-27T05:00:00Z

EPA publishes first round of expiring TSCA CBI claims

The Environmental Protection Agency (EPA) published the first list of expiring Confidential Business Information (CBI) claims for information submitted under the Toxic Substances Control Act (TSCA). The list covers CBI claims that expire from June 22, 2026, to July 31, 2026.

What are expiring CBI claims?

The Frank R. Lautenberg Chemical Safety for the 21st Century Act (which became law in June 2016) set an automatic 10-year expiration for most CBI claims made under TSCA. The first round of claims submitted since the act took effect will expire in June 2026.

EPA allows businesses to request extensions of CBI protection for up to another 10 years.

How do I know if my CBI claims are expiring?

EPA will notify businesses of expiring CBI claims directly through the Central Data Exchange (CDX), the agency's electronic reporting platform.

The agency will also release public lists of upcoming expiring CBI claims monthly on the “CBI Claim Expiration” webpage. EPA encourages businesses to review the lists to verify whether any of their claims are included.

How do I request an extension of expiring CBI claims?

Businesses seeking to extend a CBI claim beyond its expiration date must submit an extension request at least 30 days before the claim expires using the newly launched TSCA Section 14(e) CBI Claim Extension Request application in EPA’s CDX.

Here’s the general process:

  • EPA notifies the business of an expiring CBI claim directly through CDX and via the public lists on the “CBI Claim Expiration” webpage.
  • The business submits a request for extension through EPA’s CDX at least 30 days before the CBI claim expires. Requests must comply with the substantiation requirements at 40 CFR 703.5(a) and (b).
  • EPA reviews the submission and either grants or denies the request.

What are the possible outcomes?

If EPA approves the extension request, the information in the CBI claim will remain protected for up to another 10 years.

If EPA denies the extension request, the agency can publicize the information in the claim 30 days after notifying the submitter in CDX. Additionally, if a business doesn’t submit an extension request at least 30 days before the expiration date, EPA may publicize the information without notifying the submitter.

Key to remember: EPA published the first round of expiring CBI claims for information submitted under TSCA. Businesses must submit extension requests to keep the information protected.

2026-04-24T05:00:00Z

North Dakota establishes AST regulations

Effective date: April 1, 2026

This applies to: Owners and operators of aboveground storage tanks (ASTs) and liquid fuel storage tanks

Description of change: The Department of Environmental Quality adopted technical standards and corrective action requirements for ASTs. The department also approved amendments to the registration dates and fee categories of the Petroleum Tank Release Compensation Fund for liquid fuels storage tanks.

Related state info: Aboveground storage tanks (ASTs) state comparison — ASTs

2026-04-24T05:00:00Z

Ohio finalizes sewage sludge amendments

Effective date: March 1, 2026

This applies to: Facilities regulated by the sewage sludge program

Description of change: The Ohio Environmental Protection Agency finalized changes to the sewage sludge program through its 5-year review of the regulations. The approved amendments:

  • Add professional operator of record requirements for privately owned treatment works;
  • Increase and add isolation distances for facilities;
  • Prohibit beneficial use of biosolids within a vulnerable hydrogeological setting;
  • Remove dioxin monitoring requirements; and
  • Add requirements for beneficial user certification (including the application and examination process, recordkeeping requirements, and reasons for suspending or revoking a certification).
2026-04-24T05:00:00Z

New Mexico adopts Clean Transportation Fuel Program rules

Effective date: April 1, 2026

This applies to: Transportation fuel produced in, imported into, or dispensed for use in New Mexico

Description of change: The New Mexico Environment Department finalized regulations to implement the Clean Transportation Fuel Program (CTFP) to reduce the carbon intensity of transportation fuel (including gasoline and diesel). The program covers transportation fuel producers, importers, and dispensers.

The CTFP:

  • Establishes annual statewide carbon intensity standards that apply to transportation fuel (e.g., gasoline and diesel) produced, imported, and dispensed for use in New Mexico;
  • Allocates credits and calculates deficits for regulated entities based on the fuel’s carbon intensity; and
  • Sets up a marketplace for selling and purchasing credits to comply with the carbon intensity standards.

The first compliance period runs from April 1, 2026, to December 31, 2027. The first compliance period report is due by April 30, 2028. Annual compliance reports will be due by April 30 for the previous calendar year.

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Most Recent Highlights In Transportation

2026-04-24T05:00:00Z

Maine lists materials covered for packaging stewardship program

Effective date: March 3, 2026

This applies to: Entities subject to the Stewardship Program for Packaging Regulations

Description of change: The Maine Department of Environmental Protection’s amendments to the Stewardship Program for Packaging Regulations (06-096 C.M.R. Chapter 428) include:

  • Aligning the rules with changes made by An Act to Improve Recycling by Updating the Stewardship Program for Packaging (L.D. 1423), and
  • Adding Appendix A — The Packaging Material Types List to the Stewardship Program for Packaging Regulations.

L.D. 1423:

  • Excludes certain commercial, cosmetic, medical, environmental, dangerous, hazardous, and flammable product packaging from the program requirements;
  • Excludes packaging of products related to public health and water quality testing from the program requirements;
  • Requires the department to adopt a process for approving a producer payment system; and
  • Updates definitions for clarity.

Appendix A defines packaging material and designates the material types readily recyclable as applicable. It may also designate materials as compostable or reusable.

2026-04-24T05:00:00Z

California adopts permanent illegal disposal rules

Effective date: March 4, 2026

This applies to: Entities that handle, transfer, compost, transform, or dispose of solid waste

Description of change: CalRecycle made permanent the current illegal disposal emergency regulations, allowing enforcement agencies to take action against any person who illegally disposes of solid waste.

The rule also:

  • Adds the land application activities to the regulations, making the activities subject to the permitting tier structure and associated requirements (i.e., operator filing requirements, state minimum standards, recordkeeping, and enforcement agency inspection requirements); and
  • Amends sampling and recordkeeping for solid waste facilities, operations, and activities.
2026-04-24T05:00:00Z

West Virginia establishes fee schedule for UIC Program

Effective date: March 4, 2026

This applies to: Underground Injection Control (UIC) Program permittees

Description of change: This rule establishes the schedules of fees for carbon dioxide capture and sequestration authorized by the West Virginia Department of Environmental Protection’s (WVDEP’s) Division of Water and Waste Management.

EPA granted primacy to the WVDEP to implement the UIC Program for Class VI wells in February 2025.

2026-04-24T05:00:00Z

Colorado extends timeline to comply with GHG intensity targets

Effective date: April 14, 2026

This applies to: Small operators in the oil and gas sector

Description of change: The Colorado Air Quality Control Commission revised the intensity targets for reducing greenhouse gas (GHG) emissions for small oil and gas operators (those with less than 45 thousand barrels of oil equivalent (kBOE) production in 2025). The commission extended the first deadline to 2030 for small operators to meet applicable intensity requirements.

However, small operators must still submit the intensity plan for the 2027 targets, which is due by June 30, 2026.

Related state info: Clean air operating permits state comparison — Clean air operating permits

2026-04-24T05:00:00Z

Colorado finalizes state dredge and fill permit regulations

Effective date: March 30, 2026

This applies to: Projects that require preconstruction notification or compensatory mitigation

Description of change: The Colorado Water Quality Control Division finalized rules for implementing a state dredge and fill discharge authorization program established by HB24-1379. The program covers state waters that aren’t subject to federal dredge and fill permitting requirements under Section 404 of the Clean Water Act.

The division will continue issuing Temporary Authorizations until August 31, 2026. After that, applicants must apply for coverage under General Authorizations. The division already accepts applications for Individual Authorizations.

Related state info: Construction water permitting — Colorado

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Most Recent Highlights In Safety & Health

2026-04-24T05:00:00Z

New York adds wastewater cybersecurity rules

Effective date: March 26, 2026

This applies to: Wastewater treatment facilities

Description of change: The New York State Department of Environmental Conservation added cybersecurity regulations for wastewater treatment facilities. The rules:

  • Require all State Pollutant Discharge Elimination System (SPDES) permittees to report cybersecurity incidents,
  • Require publicly owned treatment works (POTWs) to establish, maintain, and implement an Emergency Response Plan and certify compliance with the provisions annually by March 28;
  • Establish baseline cybersecurity control requirements;
  • Add network monitoring and logging for certain POTWs with design flows of 10 million+ gallons per day; and
  • Require wastewater treatment plant operators to complete a minimum number of training hours within their existing required hours on cybersecurity to renew certification every 5 years.
2026-04-24T05:00:00Z

California permanently adopts EPA’s conditional exemption for airbag waste

Effective date: March 6, 2026

This applies to: Airbag waste handlers and transporters

Description of change: The California Department of Toxic Substances Control permanently adopted the Environmental Protection Agency’s (EPA’s) interim final rule that allows airbag waste handlers and transporters to meet less stringent hazardous waste requirements (e.g., not manifesting the waste) if they meet certain conditions. Once the airbag waste is received at a collection facility or designated facility for proper disposal, it must be managed as hazardous waste.

The scope of the rule applies to all airbag waste, including recalled airbag inflators.

Related state info: Hazardous waste generators — California

2026-04-24T05:00:00Z

New Jersey extends polystyrene foam exemption

Effective date: March 12, 2026

This applies to: Certain polystyrene foam food service products

Description of change: The New Jersey Department of Environmental Protection extended the exemption from the Single-Use Paper and Plastic Carryout Bags and Polystyrene Foam Food Service Products Rules for certain polystyrene foam products from May 4, 2026, to May 4, 2027. It applies to these polystyrene foam products:

  • Trays used for raw or butchered meat or fish that’s sold from a refrigerator or similar retail appliance;
  • Food products pre-packaged by the manufacturer in a polystyrene foam food service product;
  • Polystyrene foam food service products that are used for the health or safety of hospital, nursing home, or correctional facility patients or residents; and
  • Any other polystyrene foam food service product as determined needed by the department.
Effluent limitations: FAQs for direct dischargers of industrial wastewater
2026-04-16T05:00:00Z

Effluent limitations: FAQs for direct dischargers of industrial wastewater

Facilities across the country conduct industrial activities that generate wastewater containing pollutants and then release it directly into nearby surface waters, such as streams, rivers, or lakes. However, before any industrial wastewater can be discharged from a site, the facility must obtain a National Pollutant Discharge Elimination System (NPDES) permit.

The Environmental Protection Agency (EPA) uses effluent limitations as the primary method to regulate direct discharges of industrial wastewater into waters of the United States. These restrictions are incorporated into NPDES permits.

Meeting effluent limitations is the key to compliance with NPDES permits. But like other environmental regulations, these standards can get complex quickly without a solid foundation of understanding. We’ve compiled common FAQs to help you become fluent in effluent limitations.

What’s effluent?

There’s no specific statutory or regulatory definition of “effluent.” Thankfully, a 1997 document from EPA entitled Terms of Environment: Glossary, Abbreviations, and Acronyms, Revised December 1997 (EPA 175-B-97-001) provides clarity, defining effluent as “wastewater — treated or untreated — that flows out of a treatment plant, sewer, or industrial outfall.”

What’s the difference between effluent guidelines and limitations?

There are subtle but important distinctions between these two terms.

Effluent guidelines (also known as effluent limitations guidelines and standards or ELGs) are the national industrial wastewater discharge standards established by EPA for all facilities in an industrial category.

The federal agency develops effluent guidelines based on the performance of the best available technology that’s economically achievable for an industry. Notably, effluent guidelines are technology-based; they’re not based on risk or impacts to receiving waters (i.e., water quality-based).

Federal effluent guidelines (40 CFR Subchapter N) for direct dischargers of industrial wastewater are implemented through the NPDES permitting program.

Effluent limitations are any restrictions imposed “on quantities, discharge rates, and concentrations of pollutants” from industrial wastewater discharges (122.2). Simply put, effluent limitations are the specific numeric and non-numeric requirements developed for facilities to comply with the effluent guidelines. Unlike effluent guidelines, effluent limitations may be both technology- and water quality-based.

Most states issue NPDES permits, except for the District of Columbia, Massachusetts, New Hampshire, and New Mexico, where EPA serves as the permitting authority. The permit writer develops effluent limitations for NPDES permits and issues them to facilities. The permit may be general (covering multiple facilities with similar operations and discharges) or individual (customized with site-specific conditions).

What’s the bottom line? Effluent guidelines aren’t directly enforceable permit conditions, whereas effluent limitations are.

What are the types of effluent limitations?

Two categories of effluent limitations may appear in NPDES permits:

  • Technology-based effluent limitations (TBELs), and
  • Water quality-based effluent limitations (WQBELs).

TBELs are based on available treatment technologies and require facilities to meet a minimum level of treatment of pollutants in wastewater discharges.

WQBELs apply only when TBELs aren’t enough to achieve water quality standards. States develop total maximum daily loads (TMDLs). A TMDL is the maximum amount of a pollutant that can be discharged into a waterbody while still meeting the water quality standards. Specific portions of the TMDL are then allotted to permitted facilities (called wasteload allocation). Facilities can’t release more than their allocated amounts.

Any applicable wasteload allocations are incorporated into a facility’s NPDES permit.

Do facilities have to use specific control technologies?

Although EPA’s effluent guidelines are based on the use of a specific control technology, facilities aren’t required to install the same technology system. As long as they comply with the standards, facilities may implement other treatment technologies.

Key to remember: Understanding effluent limitations is key to complying with industrial wastewater discharge permits.

EPA proposes major changes to coal combustion residuals rules
2026-04-16T05:00:00Z

EPA proposes major changes to coal combustion residuals rules

The Environmental Protection Agency (EPA) published a proposed rule on April 13, 2026, to revise the existing regulations governing the disposal of coal combustion residuals (CCR) in landfills and surface impoundments as well as the beneficial use of CCR.

Who’s impacted?

The proposed rule affects coal-fired electric utilities and independent power producers subject to the CCR disposal and beneficial use regulations at 40 CFR Part 257.

What are the changes?

Significant changes the EPA proposes include:

  • Adding an option for facilities to certify the closure of legacy CCR surface impoundments by CCR removal that were closed before November 8, 2024, under regulatory oversight;
  • Expanding the eligibility criteria for facilities to defer CCR closure requirements until site-specific determinations are made for legacy surface impoundments that were closed before November 8, 2024, under regulatory oversight;
  • Exempting CCR dewatering structures (used to dewater CCR waste for the disposal of CCR elsewhere) from federal CCR regulations (Part 257);
  • Rescinding all CCR management unit (CCRMU) requirements or revising the existing CCRMU regulations;
  • Allowing permit authorities to make site-specific determinations regarding certain requirements during permitting for CCR units complying with federal CCR groundwater monitoring, corrective action, and closure requirements under a federal or an approved-state CCR permit; and
  • Revising the beneficial use requirements by:
    • Removing the environmental demonstration requirement for non-roadway use of more than 12,400 tons of unencapsulated CCR; and
    • Excluding these beneficial uses from federal CCR regulations (Part 257):
      • CCR used in cement manufacturing at cement kilns,
      • Flue gas desulfurization (FGD) gypsum used in agriculture, and
      • FGD gypsum used in wallboard.

Key to remember: EPA plans to make significant amendments to the coal combustion residuals requirements.

See More

Most Recent Highlights In Human Resources

What to know about the EPA’s proposed manifest sunset rule
2026-04-14T05:00:00Z

What to know about the EPA’s proposed manifest sunset rule

The U.S. Environmental Protection Agency (EPA) is taking another major step toward modernizing hazardous waste tracking. The Agency’s proposed “manifest sunset rule” would officially phase out paper hazardous waste manifests and require the exclusive use of the e-Manifest system. For employers, especially those generating or managing hazardous waste, it’s a fundamental shift in how waste shipments are documented, tracked, and audited.

Since 2018, EPA’s e-Manifest system has been available as a digital alternative to paper manifests. Over the years, the agency has added requirements pushing the industry toward adoption, including mandatory registration and electronic data submission. But despite those efforts, many companies have continued to rely on paper manifests, either out of habit, convenience, or because parts of their waste chain weren’t ready to go digital. EPA even states in the proposed rule that less than one percent of all e-manifest users have completely switched to digital manifest. The proposed sunset rule is designed to close that gap. Once finalized, it would set a firm deadline (24 months) after which paper manifests would no longer be allowed.

Why EPA wants to eliminate paper manifests

EPA’s reasoning is pretty straightforward. Paper manifests are slower, easier to lose, and more prone to errors. They rely on manual handling and delayed processing, which can create gaps in tracking and compliance. A fully electronic system, on the other hand, allows for real-time visibility, standardized data entry, and faster correction of mistakes. It also gives regulators a clearer, more immediate picture of what’s happening across the entire waste life cycle.

Addressing one of the biggest digital barriers: signatures

One overlooked part of the proposed rule is how EPA is trying to solve one of the biggest barriers to going fully digital, which is signatures in the field. Anyone who has dealt with manifests knows that the weak point is often the hand-off between the generator and the transporter, especially when drivers don’t have system access or reliable connectivity. To address that, EPA is proposing new functionality that would allow users to sign manifests using quick response (QR) codes or even short message service (SMS). In practice, this could mean a driver scans a QR code or receives a text prompt, then completes the signature process directly from their phone. So, no login or full system access needed. EPA is also exploring the ability to use SMS and QR-based tools to make updates to manifest data without needing full system permissions. That’s a big deal operationally, because it removes one of the most common bottlenecks in needing a registered user at a specific site to make even minor corrections.

Operational challenges companies should expect

With that said, moving to a fully digital system still comes with potential issues. It requires coordination across your entire operation. Generators, transporters, and disposal facilities all have to be aligned and capable of using the system effectively. If one party in that chain struggles, it can create delays or compliance issues for everyone involved. There’s also an upfront investment to consider. Companies may need to upgrade internal systems, ensure reliable connectivity, and train employees in new work processes. For organizations with multiple sites or field operations, which can take some planning. But over time, many of those burdens are expected to decrease. Electronic signatures, reusable templates, and centralized record-keeping can significantly reduce administrative work.

One of the biggest shifts employers will notice is the level of visibility. With paper manifests, there’s often a lag between shipment and final documentation. In a digital system, that lag disappears. Information becomes available almost immediately, and regulators have access to the same data. That means errors or discrepancies are easier to find and harder to ignore.

The good news is that companies don’t have to wait for the final rule to start preparing. Taking a close look at your current manifest process is a good first step. If paper is still a major part of your workflow, that’s a clear signal that changes are coming. Making sure your e-Manifest account is fully set up and that employees understand how to use it, will go a long way in avoiding future disruptions.

Keys to remember: The EPA’s proposed Paper Manifest Sunset Rule would set a firm date to phase out paper hazardous waste manifests and require that all covered shipments be tracked through the agency’s electronic e‑Manifest system, in which the Agency says will improve hazardous‑waste tracking and transparency while reducing administrative burden and saving regulated entities roughly $28.5 million per year.

How incinerators are permitted: A look at the regulatory framework and EPA’s new streamlining proposal
2026-04-13T05:00:00Z

How incinerators are permitted: A look at the regulatory framework and EPA’s new streamlining proposal

Incinerators in the United States operate under a complex permitting framework designed to protect air quality, public health, and the environment. Under the Clean Air Act (CAA), facilities that burn waste must meet strict emission standards, maintain operating controls, and follow extensive monitoring and reporting rules. These requirements ensure that incineration, while a valuable tool for waste management, wildfire mitigation, and disaster recovery, remains safe and consistent with federal air quality objectives. Against this backdrop, the Environmental Protection Agency (EPA) recently proposed a rule to streamline permitting for specific types of incinerators used in wildfire prevention and disaster cleanup, a move that could reduce delays for state and local governments.

The regulatory basis for incinerator permitting

Most incinerators fall under Section 129 of the CAA, which mandates EPA to establish performance standards and emission guidelines for categories of solid waste combustion units. These standards govern pollutants such as particulate matter, carbon monoxide, sulfur dioxide, nitrogen oxides, lead, cadmium, mercury, hydrogen chloride, and dioxins/furans. Operators must also conduct emissions testing, maintain continuous monitoring equipment, track operational parameters, and submit regular compliance reports.

Permitting generally occurs through Title V operating permits, which consolidate all applicable air quality requirements into a single enforceable document. A Title V permit typically requires annual certifications, detailed recordkeeping, periodic emissions tests, and reporting of deviations. While the Title V program doesn't impose new standards, it ensures that incinerators comply with all existing federal and state air quality rules.

Different categories of incinerators, such as large municipal waste combustors (LMWC), small municipal waste combustors (SMWC), commercial and industrial solid waste incinerators (CISWI), and other solid waste incinerators (OSWI), have distinct requirements. These subcategories reflect variations in unit size, waste composition, and operational design, and each has its own subpart under EPA’s air quality regulations.

Air curtain incinerators: A special case

Air curtain incinerators (ACIs), which burn wood waste, yard debris, and clean lumber, occupy a niche segment of the permitting landscape. They use a mechanized “curtain” of air to increase combustion efficiency and reduce particulate emissions compared to open burning. However, their regulatory treatment has historically been inconsistent.

Because ACIs fit partly within several existing subparts, operators often face confusion about which monitoring, opacity limits, and reporting duties apply. Overlap across four regulatory categories can create delays, particularly during emergencies when ACIs are deployed to remove vegetative fuels that increase wildfire risk or to process debris after storms.

EPA’s emergent focus on streamlining

In March 2026, EPA announced a proposal to consolidate the regulatory requirements for ACIs used solely to burn wood-derived materials into a single subpart under Section 129 of the CAA. The proposal would also allow these ACIs to operate without a Title V permit unless located at a facility that otherwise requires one.

EPA stated that the change would “cut red tape” and provide clarity for state, local, and Tribal governments, allowing them to respond more effectively to natural disasters and conduct wildfire mitigation activities without unnecessary administrative delays. The agency emphasized that unprocessed debris contributes to poor air and water quality and poses safety risks, particularly in post disaster environments.

Context: Broader federal actions on disaster-related incineration

The proposal follows earlier federal steps to ease the temporary use of incinerators during emergencies. In 2025, EPA issued an interim final rule permitting CISWI units to burn nonhazardous disaster debris for up to 8 weeks without prior EPA approval, a provision intended to accelerate cleanup after hurricanes, wildfires, and floods. These units must still operate their pollution control equipment, and extensions beyond 8 weeks require EPA authorization.

Such measures reflect the increasing volume of debris associated with severe weather events and the need for rapid, environmentally sound disposal mechanisms. The current proposal for ACIs builds on these efforts by targeting the specific regulatory bottlenecks associated with vegetative and wood waste disposal.

Looking ahead

EPA’s streamlined permitting proposal doesn't alter emission standards but rather clarifies and simplifies administrative pathways. If finalized, it may make ACIs more accessible during periods of heightened wildfire risk and in the critical early stages of disaster recovery.

Key to remember: At its core, the permitting system for incinerators aims to balance environmental protection with operational flexibility. The new proposal underscores EPA’s recognition that, in emergency contexts, speed matters but so does environmental stewardship.

EPA delays TSCA Section 8(a)(7) PFAS reporting timeline again
2026-04-13T05:00:00Z

EPA delays TSCA Section 8(a)(7) PFAS reporting timeline again

On April 13, 2026, the Environmental Protection Agency (EPA) published a final rule that further delays the submission period for the one-time report required of manufacturers on per- and polyfluoroalkyl substances (PFAS) by the PFAS Reporting and Recordkeeping Rule (PFAS Reporting Rule).

This final rule pushes the starting submission period to either 60 days after the effective date of a future final rule updating the PFAS Reporting Rule or January 31, 2027, whichever is earlier.

Who’s impacted?

Established under Toxic Substances Control Act (TSCA) Section 8(a)(7), the PFAS Reporting Rule (40 CFR Part 705) requires any business that manufactured (including imported) any PFAS or PFAS-containing article between 2011 and 2022 to report. Covered manufacturers and importers must submit information on:

  • Chemical identity, uses, and volumes made and processed;
  • Byproducts;
  • Environmental and health effects;
  • Worker exposure; and
  • Disposal.

What’s the new timeline?

The opening submission period was moved from April 13, 2026, to either 60 days after the effective date of a future final PFAS Reporting Rule or January 31, 2027, whichever is earlier.

Most manufacturers have 6 months to submit the report. Small manufacturers reporting only as importers of PFAS-containing articles have 1 year.

TSCA Section 8(a)(7) PFAS Reporting Rule submission period
Start dateEnd date
Most manufacturers60 days from effective date of final PFAS Reporting Rule or January 31, 2027 (whichever is earlier)6 months from start date or July 31, 2027 (whichever is earlier)
Small manufacturers reporting solely as PFAS article importers60 days from effective date of final PFAS Reporting Rule or January 31, 2027 (whichever is earlier)1 year from start date or January 31, 2028 (whichever is earlier)

Why the delay?

In November 2025, the agency proposed updates to the PFAS Reporting Rule. EPA has delayed the reporting period to give the agency time to issue a final rule (expected later this year).

Key to remember: EPA has delayed the starting submission deadline for the TSCA Section 8(a)(7) PFAS Reporting Rule from April 2026 to no later than January 2027.

EPA amends specific oil and gas emission standards
2026-04-10T05:00:00Z

EPA amends specific oil and gas emission standards

On April 9, 2026, the Environmental Protection Agency (EPA) published a final rule that makes technical changes to the emission standards established in March 2024 (2024 Final Rule) for crude oil and natural gas facilities. This rule (2026 Final Rule) amends the requirements for:

  • Temporary flaring of associated gas, and
  • Vent gas net heating value (NHV) monitoring provisions for flares and enclosed combustion devices (ECDs).

Who’s impacted?

The 2026 Final Rule affects new and existing oil and gas facilities. Specifically, it applies to the regulations for the Crude Oil and Natural Gas source category, including the:

  • New Source Performance Standards at 40 CFR 60 Subpart OOOOb, and
  • Emission guidelines at 60 Subpart OOOOc.

These emission standards are commonly referred to as OOOOb/c.

What are the changes?

The 2026 Final Rule implements technical changes to the temporary flaring and vent gas NHV monitoring requirements set by the 2024 Final Rule.

Temporary flaring

The rule extends the baseline time limit for temporary flaring of associated gas at well sites in certain situations (like conducting repairs or maintenance) from 24 to 72 hours. Owners and operators must stop temporary flaring as soon as the situation is resolved or the temporary flaring limit is reached (whichever happens first).

It also grants allowances beyond the 72-hour limit if exigent circumstances occur (such as severe weather that prevents safe access to a well site to address an emergency or maintenance issue) and there’s a need to extend duration for repairs, maintenance, or safety issues. Owners and operators must keep records of exigent circumstances and include the information in their annual reports.

NHV monitoring

For new and existing sources, the 2026 Final Rule exempts all flare types (unassisted and assisted) and ECDs from monitoring due to high NHV content, except when inert gases are added to the process streams or for other scenarios that decrease the NHV content of the inlet stream gas. In these cases, EPA requires NHV monitoring via continuous monitoring or the alternative performance test (sampling demonstration) option for all flares and ECDs.

Other significant changes include:

  • Replacing the general exemption from NHV monitoring for associated gas for any control device used at well site affected facilities with NHV monitoring requirements,
  • Granting operational pauses during weekends and holidays for the consecutive 14-day sampling demonstration requirements (limiting it to no more than 3 operating days from the previous sampling day), and
  • Permitting less than 1-hour sampling times for twice daily samples where low or intermittent flow makes it infeasible (as long as owners and operators report the sampling time used and the reason for the reduced time).

The 2026 Final Rule takes effect on June 8, 2026.

Key to remember: EPA’s technical changes to the emission standards for oil and gas facilities apply to temporary flaring provisions and vent gas NHV monitoring requirements.

EHS Monthly Round Up - March 2026

EHS Monthly Round Up - March 2026

In this March 2026 roundup video, we'll review the most impactful environmental health and safety news.

Hi everyone! Welcome to the monthly news roundup video, where we’ll review the most impactful environmental health and safety news. Let’s take a look at what happened over the past month.

OSHA released an updated Job Safety and Health poster. Employers can use either the revised version or the older one, but the poster must be displayed in a conspicuous place where workers can easily see it.

OSHA recently removed a link from its Data topic webpage that displayed a list of “high-penalty cases” at or over $40,000 since 2015. The agency says it discontinued and removed it in December. The data is frozen and archived elsewhere.

OSHA published two new resources as part of its newly launched Safety Champions Program. The fact sheet provides an overview of how the program works, eligibility criteria, and key benefits. The step-by-step guide helps businesses navigate the core elements of OSHA’s Recommended Practices for Safety and Health Programs.

Several forces are nudging OSHA to address a number of workplace hazards and high-hazard industries. This comes from other agencies, safety organizations, watchdogs, legislative proposals, and persistent injury/fatality data. Among the hazards are combustible dust; first aid; personal protective equipment; and workplace violence. How all this translates into new regulations, guidance, programmed inspections, or other initiatives remains to be seen.

Turning to environmental news, EPA issued a proposed rule to require waste handlers to use electronic manifests to track all RCRA hazardous waste shipments. Stakeholders have until May 4 to comment on the proposal.

On March 10, EPA finalized stronger emission limits for new and existing large municipal waste combustors and made other changes to related standards.

And finally, EPA temporarily extended coverage under the 2021 Multi-Sector General Permit for industrial stormwater discharges until the agency issues a new general permit. The permit expired February 28 and remains in effect for facilities previously covered. EPA won’t take enforcement action against new facilities for unpermitted stormwater discharges if the facilities meet specific conditions.

Thanks for tuning in to the monthly news roundup. We’ll see you next month!

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Forklifts and powered industrial trucks

Forklifts and powered industrial trucks

The Occupational Safety and Health Administration (OSHA) has standards for the operation and maintenance of Powered Industrial Trucks (PITs) in the workplace. Design, training, operation, and capacity stability requirements ensure that operators of PITs of all classes are safe in the workplace. Additionally, OSHA requires daily inspections of PITs to ensure that every component is in working order.

What equipment is covered?

  • OSHA’s PIT standard applies to vehicles including forklifts, order pickers, powered pallet jacks, yard jockeys, and stand-up and narrow aisle lift trucks.
  • The OSHA PIT standard does not cover scissor lifts, aerial lifts, or over-the-road haulage trucks and earth-moving equipment that has been modified to accept forks.

The Occupational Safety and Health Administration’s (OSHA) Powered Industrial Truck (PIT) standard applies to most types of material handling equipment that are powered for horizontal movement. This includes:

  • Forklifts
  • Order pickers
  • Powered pallet jacks
  • Yard jockeys
  • Stand-up and narrow aisle lift trucks

What equipment is not covered?

OSHA’s PIT standard does not cover the following: scissor lifts, aerial lifts, or over-the-road haulage trucks and earth-moving equipment that has been modified to accept forks.

What are the different classes of PITs?

  • Different classes of PITs are approved for different uses, but drivers must be trained and evaluated to the OSHA PIT standard to operate any of them.

There are many classes and types of Powered Industrial Trucks (PITs), from the common sit-down type to the narrow aisle stand-up type, and from order pickers to powered pallet jacks. They may be powered by electricity, liquefied petroleum gas (LPG), diesel fuel, or gasoline. Some classes are approved for use in certain hazardous conditions. PITs can be grouped into the following classifications:

  • Class 1 — Electric motor, sit-down rider, counterbalanced trucks (solid or pneumatic tires).
  • Class 2 — Electric motor, narrow aisle trucks (solid tires).
  • Class 3 — Electric motor hand trucks or hand/rider trucks (solid tires).
  • Class 4 — Internal combustion engine trucks (solid tires).
  • Class 5 — Internal combustion engine trucks (pneumatic tires).
  • Class 6 — Electric and internal combustion engine tractors (solid or pneumatic tires).
  • Class 7 — Rough terrain trucks (pneumatic tires).

No matter the class, the Occupational Safety and Health Administration (OSHA) requires operators be trained and evaluated prior to operating the equipment in the workplace.

As a historical note, OSHA issued a Request for Information in the March 11, 2019, Federal Register, acknowledging that the PITs standard at 1910.178 lists 11 different designations of trucks— D, DS, DY, E, ES, EE, EX, G, GS, LP, and LPS. However, the notice stated that eight other type-designated units — CGH, CN, CNS, DX, G/CN, G/LP, GS/CNS, and GS/LPS — are not reflected in OSHA’s current standard. The agency explains that these eight type-designated units have different requirements for safe operation, maintenance, and handling due to their fuel source, but they are generally the same in design and function as the 11 truck types currently listed in the standard. OSHA is considering adding the eight truck types to modernize its standard, but a proposal is a long-term to-do item

What are the design requirements?

  • OSHA requires that all PITs comply with the ANSI standard for safety.

The most basic provision in the Occupational Safety and Health Administration’s (OSHA) Powered Industrial Truck (PIT) standard is that equipment must be designed to meet certain safety standards. In doing this, OSHA requires that all new or acquired PIT equipment comply with the American National Standards Institute (ANSI) B56.1-1969, Safety Standard for Powered Industrial Trucks.

The ANSI standard has undergone several revisions — the most current being ANSI/ITSDF B56.1-2020, Safety Standard for Low Lift and High Lift Trucks — so most equipment purchased will likely be made to a newer version of ANSI B56.1 than the one from 1969. As a historical note, on February 16, 2022, OSHA proposed to modernize the design and construction requirements for its PITs standard to add reference to the latest ANSI/ITSDF design and construction standards. These include ANSI/ITSDF B56.1-2020, B56.5-2019, and B56.6-2021. PIT manufacturers and users will want to watch for the issuance of a final rule.

Employers must pay particular attention with the rapid changes in technology for safety devices and attachments for forklifts and other PITs:

  • Barcode scanners and Radio Frequency Identification (RFID) technology so employers can control who operates and inspects the equipment,
  • GPS systems so employers can track equipment,
  • Attachments to lift anything from a drum to carpet roll,
  • QR codes that can link to training videos right from a smartphone, and
  • Lights and alarms.

As long as equipment comes with these devices already installed by the manufacturer, there is usually no issue in regard to OSHA accepting the design, even though these devices may not have been available when the original OSHA standard was written.

What are the hazards?

  • Different classes of PITs have different associated hazards, therefore requiring specialized approaches to accident prevention.
  • Excessive speed, obscured vision, load instability, workplace conditions, and improper use are all common causes of PIT accidents in the workplace.

Powered Industrial Trucks (PITs) are used in almost all industries. They can be used to move, raise, lower, or remove large objects or a number of smaller objects on pallets or in boxes, crates, or other containers. Because PIT movement is controlled by the operator and is not restricted by the frame of the machine or other impediments, virtually unrestricted movement of the vehicle about the workplace is possible.

The hazards commonly associated with PITs vary for different vehicle types, makes, and models. Each type of truck presents different operating hazards. For example, a sit-down, counterbalanced high lift rider truck is more likely than a motorized hand truck to be involved in a falling load accident, because the sit-down rider trucks can lift a load much higher than a hand truck can.

Accident prevention

The methods or means to prevent an accident and to protect employees from injury vary for different types of trucks. For example, operators of sit-down rider trucks are often injured in tip-over accidents because of the natural tendency to jump downward and land on the floor or ground, where they can then be crushed by the vehicle’s overhead guard as the vehicle tips over. Therefore, operators of sit-down trucks need to be trained to remain in the operator’s position in a tip-over accident and to lean away from the direction of fall to minimize the potential for injury.

On the other hand, when a stand-up rider truck tips over, the truck operator can exit the vehicle by simply stepping backward, perpendicular to the direction of the vehicle’s fall, to avoid being crushed. In this situation, the operator usually should attempt to jump clear of the vehicle and should be trained accordingly.

Safe operation and workplaces

Driving a PIT at excessive speed can result in loss of control, causing the vehicle to skid, tip over, or fall off a loading dock or other elevated walking-working surface. This accident can be made more dangerous if the load being carried partially obscures the operator’s vision. A vehicle that is out of control or being operated by a driver whose vision is obscured can strike an employee, run into a column or other part of the building, or strike material, causing it to topple and injure employees in the area. Effective driver training teaches operators to minimize these hazards.

Other characteristics of a PIT that affect safe truck operation are the truck’s tendency to become unstable, its ability to carry loads high off the ground, and its characteristic mode of steering with the rear wheels while being powered by the front wheels. Moving loads upward, downward, forward, and backward causes a shift of the center of gravity of the vehicle and can adversely affect its stability. When a load is raised or moved away from the vehicle, the vehicle’s longitudinal stability is decreased. When the load is lowered or moved closer to the vehicle, its longitudinal stability is increased.

The workplaces where PITs are being used can also present a variety of different hazards. The safety of industrial truck operations can be decreased by workplace conditions such as rough, uneven, or sloped surfaces; unusual loads; hazardous areas; narrow aisles, blind spots, or intersections; and pedestrian traffic or employees working close to the path of travel. Finally, there are hazardous work practices that relate to all trucks, including operating at excessive speed, operating too close behind another PIT, poor loading practices, and carrying unauthorized passengers. In addition, poor truck maintenance can contribute to accidents.

Many accidents have occurred because of unsafe truck operation. For example, employees have fallen from trucks while using them to change light bulbs on overhead fixtures or riding on the forks to manually retrieve items from high racks. Many accidents have occurred when an operator has attempted to drive with an obstructed view in the direction of travel and has run into another employee. Improper truck maintenance has caused death from over exposure to carbon monoxide, loss of brakes, or rupture of hydraulic lines. Also, PITs that damage the legs of a storage rack may expose employees to struck-by hazards from falling materials stored on the rack.

Caution about under-ride hazards

A stand-up forklift operator was crushed and killed when the bottom half of the forklift passed beneath a beam of a storage rack. The Occupational Safety and Health Administration (OSHA) cited the employer under section 5(a)(1) of the Occupational Safety and Health Act for not furnishing a workplace free of recognized serious hazards, such as the under-ride hazard. The Occupational Safety and Health Review Commission later confirmed that employer training and extra-wide aisles were “inadequate” precautions in the case. Instead, the commission said OSHA’s suggested abatement measures were physically and economically feasible and would materially reduce the hazard. Those measures included adjusting shelf heights, installing rack barriers, or installing rear post guards on the forklifts.

What are key definitions?

  • There are a few key terms to understand in order to ensure safe PIT operation in a workplace.

Center of gravity: The point on an object at which all of the object’s weight is concentrated. For symmetrical loads, the center of gravity is at the middle of the load.

Counterweight: The weight that is built into the truck’s basic structure and used to offset the load’s weight and maximize the vehicle’s resistance to tipping over.

Grade: The slope of a surface, which is usually measured as the number of feet of rise or fall over a 100-foot horizontal distance (the slope is expressed as a percent).

Load center: The horizontal distance from the load’s edge (or the fork or other attachment’s vertical face) to the line of action through the load’s center of gravity.

Powered industrial truck (PIT): Fork trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines, excluding compressed air or nonflammable compressed gas-operated industrial trucks, farm vehicles, and vehicles intended primarily for earth moving or over-the-road hauling.

Stability triangle: The three-point suspension system that runs along an imaginary line between a forklift’s two front tires and the center of the rear axle. Even though the vehicle has four wheels, it is only supported at these three points.

Motorized hand truck: The Occupational Safety and Health Administration’s (OSHA) term for a powered pallet jack.

Pallet jack: A type of PIT used to move materials from one place to another. They do not typically raise the material very high.

Walkie: A common industry term for powered pallet jack that can only be operated by a walking operator.

Walkie-rider: A type of pallet jack that can be operated by a walking operator on the ground, or by a riding operator who stands on a built-in platform.

What are the training requirements?

  • OSHA does not have specific requirements or certifications for trainers of PIT operators, other than that they must possess the “knowledge, training, and experience” to train and evaluate operators.
  • PIT operators must have their performance evaluated initially and every three years and participate in refresher training when needed.

Failure to train and evaluate a Powered Industrial Truck (PIT) operator is a top serious OSHA violation for the PITs standard, so that means Occupational Safety and Health Administration (OSHA) officers will likely be checking to see that proper training has been completed in any facility with PIT operations, and failure to train PIT operators can lead to hefty OSHA penalties.

OSHA has specific requirements for PIT operator training. These requirements include who can train operators, the frequency at which they should be trained, the content of the trainings, and more specific requirements based on the type of truck and workplace.

Who can train?

OSHA requires that trainers have the “knowledge, training, and experience” to train operators and evaluate their competence. The OSHA standard does not further define this requirement or set any specific certifications.

However, for PIT operators that are temporary employees, OSHA’s Temporary Worker Initiative (TWI) Bulletin No. 7 explains that the staffing agency is responsible for generic PIT training, and the host employer provides the necessary site-specific PIT training and evaluation. That’s because the host employer is most familiar with the equipment being used and controls the conditions of the worksite.

Frequency

While forklift training is not required annually, OSHA does require an evaluation of each PIT operator’s performance at least once every three years.

In addition, refresher training must be provided when:

  1. The operator has been observed to operate the vehicle in an unsafe manner.
  2. The operator has been involved in an accident or a near-miss incident.
  3. The operator has received an evaluation that reveals that they are not operating the truck safely.
  4. The operator is assigned to drive a different type of truck.
  5. A condition in the workplace changes in a manner that could affect safe operation of the truck.

Content

PIT operators must receive a combination of the following types of training:

  • Formal instruction, such as: lecture, discussion, interactive computer learning, video, and/or written material.
  • Practical training, including: demonstrations performed by the trainer, and practical exercises performed by the trainee.
  • Evaluation of the operator’s performance in the workplace.

Truck-specific

  • OSHA requires employees to be trained on the specific type of PIT they will be operating.

The Occupational Safety and Health Administration (OSHA) regulation outlines several Powered Industrial Truck (PIT)-related topics:

  • Operating instructions, warnings, and precautions for the types of truck the operator will be authorized to operate;
  • Differences between the truck and the automobile;
  • Truck controls and instrumentation (where they are located, what they do, and how they work);
  • Engine and motor operation;
  • Steering and maneuvering;
  • Visibility (including restrictions due to loading);
  • Fork and attachment adaptation, operation, and use limitations;
  • Vehicle capacity;
  • Vehicle stability;
  • Any vehicle inspection and maintenance that the operator will be required to perform;
  • Refueling and/or charging and recharging of batteries;
  • Operating limitations; and
  • Any other operating instructions, warnings, or precautions listed in the operator’s manual for the types of vehicle that the employee is being trained to operate.

Workplace-specific

  • The Occupational Safety and Health Administration (OSHA) regulations require workplace-specific Powered Industrial Truck (PIT) training.
The regulation also requires training in several workplace-related topics:
  • Surface conditions where the vehicle will be operated;
  • Ramps and other sloped surfaces that could affect the vehicle’s stability;
  • Composition of loads to be carried and load stability;
  • Load manipulation, stacking, and unstacking;
  • Pedestrian traffic in areas where the vehicle will be operated;
  • Narrow aisles and other restricted areas where the vehicle will be operated;
  • Hazardous (classified) locations where the vehicle will be operated;
  • Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust; and
  • Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.

Evaluation

Evaluation of each PIT operator’s performance is required at least once every three years.

Certification

OSHA has no requirement that a forklift operator have a valid driver’s license but does require that every forklift operator be trained and certified to operate the PIT in the workplace. The employer must have a record documenting that the driver has successfully completed the training.

What are the requirements to operate in hazardous atmospheres?

  • Depending on hazards present, certain Powered Industrial Truck (PIT) types are better suited for different workplaces.

Where chemicals or other hazardous substances are or can be present, special precautions must be taken to select the correct type of PIT.

To make the correct selection, the employer must know the:

  • Type of location (known as Class),
  • Specific chemical or substance,
  • Likelihood for the hazard to exist (Division), and
  • Type Designation for each PIT.

Classified locations

The table below, used with permission of the Washington Department of Labor and Industries, shows the criteria to pick the safest forklift for certain workplaces.

  1. The first column of the table shows the hazard class of the material.
  2. The rows contain chemicals or substances that might be handled at a workplace.
  3. The second and third columns are the divisions that represent the exposure condition.
  4. The hazard designations listed in the second or third column are interpreted in the Explosion/Combustion Hazards table below.

In an area where this hazard classification is present:Operators should use this type of forklift.
Class I
Flammable gases or vapors are or may be present in quantities sufficient for explosion or ignition.
Division I
Condition exists continuously, intermittently, or periodically under normal operating conditions.
Division II
Condition may occur accidentally, e.g., puncture of a storage drum.
Acetylene, acetaldehyde, butadiene, cyclopropane, diethyl ether, ethylene, ethylene oxide, isoprene, propylene oxide, hydrogen (or gases or vapors equivalent in hazard to hydrogen, such as manufactured gas), unsymmetrical dimenthylhydrazine (UDMH)Forklift use prohibited.DY, EE, EX (also DS, ES, GS, LPS) if the only exposure is sealed containers or liquefied or compressed gases in containers.
Acetone, acrylonitrile, alcohol, ammonia, benzine, bensol, butane, ethylene dichloride, gasoline, hexane, lacquer solvent, natural gas, naphtha, propane, propylene, styrene, xylenes, vinyl acetate, vinyl chloride.EXDY, EE, EX (also DS, ES, GS, LPS) if the only exposure is sealed containers or liquefied or compressed gases in containers.
Class II
Combustible dust is present.
Division I
Explosive or conductive mixture may be present under normal conditions or where equipment failure can lead to both this condition and arching or sparking.
Division II
Explosive mixture not normally present but where deposits of dust may cause heat rise in electrical equipment
Aluminum, magnesium, and their commercial alloys; other metals of similarly hazardous characteristics.Forklift use prohibited.Forklift with electrical enclosures manufacturer approved where magnesium, aluminum, or aluminum bronze may be present.
Carbon black, coal or coke dust. EXForklift manufacturer approved for this location.
Other combustible dusts. EXDY, EE, EX
Class III
Easily ignitable fibers or flyings are present but not likely to be in suspension in quantities sufficient to ignite.
Division I
Locations in which these materials are handled, manufactured, or used.
Division II
Locations in which these materials are stored or handled (other than manufacturer).
Baled waste, cocoa fiber, cotton, excelsior, hemp, istle, jute, kapok, oakum, sisal, Spanish moss, synthetic fibers, tow.DY, EE, EXDS, DY, ES, EE, GS, LPS (Type E may continue to be used if used previously at this location.)
Unclassified Locations
Piers and wharves inside and outside general storage, general industrial, or commercial properties.
D, E, G, LP (more protective designations may also be used)

Explosion/Combustion hazards

All forklifts have a hazard designation assigned to them that tells whether they are suitable for use in certain kinds of hazardous atmospheres. The designation can be found on the forklift’s load capacity plate. The table below explains the designations.

TypeBuilt-in safeguards against fire hazards
D (Diesel forklift)Minimal safeguards for fire hazards
DSD + additional for fuel, exhaust and electrical systems
DYDS + all electrical equipment enclosed
EMinimal safeguards for fire hazards
ESE + prevents sparks and limits surface temperatures
EEES + all electric motors and equipment completely enclosed
EXCan be used in flammable vapor or dust atmospheres
G (Gasoline forklift)Minimal safeguards for fire hazards
GSG + additional for fuel, exhaust and electrical systems
LPMinimal safeguards for fire hazards
LPSLP + additional for fuel, exhaust and electrical systems

What are capacity and stability requirements?

  • PIT operators must participate in stability training.

Perhaps the most critical operational element for Powered Industrial Trucks (PITs) is capacity and stability. In fact, it’s the basic reason most PITs exist. But it can be a hard concept to grasp and explain to workers.

Most PITs work on essentially the same principle as a teeter-totter — the weight of the load on the forks must be counterbalanced by the weight of the truck body. The load weight that each lift can handle can be found on the nameplate, also known as a data plate, capacity plate, or ID plate. The nameplate will state the capacity of the lift — in other words, the manufacturer’s guideline for how much weight can be safely lifted.

The capacity data on the nameplate is critical information, but it was calculated using a load with a specific load center, commonly 24 inches. So, unless every load an operator lifts has a load center of 24 inches — or whatever load center the truck was rated at — and is placed perfectly on the forks, employers have to remember that the actual capacity will be reduced. The same thing goes for attachments — which also typically reduce capacity.

Stability training

Trainers need to have a thorough understanding of load composition and impart it to operators. Trainers must be thoroughly familiar with concepts such as:

  • Center of gravity — The point on an object at which all of the object’s weight is concentrated. For symmetrical loads, the center of gravity is at the middle of the load.
  • Counterweight — The weight that is built into the truck’s basic structure and used to offset the load’s weight and maximize the vehicle’s resistance to tipping over.
  • Fulcrum — The truck’s axis of rotation when it tips over.
  • Grade — The slope of a surface, which is usually measured as the number of feet of rise or fall over a 100-foot horizontal distance (the slope is expressed as a percent).
  • Lateral stability — A truck’s resistance to overturning sideways.
  • Line of action — An imaginary vertical line through an object’s center of gravity.
  • Load center — The horizontal distance from the load’s edge (or the fork or other attachment’s vertical face) to the line of action through the load’s center of gravity.
  • Longitudinal stability — The truck’s resistance to overturning forward or rearward.
  • Moment — The product of the object’s weight times the distance from a fixed point (usually the fulcrum). In the case of a PIT, the distance is measured from the point at which the truck will tip over to the object’s line of action. The distance is always measured perpendicular to the line of action.
  • Track — The distance between the wheels on the same axle of the truck.
  • Wheelbase — The distance between the centerline of the vehicle’s front and rear wheels.

Stability

  • The three-point support system on counterbalanced PITs forms a stability triangle.
  • To avoid tipping, a PIT must achieve longitudinal, lateral, and dynamic stability.

Stability triangle

Almost all counterbalanced PITs have a three-point suspension system, meaning the vehicle is supported at three points. This is true even if the vehicle has four wheels. The truck’s steer axle is attached to the truck by a pivot pin in the axle’s center. When the points are connected by imaginary lines, this three-point support forms a triangle called the stability triangle.

Longitudinal stability

The axis of rotation when a truck tips forward is the front wheels’ points of contact with the pavement. When PITs tip forward, the truck will rotate about this line. When a truck is stable, the vehicle moment must exceed the load-moment. As long as the vehicle-moment is equal to or exceeds the load-moment, the vehicle will not tip over. On the other hand, if the load-moment slightly exceeds the vehicle-moment, the truck will begin to tip forward, thereby causing the rear to lose contact with the floor or ground and result in loss of steering control. If the load-moment greatly exceeds the vehicle-moment, the truck will tip forward.

To determine the maximum safe load-moment, the truck manufacturer normally rates the truck at a maximum load at a given distance from the front face of the forks. The specified distance from the front face of the forks to the line of action of the load is the load center.

Because larger trucks normally handle loads that are physically larger, these vehicles have greater load centers. Trucks with a capacity of 30,000 pounds or less are normally rated at a given load weight at a 24-inch load center. Trucks with a capacity greater than 30,000 pounds are normally rated at a given load weight at a 36- or 48-inch load center. To safely operate the vehicle, the operator should always check the data plate to determine the maximum allowable weight at the rated load center.

Although the true load-moment distance is measured from the front wheels, this distance is greater than the distance from the front face of the forks. Calculating the maximum allowable load-moment using the load-center distance always provides a lower load moment than the truck was designed to handle.

When handling unusual loads, such as those that are larger than 48 inches long (the center of gravity is greater than 24 inches) or that have an offset center of gravity, etc., a maximum allowable load moment should be calculated and used to determine whether a load can be safely handled. For example, if an operator is operating a 3,000-pound capacity truck (with a 24-inch load center), the maximum allowable load-moment is 72,000 inch-pounds (3,000 times 24). If a load is 60 inches long (30-inch load center), then the maximum that this load can weigh is 2,400 pounds (72,000 divided by 30).

Lateral stability

The vehicle’s lateral stability is determined by the line of action’s position relative to the stability triangle. When the vehicle is not loaded, the truck’s center of gravity location is the only factor to be considered in determining the truck’s stability. As long as the line of action of the combined vehicle and load’s center of gravity falls within the stability triangle, the truck is stable and will not tip over. However, if the line of action falls outside the stability triangle, the truck is not stable and may tip over.

Factors that affect the vehicle’s lateral stability include the load’s placement on the truck, the height of the load above the surface on which the vehicle is operating, and the vehicle’s degree of lean.

Dynamic stability

The stability of a PIT is further complicated by dynamic forces that result when the vehicle and load are put into motion. The weight’s transfer and the resulting shift in the center of gravity due to the dynamic forces created when the machine is moving, braking, cornering, lifting, tilting, and lowering loads, etc., are important stability considerations.

When determining whether a load can be safely handled, the operator should exercise extra caution with loads that cause the vehicle to approach its maximum design characteristics. For example, if an operator must handle a maximum load, the load should be carried at the lowest position possible, the truck should be accelerated slowly and evenly, and the forks should be tilted forward cautiously. However, no precise rules can be formulated to cover all of these eventualities.

How are PITs inspected?

  • OSHA has specific standards for the frequency of PIT inspections.

Frequency

The Occupational Safety and Health Administration (OSHA) requires that forklift vehicles be inspected at least daily, or after each shift when used around the clock.

Daily inspections – External

  • A PIT’s tires, forks, mast and carriage, body, cab, and (for certain types) platform must be inspected daily to ensure proper operation and safety in the workplace.

The daily inspection requirements below broadly apply to several kinds of Powered Industrial Trucks (PITs): electric forklifts, gas and diesel forklifts, liquefied petroleum gas (LPG) forklifts, order pickers, powered pallet jacks, reach trucks, and stand-up tow tractors. They must be inspected for these requirements daily, with additional specific requirements for every type of PIT.

Tires

On electric forklifts, gas and diesel forklifts, LPG forklifts, powered pallet jacks, reach trucks, stand-up tow tractors, and pallet jacks, the tires must be in good repair (e.g., no cuts, separation from the rim, or excessive wear) and properly inflated. There must be lug nuts present on each tire, and the lug nuts must each be tightly secure.

Forks

On electric forklifts, gas and diesel forklifts, LPG forklifts, order pickers, powered pallet jacks, reach trucks, and pallet jacks, the forks must be properly aligned and in good repair (e.g., no cracks, bends, or excessive wear). Where present, the top clip retaining pin for each fork must be tightly secure and in good repair (e.g., no cracks). Load back rests must be securely attached and in good repair (e.g., no cracks or bends).

On reach trucks, the telescoping forks must be in good repair (e.g., no cracks, bends, or excessive wear).

Mast and carriage

On electric forklifts, gas and diesel forklifts, LPG forklifts, order pickers, and reach trucks, the mast assembly must be in good repair (e.g., no cracks or dents, missing stops, or broken welds). The hydraulic cylinders must be in good repair (e.g., no cracks or leaks). The lift chains and rollers must be in good repair (e.g., no cracks, kinks, or rust) and properly lubricated. Additionally, the tension of the lift chains must be correct.

On an order picker, the hoist lines, cables, lift chains, and rollers must be in good repair (e.g., no cracks, kinks, or rust).

Body

The body of the PIT must be in good repair (e.g., no cracks or dents) and clean (e.g., no grease or lint). The covers over the battery and other hazardous parts must be in place and secure. The overhead guard must be securely attached and in good repair (e.g., no cracks, bends, broken welds, or missing bolts). The nameplate must be present and legible. The safety decals or warning labels must also be legible. Any wiring, belts, lights, headlights, taillights, reflectors, warning lights, hoses, chains, and cables must be in good repair (e.g., no cracks, bends, frays, breaks, leaks, or kinks). Any lights or headlights must be aimed correctly. The control levers must be properly labeled.

On a powered pallet jack, the operator must ensure the hand guard is in place.

Cab

The cab should be clean, with the seatbelt working properly and in good repair (e.g., no frays or excessive wear). The seat itself must also be in good repair and adjusted properly. Control levers must be properly labeled. The mirrors must be in good repair (e.g., no cracks or breaks), clean, and adjusted properly.

Platform

Operators of order pickers, powered pallet jacks, and stand-up tow tractors must also inspect the PIT’s platform. The order picker’s work platform must be clean and in good repair (e.g., no cracks or holes). The guardrails or other limiting devices on the order picker must be in good repair (e.g., no cracks or bends) and must close properly and lock securely. The powered pallet jack and stand-up tow tractor riding platforms must be clean and in good repair (e.g., no cracks or holes).

Daily inspections — Operational

  • A PIT’s fluids, power sources, attachments, systems and controls, must be inspected and maintained to ensure proper operation and safety in the workplace.

Fluids

Where applicable, such as sit-down forklifts, hydraulic and brake fluid levels must be adequate.

Gas or diesel forklifts should have sufficient fuel for operation and adequate engine oil and radiator coolant levels.

Where applicable, operators should ensure the engine oil level, radiator coolant level, and transmission fluid level are adequate.

Battery

A PIT’s battery must be charged and in good repair (e.g., no corrosion or missing cable insulation), with its connections tight and in good repair (e.g., no cracks or excessive wear) as well. The cell caps in the battery cover must be in place and the electrolyte level must be adequate.

Battery gates (pallet jacks) and compartments should be secured.

Attachments

The nameplate on the PIT should account for any attachment being used, with the attachment in good repair (e.g., no cracks or bends).

Systems and controls

PIT inspectors (which can be the operator) must check that several components of the system and controls are working. They must check if the motor is running smoothly. They must also check that the accelerator is working and functioning smoothly, and that the steering is smooth and responsive (e.g., free of excessive play).

The employee must ensure the horn, whistle, gong, or other warning device sounds. The brake must be working and functioning smoothly (e.g., no grabbing), along with the parking brake (e.g., holds the forklift on the incline). The drive control and tilt control must work in forward and reverse and function smoothly (e.g., no excess drift for the tilt control). The lift controls must raise and lower the forks properly and function smoothly (e.g., no excess drift), and the attachment control must work and function smoothly (e.g., no hesitation). Additionally, the turn signal, backup alarm, lights, battery discharge indicator, and hour meter should also be working.

On electric forklifts, order pickers, powered pallet jacks, reach trucks, stand-up tow tractors, and pallet jacks, employees should ensure the battery discharge indicator is working.

Gas or diesel forklift and LPG forklift operators must ensure the engine runs smoothly, and that the fuel gauge, ammeter indicator lamp, oil pressure indicator lamp, and water temperature gauge work.

Propane tank

On an LPG forklift, the operator must ensure the propane tank restraint brackets are in good repair (e.g., no cracks, bends, or rust) and that the tank is properly mounted on the locator pin. The tank must fit within the profile of the truck and be in good repair (e.g., no cracks, dents, or rust). The hoses and connectors must be in good repair (e.g., no cracks or kinks) and securely attached. Additionally, the pressure relief valve must be pointing up.

Pallet jack

  • OSHA requires powered pallet jack operators to inspect their vehicle daily.

Pallet jacks have their own set of inspection requirements. Pallet jack operators must inspect the:

  • Forks
  • Raise/lower controls
  • Forward/reverse controls
  • Tires
  • Frame
  • Control arm
  • Backrest
  • Belly button switch
  • Hand guard
  • Brakes
  • Grab bar (if applicable)
  • Horn
  • Data plate
  • Warning labels
  • Battery (condition/cables)
  • Battery compartment/retainer
  • On/off/disconnect

General

  • There are specific ANSI standards for the general use and maintenance of PITs and the workplaces they operate in.

Operation

All Powered Industrial Trucks (PITs) must be designed and constructed in compliance with the American National Standards Institute (ANSI) standard B56.1-1969. (1910.178(a)(2)) Employers must ensure that only approved trucks are used in areas where flammable gases or vapors, combustible dust, or ignitable fibers are present in the atmosphere. Trucks with internal combustion engines that operate in buildings or enclosed areas must be checked to ensure they do not cause harmful concentrations of dangerous gases or fumes.

Any trucks not in safe operating condition are to be promptly removed from service. (1910.178(q)(1)) Repairs to fuel and ignition systems must be conducted only in areas specifically designated for them. (1910.178(q)(3)) Trucks are to be inspected daily, or after each shift if used around the clock, and before being placed in service. (1910.178(q)(7)) Directional lighting must be provided on each truck that operates in an area with less than two foot-candles per square foot of general lighting. (1910.178(h)(2)) Any trucks used by a company must be correctly designated for that type of operation (based on atmosphere, hazards of materials handled, etc.). (1910.178(c)(2))

Material handling

When assessing how a PIT will handle material, employers and operators must ensure there is sufficient clearance for equipment through aisles and doorways. (1910.176(a)) There must also be clearance signs to warn of clearance limits, and permanent aisles and passageways must be appropriately marked. (1910.176(e), 1910.176(a)) Bags, containers, bundles, etc. need to be stacked, blocked, interlocked, and limited in height so they are stable and secure. (1910.176(b))

Operators must use dock boards (bridge plates) when loading or unloading operations are taking place between vehicles and docks, and trucks and trailers should be secured from movement. (1910.178(m)(7))

Battery charging

Battery charging installations (located in areas designated for that purpose) and the batteries themselves must be charged in a properly vented room. (1910.178(g)(1), 1910.178(g)(2)) The local ventilation must be sufficient to disperse fumes. (1910.178(g)(2)). Facilities must be provided for flushing and neutralizing spilled electrolyte, fire protection, and protecting charging apparatus from damage by trucks. (1910.178(g)(2))

A conveyor, overhead hoist, or equivalent material handling equipment must be provided for handling batteries. (1910.178(g)(4)) Any reinstalled batteries must be properly positioned and secured in the truck. (1910.178(g)(5)) A carboy tilter or siphon must be provided for handling electrolyte. (1910.178(g)(6))

When charging batteries, employees must make certain not to pour water into acid, and that trucks are properly positioned with brakes applied first. (1910.178(g)(7), 1910.178(g)(8)) They must also ensure that the vent caps are functioning. (1910.178(g)(9)) Smoking must be prohibited in battery charging areas, and precautions taken to prevent open flames, sparks, or electric arcs in the charging area, such as keeping tools and other metallic objects away from the top of any uncovered batteries. (1910.178(g)(10)-(12))

Fueling

Fueling an internal combustion engine with a flammable liquid while the engine is running must be prohibited. (1910.178(p)(2)) Employees should ensure fueling operations are done in such a manner that the likelihood of spillage will be minimal. (1910.178(p)(2)) If spillage does occur, employees should take measures to control any vapors before restarting the engine. (1910.178(p)(3))

Aisles and walkways

Aisles must be marked and in good condition, with their widths maintained. (1910.22(b)(1)-(2)) They must also be clean and free of obstructions. (1910.22(b)(1)) Additionally, employees must ensure that fire aisles, access to stairways, and fire equipment are all clear. (1910.178(m)(14)) The aisles and passageways must be properly illuminated.

There should be safe clearance for equipment through all aisles and doorways. (1910.176(a)) Any pits and floor openings should be covered or otherwise guarded. (1910.22(c); .23(a)) Additionally, there must be standard guardrails present where aisle or walkway surfaces are elevated four feet or more above any adjacent floor or the ground. (1910.23(c)) Adequate barriers and warnings should be provided to prevent employees from stepping into the path of traffic where vehicles may be operated.

Housekeeping

Work areas, floors, walkways, and other surfaces should be clean and orderly. (1910.22(a), 1910.141(a)(3)(i)) Employees should check if there are any spilled materials or liquids present and if work surfaces are dry, and mats or grating should be used where drainage is needed. (1910.141(a)(3)(ii) 1910.22(a)(2)) Employees should use compressed air for cleaning under 30 pounds per square inch (psi). (1910.242(b)) Employees should also check for any accumulation of dust and/or other potential contaminants. (1910.141(a)(3))

Personal protective equipment (PPE)

Employees must wear foot protection anywhere there is risk of foot injuries in the workplace. (1910.132(a); .136(a)) They must also wear hard hats anywhere danger of falling objects exists. (1910.135(a)(1)) Companies should also ensure the use of protective goggles or face shields where there is danger of flying particles or corrosive materials. (1910.133(a)(1))

Approved safety glasses must be worn where there is a risk of eye injuries such as punctures, abrasions, contusions, or burns. 1910.133(a)(2) Employees should wear appropriate safety glasses, face shields, etc. while using hand tools or equipment which might produce flying materials or be subject to breakage. (1910.133(a)(1))

Companies must ensure that employees use required protective clothing or equipment as needed, and that it fits properly, is functional and in good repair, and marked with ANSI or ASTM International specifications. (1910.132(a), 1910.132(e), .135(b))

Postings

Required truck operating rules should be posted.

Recordkeeping

Any inspection and maintenance records should be kept on file.

Training

Only trained personnel should be allowed to operate industrial trucks, and the training methods used to train operators must be documented and meet the requirements specified in 1910.178(l).

Documentation

The Occupational Safety and Health Administration (OSHA) requires that forklift vehicles be inspected at least daily, or after each shift when used around the clock.

Removal from service

  • Any safety issues identified during a daily inspection must be fixed before a Powered Industrial Truck (PIT) is operated again.

Once an inspection has been conducted, the Occupational Safety and Health Administration (OSHA) expects employers to fix safety issues before allowing operation. But what constitutes something severe enough to require the equipment be taken out of service?

In OSHA’s standards, there are a few very specific conditions that warrant immediate removal of equipment from service. These include:

  • Hazardous sparks from the exhaust,
  • Excess operating temperatures, and
  • Leaky fuel systems.

In addition, there is also a general provision to remove “unsafe” equipment. OSHA has said they will take a variety of factors into consideration when making the determination as to whether a truck is unsafe. But, at the least, any item that could present harm or risk would need to be taken out of service.

Items that could constitute unsafe conditions include:

  • Improperly functioning gauges,
  • Broken welds,
  • Missing bolts,
  • Damage to the overhead guard, and
  • Tires missing large pieces of rubber.

What are safe operation requirements?

  • OSHA has specific tips and rules to ensure the safe operation of PITs.

Safe procedures

The Occupational Safety and Health Administration’s (OSHA) Powered Industrial Truck (PIT) standard does provide a few “rules of the road” that operators should adhere to. The key to a successful safety program is setting proper rules, training operators on those rules, and then following up consistently when there are deviations.

The basic rule for traveling is that operators maintain control of the PIT at all times. Other rules include:

  • Operators must only operate a forklift while in the seat or operator’s station. The operator should never start it or operate the controls while standing beside the forklift.
  • Operators should never allow passengers unless the PIT was designed for a passenger.
  • Operators should not put any part of their body between the uprights of the mast, or when traveling, outside of the forklift frame.
  • Operators should always look in the direction of travel and keep a clear view of the travel path, and travel in reverse if the load blocks their view.
  • Operators should keep a distance of at least three forklift lengths between themselves and any forklift traveling in front of them.
  • Operators should not pass a forklift traveling in the same direction if it is at a blind spot, intersection, or other dangerous location.
  • Operators should never drive a forklift up to anyone in front of a bench or other fixed object.
  • Operators should never allow anyone to walk or stand under the elevated forks, even if the forks are not carrying a load.
  • Operators should check that there is adequate clearance under beams, lights, sprinklers, and pipes for the forklift and load to pass.
  • Operators should never engage in stunt driving or horseplay.

Load handling

Many incidents can happen during load placement or retrieval. To avoid this, employers should ensure that operators are:

  • Making sure the load is stable before picking it up and securing it as necessary;
  • Checking that the load fits within the capacity of the PIT, factoring in the highest elevation and extension to be used;
  • Placing the forks squarely into the load, with forks spread to keep the load balanced;
  • Driving the forks all the way under the load;
  • Tilting the mast to stabilize the load and lift;
  • Checking the destination or drop off point, refraining from placing heavy loads on light loads, observing stacking heights or limitations if listed on the carton/box, knowing the racking capacities they’ll be using, and checking that racks are in good condition;
  • Using a spotter when needed;
  • Using access control when needed, either cones or spotter; and
  • Placing the load at the destination by squaring up in front of the rack, stack or location, tilting the mast to level, lowering the forks, and backing away.

How do employees operate safely around pedestrians?

  • OSHA has specific requirements for workplace environments where PITs are being operated to ensure pedestrian safety.

The Occupational Safety and Health Administration (OSHA) requires that permanent aisles and passageways be free from obstructions and appropriately marked where mechanical handling equipment is used. OSHA recommends that employers consider separating pedestrians from lift trucks by providing:

  • Pedestrian walkways;
  • Permanent railings or other protective barriers;
  • If pedestrians must use equipment aisles, adequate walking space at least on one side;
  • If barriers cannot be used, pedestrian walkway striping on the floor;
  • Convex mirrors at blind aisle intersections; and/or
  • Traffic control signs and posted speed limits.

Operators and pedestrians should be trained on the plant’s procedures and hazards associated with Powered Industrial Truck (PIT) operation in pedestrian areas.

It is noteworthy that OSHA proposed a nearly $13,000 penalty for a serious violation of Section 5(a)(1) of the Occupational Safety and Health Act when a distribution center allegedly exposed employees to struck-by hazards from PITs and over-the-road trucks in the yard area at night. The agency explains that the company could abate the hazards by providing and requiring the use of high visibility reflective vests for workers who walk or work in the yard area.

What are requirements for parking?

  • Operators must take specific actions before leaving a PIT unattended in a workplace.

A Powered Industrial Truck (PIT) is considered “unattended” when the operator is 25 feet or more away from the vehicle (even if it remains in their view), or whenever the operator leaves the vehicle, and it is not in their view.

When a PIT is left unattended, the:

  • Load engaging means must be fully lowered,
  • Controls neutralized,
  • Power shut off, and
  • Brakes set.

Note: Wheels must be blocked if the truck is parked on an incline.

When the operator of an industrial truck is dismounted and within 25 feet of the truck still in their view, the:

  • Load engaging means must be fully lowered,
  • Controls neutralized, and
  • Brakes set.

Put another way, when the operator is dismounted and within 25 feet of the PIT still in the operator’s view, as long as the operator takes the three actions, the power may be left on.

OSHA was asked to define “in his [or her] view,” wondering if this includes when the operator is not looking at the vehicle for short periods of time. The agency replied in a September 11, 2018, letter of interpretation, “The standard does not define the term ‘in his [or her] view.’ ... [A] vehicle would normally remain in view of an operator during momentary or brief periods of time that an operator may glance away from the vehicle, provided that there are no other obstructions to the view.”

How do PITs operate on ramps/inclines?

  • Operators must follow procedures to ensure safety when operating PITs on ramps and inclines.

Many injuries occur when forklift operators lose control while driving on ramps. For example, an operator was backing a forklift out of a warehouse and came too close to the side of a ramp. The forklift went over the edge of the ramp, tipped over, and crushed the operator.

Operators should be aware of procedures to follow when traveling on ramps and other inclines with a load. These include:

  • When traveling with a load, the load should point up the incline, regardless of direction of travel. This keeps weight on the wheels to allow for steering, and helps secure the load.
  • When traveling without a load, the forks should point downgrade, regardless of direction of travel.

When walking with a pallet jack with or without a load, generally the forks should be pointed downgrade, regardless of direction of travel.

Where are the requirements to enter truck trailers?

  • Special precautions must be taken when entering truck trailers with a PIT.

One of the most dangerous operations involving powered industrial trucks (PITs) is the loading or unloading of trucks, trailers, and railroad cars. Not only may the vehicle being entered be unstable, but the means of going from the warehouse to the vehicle by way of a dockboard can also be dangerous. While entering and leaving truck trailers or railroad cars, operators must be aware of the following:

  • Falling off the edge of a loading dock.
  • Trucks or railroad cars moving during loading and unloading.
  • Slipping or inadequate dockboards.

Brakes/Wheel chocks

  • The Federal Motor Carrier Safety Administration (FMCSA) says their parking brake requirement is sufficient to prevent the trailer from moving during loading/unloading.

OSHA/FMCSA jurisdiction

  • FMCSA has its own set of regulations for CMV brakes that preempt OSHA’s for CMVs in interstate commerce.
  • OSHA's wheel chocking requirements still apply in certain situations, but an enforcement directive offers flexibility.
  • OSHA requires dockboards be strong and secure enough to handle PIT operation.

One of the common uses of forklifts and pallet jacks is to load/unload trucks, trailers, or rail cars. This requires the powered industrial truck (PIT) to enter the transport vehicle over a dockboard (also known as a bridge plate) at loading docks.

OSHA forklift regulations

The Occupational Safety and Health Administration (OSHA) PIT provisions (at 29 CFR 1910.178(k) and (m)(7)) list a number of situations in which special procedures must be followed before starting entry into a truck, trailer, or rail car:

  • The brakes of highway trucks must be set, and either wheel chocks or wheel blocks placed under the rear wheels to prevent the trucks from rolling while they are boarded with PITs.
  • The brakes shall be set and wheel blocks must be in place to prevent movement of uncoupled trailers while loading or unloading.
  • Wheel stops or other recognized positive protection must be provided to prevent railroad cars from moving during loading or unloading operations.
  • Fixed jacks may be necessary to support a semi-trailer and prevent upending during the loading or unloading when the trailer is not coupled to a tractor. (Note that OSHA’s standard does not specify a particular type of jack, nor the number and placement of such jacks, but the agency strongly recommends following both the trailer and the jack manufacturer’s instructions on the appropriate number and placement of these jacks.)
  • Positive protection must be provided to prevent railroad cars from being moved while dockboards or bridge plates are in position.

OSHA enforcement directive

Be aware that OSHA enforcement directive STD 01-11-007, dated August 5, 1981, explains that under the following conditions, failure to use wheel chocks in accordance with 1910.178(k)(1) and (m)(7) will be deemed to be de minimis violations and will not be cited:

  • A positive mechanical means to secure trucks or trailers to a loading dock is allowed provided the system is installed and used in a manner that effectively prevents movement of trucks and trailers during loading, unloading, and boarding by hand trucks and PITs;
  • All of the mechanical equipment is installed, maintained, and used as recommended by the manufacturer; and
  • Any damaged mechanical equipment will be removed from service immediately.

Under the STD, OSHA will regard failure to use wheel chocks or blocks as a de minimis violation and no citation will be issued if alternative methods of preventing truck movement are used. A September 14, 2005, OSHA letter of interpretation explains that these alternatives may include the use of dock lock mechanisms, dock monitoring systems, or other systems which will prevent the unintentional movement of trucks and trailers while being boarded with PITs.

DOT jurisdiction

In addition, there are some jurisdictional issues with the Department of Transportation (DOT) parking-brake requirement, which that agency deems appropriate to prohibit movement of vehicles during all loading conditions. Section 4(b)(1) of the Occupational Safety and Health (OSH) Act bars the application of the OSH Act to working conditions regulated by other federal agencies.

The Federal Motor Carrier Safety Administration's (FMCSA's) braking regulations at 49 CFR 393, Subpart C, preempt OSHA from enforcing 1910.178(k)(1), requiring the chocking of highway trucks while they are being boarded by PITs, and 1910.178(m)(7), requiring the blocking of trucks, trailers, or railroad cars while loading or unloading, against operators of commercial motor vehicles (CMVs).

Therefore, if the trailer is a CMV, as defined in 49 U.S.C. 31132(1), OSHA would not enforce its chocking requirements under 1910.178. The U.S. Code defines a “commercial motor vehicle" as, among other things, a self-propelled or towed vehicle used on the highways in interstate commerce, if the vehicle:

  • Has a gross vehicle weight rating or gross vehicle weight of at least 10,001 pounds, whichever is greater; or
  • Is used in transporting materials found by the DOT to be hazardous as defined by DOT regulations and transported in a quantity requiring placarding under DOT regulations (per 49 U.S.C. 31132).

OSHA jurisdiction

However, if the trailer is not considered a CMV, OSHA would enforce its chocking requirements at 1910.178. Because the FMCSA parking-brake regulations do not apply to vehicles that are not CMVs, OSHA is not pre-empted from enforcing its chocking requirements with respect to those non-CMV vehicles.

Furthermore, because the FMCSA parking-brake regulations do not apply to employers that do not own, operate, or lease CMVs, OSHA has authority to enforce standards requiring such employers to take precautions to protect their employees (like forklift operators) from the movement of trailers.

OSHA state-plan states

Note that the OSHA jurisdictional limits pursuant to section 4(b)(1) of the OSH Act and relevant case law are not directly applicable to the OSHA state-plan states. The 22 state plans covering the private sector are not required to have a provision equivalent to section 4(b)(1) in their state enabling legislation and may have different statutory language regarding overlap of jurisdictional authority with other federal agencies. If a state does not honor the federal jurisdictional limitations, it would be expected to litigate any challenges to its exercise of a broader authority to establish its own body of relevant case law.

More information

For further information, see the following OSHA letters of interpretation:

  • November 8, 2005, “Chocking requirements for trailers docked to buildings with downward approaches.”
  • March 7, 2011, “Clarification of OSHA's authority to enforce wheel chocking of commercial motor vehicles and related safety hazards at loading facilities.”
  • June 14, 2011, “Enforcement of wheel chocking requirements in State Plan States.”

Dockboards

The Occupational Safety and Health Administration (OSHA) Walking-Working Surfaces standards at 29 CFR 1910 Subpart D contain requirements for dockboards. Dockboard means a portable or fixed device that spans a gap or compensates for a difference in elevation between a loading platform and a transport vehicle (e.g., trucks, trailers, semi-trailers, and rail cars). Dockboards include, but are not limited to, bridge plates, dock plates, and dock levelers.

Specifically, the standards require the following under 1910.26:

  • Portable and powered dockboards must be strong enough to carry the maximum intended load — the total load of all workers, equipment, vehicles, tools, materials, and other loads that the employer “reasonably anticipates” to be applied to the dockboard surface at one time.
  • Dockboards put into initial service on or after January 17, 2017, must be designed, constructed, and maintained to prevent transfer vehicles from running off the dockboard edge. (When the employer demonstrates there is no hazard of transfer vehicles running off the dockboard edge, the employer may use dockboards that do not have run-off protection.)
  • Portable dockboards must be secured in position, either by being anchored or equipped with devices which will prevent their slipping. (When the employer demonstrates that securing the dockboard is not feasible, there must be sufficient contact between the dockboard and the surface to prevent the dockboard from moving out of a safe position.)
  • Handholds, or other effective means, must be provided on portable dockboards to permit safe handling.
  • Measures, such as wheel chocks or sand shoes, must be used to prevent the transport vehicle (e.g., a truck, semi-trailer, trailer, or rail car) on which a dockboard is placed, from moving while employees are on the dockboard.

Load capacity

A dockboard evaluation helps employers determine if their dockboards can support the maximum intended load. The maximum intended load (weight and force) includes all workers, equipment, vehicles, tools, materials, and other loads reasonably anticipated at one time. The term maximum intended load refers not only to total loads currently applied to a walking-working surface, such as a dockboard, but also to total loads that the employer has a “reasonable anticipation” will be placed on the walking-working surface.

Employers must decide, based on the maximum intended load, what structural material must be used to construct a dockboard. For example, portable dockboards that only need to support lightweight loads moved by a handtruck could be made from aluminum. On the other hand, steel may be needed to construct a portable dockboard that will have to support the weight of a motorized pallet jack, load, and employee.

The dockboard load requirement applies to all dockboards that employees use, regardless of whether the employer or some other entity owns or provides the dockboard; whether the dockboard is portable, fixed, powered, or manual; or whether the employer uses the dockboard as a bridge to a transport vehicle.

Preventing run-offs

All dockboards put into service on or after January 17, 2017, must comply with the requirements of OSHA’s Walking-Working Surfaces standards. This includes designing, constructing, and maintaining them to prevent transfer vehicles from running off the dockboard edge. Examples of run-off protection may include run-off protection, guards, or curbs.

OSHA believes this provision (for dockboards put into service for the first time on or after January 17, 2017) is necessary to protect employees. A transfer vehicle that runs off the side of a dockboard could kill or injure employees working on or near it. For example, forklifts used to load items onto a transport vehicle could seriously injure or kill the operator and nearby employees if the forklift runs off the side of the dockboard.

However, OSHA offers two exceptions to the run-off protection requirement:

  • The employer can demonstrate there is no hazard of forklifts or other transfer vehicles running off the dockboard edge. OSHA explains that run-off protection is not necessary when there is insufficient space for equipment to run off the side of the dockboard. Therefore, employers should evaluate whether a particular opening poses a hazard, including considering factors such as the type and size of transfer vehicle the employee is using.
  • The dockboard was in service before January 17, 2017. Employers do not have to replace or retrofit dockboards if the were in use back then.

Securing the dockboard

OSHA also requires employers to secure portable dockboards by anchoring them in place or using equipment or devices to prevent the dockboard from moving out of a safe position. If the employer does not securely anchor the dockboard or equip it with a device that prevents movement, it could slide or drop off of the loading platform or transport vehicle, and the employee could fall. Employees also could fall if the dockboard moves or slides while they are on it. In addition, failure to secure a dockboard could expose employees to crush or caught-in hazards if the dockboard moves, and pins or strikes the employee, or causes the load the employee is moving to shift or fall against the employee.

The regulation specifies that, when the employer can demonstrate that it is not feasible to secure the dockboard, the employer must ensure that there is sufficient contact between the dockboard and the surface to prevent it from moving out of a safe position. What constitutes an adequate overlap may involve a number of factors that employers need to determine on a case-by-case basis.

Handholds or other handling means

Employers must equip portable dockboards with handholds or other means that permit employees to safely handle the dockboard. Handholds and other means of gripping enable employees to move and place dockboards without injuring themselves or others. If employees cannot handle or grip a dockboard safely, they could drop it on their feet, crush their fingers while putting the dockboard into place, or fall. Handholds also make it possible to place dockboards into the proper position (e.g., with adequate overlap in a secure position), so the dockboards will be safe for employees to use.

When portable dockboards will be moved mechanically, OSHA suggests the use of effective means, such as forklift loops or lugs.

Wheel chocks or sand shoes

If a transport vehicle moves when an employee is on a dockboard, the sudden movement may cause the employee to fall off the dockboard, or the dockboard may be displaced and fall to the ground along with the employee. Therefore, the OSHA regulation at 1910.26(d) requires measures, such as wheel chocks or sand shoes, to be used to prevent the transport vehicle (e.g., a truck, semi-trailer, trailer, or rail car) from moving while dockboards are in place and employees are using them.

The regulation gives employers flexibility in selecting measures to prevent the transport vehicle from moving. The catch is that employers must ensure whatever measures they use are effective in preventing movement, regardless of the type of transport vehicle the employer is loading/unloading. For example, for wheel chocks, which are one of the most frequently used measures to prevent transport vehicles from moving, the size of the transport vehicle wheel determines the size of the wheel chock that will be effective to prevent the vehicle from moving.

At the same time, there are some jurisdictional issues with the Department of Transportation (DOT) parking-brake requirement, which that agency deems appropriate to prohibit movement of vehicles during all loading conditions. Specifically, DOT regulates interstate transportation of “commercial motor vehicles” (CMVs) traveling on public roads; thus, pursuant to section 4(b)(1) of the Occupational Safety and Health (OSH) Act, OSHA is preempted in that situation.

However, DOT regulations do not apply to transport vehicles that do not meet the definition of CMV, do not operate in interstate transportation, or are not used on public roads. OSHA continues to have authority over:

  • Transport vehicles that do not meet the definition of CMV; and
  • CMVs not operated in interstate commerce, which includes CMVs that transport materials on private roads or within a work establishment.

In fact, OSHA has the authority to enforce chocking requirements in these situations that are not covered by DOT’s Federal Motor Carrier Safety Administration (FMCSA). OSHA believes paragraph 1910.26(d) is necessary because not all transport vehicles are CMVs or used on public roads. For example, employers use transport vehicles to move material and equipment within their facilities. In addition, most transport vehicles are loaded and unloaded off public roads.

Furthermore, because the FMCSA parking-brake regulations do not apply to employers that do not own, operate, or lease CMVs, OSHA is not pre-empted from enforcing standards requiring such employers to take precautions to protect their employees, such as forklift operators, from the movement of trailers.

Note that the OSHA jurisdictional limits pursuant to section 4(b)(1) of the OSH Act and relevant case law are not directly applicable to the OSHA state-plan states. The 22 state plans covering the private sector are not required to have a provision equivalent to section 4(b)(1) in their state enabling legislation and may have different statutory language regarding overlap of jurisdictional authority with other federal agencies. If a state does not honor the federal jurisdictional limitations, it would be expected to litigate any challenges to its exercise of a broader authority to establish its own body of relevant case law.

For further information, see the OSHA letters of interpretation on chocking dated November 8, 2005, March 7, 2011, and June 14, 2011.

What are requirements for fueling?

  • When it comes to batteries and fueling, OSHA has specific safety requirements for PIT operators.

Battery charging

The Occupational Safety and Health Administration (OSHA) requires employers to charge batteries only in a properly equipped location. A properly equipped battery charging area will have:

  • No smoking.
  • Warning signs posted.
  • Adequate fire protection.
  • Ample and readily available water supply for flushing and neutralizing spilled electrolyte.
  • An eyewash able to provide a 15-minute flow, and for large installations, a drench shower and an eyewash.
    Note: OSHA has said that where batteries are simply being plugged in for charging — there is no maintenance performed, no removal of batteries from the trucks, and no electrolyte is present in the area — there usually isn’t a need for an eyewash/shower.
  • A phone or other means of communication in the event of an emergency.
  • Adequate ventilation to avoid the buildup of hydrogen gas during battery charging.
  • Soda ash or other neutralization materials in the immediate area.
  • A dry chemical, CO2, or foam fire extinguisher.
  • Means to protect charging apparatus from damage from trucks.

Only trained personnel should charge and change batteries in electric forklifts. In addition to training in battery changing and charging procedures, these employees should be trained on emergency procedures in the event of an acid splash, including how to use eyewash and shower facilities.

OSHA directive STD 01-11-004 offers further clarification. It says that “battery charging” areas where power industrial truck batteries are charged only — meaning no maintenance is performed, batteries are not removed from the trucks, and no electrolyte is present in the area — are not subject to the requirement of paragraph (g)(2) of 1910.178. However, the charging areas shall be in compliance with paragraphs (g)(1) and (g)(8) to (g)(12) of the regulation, and personal protective equipment (PPE) shall be used when and where required.

Best practices and requirements

In addition to having a properly equipped charging area, it is important employees follow safety procedures when charging batteries. OSHA has requirements covering some portions of the charging operation. Trained personnel should:

  • Follow the recharger manufacturer’s recommendations for attaching and removing cables and for proper operation of the equipment.
  • Properly position trucks and apply brakes before attempting to change or charge batteries.
  • Use a lifting beam or equivalent material handling equipment when lifting the battery. Employees should not use a chain with two hooks. This may cause distortion and internal damage.
  • Charge batteries in the designated battery charging area.
  • Pour acid into water when charging batteries. Employees should never pour water into acid.
  • Take care to assure that vent caps are functioning. The employee must ensure the battery (or compartment) cover(s) are open to dissipate heat.
  • Prohibit smoking in the charging area.
  • Take precautions to prevent open flames, sparks, or electric arcs in battery charging areas.
  • Remove all metallic jewelry before recharging. Employees should keep tools and other metallic objects away from the top of uncovered batteries.
  • Wear PPE (e.g., face shield, safety goggles, neoprene or rubber gloves and apron).
  • Check the electrolyte level before recharging. Employees should record the specific gravity with the hydrometer in the service log and check the pilot cell.
  • Check the water level. Employees should not add water prior to recharging. This should be recorded in the service log.
  • Check the voltage. If the battery has sealed vents, employees should not recharge with a current greater than 25 amperes.
  • Unplug and turn off the charger before connecting or disconnecting the clamp connections.
  • Attach the positive clamp (+, usually colored red) to the positive terminal first and then the negative clamp (-, usually colored black) to the negative terminal, keeping the proper polarity.
  • Turn off the charger if the battery becomes hot or the electrolyte fluid comes out of the vents. Employees should restart charging at a lower charging rate.
  • Check water level after charging. Employees should add distilled water or de-ionized water if water level is below level indicator and record in service log.
  • Return battery to forklift with lifting beam and secure in place after charging.
  • Check the indicator on the hour meter to see that the battery is fully charged.

LPG cylinders

  • Industry best practices for handling cylinders on LPG-powered forklifts ensure employee safety.

Liquefied petroleum gas (LPG) is a commonly used fuel for powered industrial trucks (PITs). It is a safe fuel when handled properly. However, when handled improperly, it can cause serious injury or death. In fact, LPG vapor is heavier than air and will seek the lowest lying area. If not adequately dissipated, it will collect in pockets and possibly ignite when exposed to a heat source.

What’s more, LPG is extremely flammable, and it is extremely cold when exposed to the atmosphere. If skin is exposed to LPG, it can get frostbite. To combat these hazards, employers should adhere to the following:

  • Not refuel LPG-powered trucks in confined areas where LPG vapors could collect if a leak occurs.
  • Not leave LPG-powered trucks near heat sources, stairways, exits, or other egress areas.
  • Turn the service valve off when parking LPG-powered trucks for a long period of time.
  • Only allow trained and authorized personnel to replace LPG containers.
  • Follow proper procedures for storing and handling LPG, under 29 CFR 1910.110.

While the Occupational Safety and Health Administration (OSHA) Powered Industrial Truck (PIT) standard does not specifically address changing cylinders on liquid petroleum gas (LPG)-powered forklifts, industry best practices include:

  • Wearing protective gloves to avoid freeze burn from contact with LPG.
  • Before starting, employees should close the fuel line valve on the cylinder, then run the engine until it stops to empty the connection hose.
  • Employees should shut off the ignition, disconnect the hose and the holding straps, and remove the empty cylinder.
  • Employees should never use metal tools to change a cylinder. One small spark could ignite a fire or explosion.
  • Employees should replace the empty cylinder with a full one in the proper position.
  • The locating pin should engage the hole in the cylinder handle, so the relief valve is straight up in the 12 o’clock position.
  • Employees should connect the holding straps, tighten the connecting nut, and check the hose to make sure it’s tight.
  • Employees should slowly open the valve on the cylinder part way and check for leaks: employees should smell, listen, and look for leaks. A solution of soap and water to test the seal can be used to check the seal. Matches or a flame should never be used.
  • If the valve leaks, the employee must:
    • Tighten the nut and continue.
    • If it still leaks, change the cylinder.
    • If it still leaks after that, have the hose changed or repaired.
  • Once there are no leaks, the employee can slowly open the valve all the way, secure the cylinder, and start the engine.

What requirements apply to modifications/attachments?

  • Any PIT modifications or attachments must be approved by the manufacturer and comply with OSHA requirements.

When it comes to making modifications to forklifts or other Powered Industrial Trucks (PITs), the Occupational Safety and Health Administration (OSHA) is stringent. OSHA requires that employers obtain the manufacturer’s prior written approval for modifications or additions that “affect capacity and safe operation.” OSHA has interpreted this provision broadly to include most lifting attachments, as well as manbaskets.

When these changes are allowed, capacity, operation, and maintenance instruction plates, tags, or decals must be changed accordingly.

Front-end attachments

If the truck is equipped with front-end attachments other than factory installed attachments, employers must request the truck be marked to identify the attachments and show the approximate weight of the truck and attachment combination at maximum elevation with load laterally centered.

Other provisions

OSHA also has a couple of other “hidden” provisions that pertain to altering PITs. (“Hidden” in that they are in a separate section of the regulation than the modification/attachment section.)

OSHA requires that all parts be replaced only by parts equivalent as to safety with those used in the original design.

OSHA also requires that PITs are not altered so that the “relative positions” of the parts are different from what they were when originally received from the manufacturer. They must not be altered either by the addition of extra parts not provided by the manufacturer or by the elimination of any parts.

When in doubt, ask

When an employer or employee has questions about adding or replacing parts, it’s best to check with the equipment manufacturer or OSHA local area office, to be on the safe side. There are many variables that can come into play, and that may not be obvious at first glance. For example, the addition of an after-market hours meter may seem (and may well be) perfectly harmless, but if the truck has been rated to operate in certain explosive/hazardous locations, the installation could potentially negate that rating if the meter isn’t up to the same standards.

What requirements apply to safety devices, lights?

  • Employers must ensure the use of safety devices such as seat belts and horns on PITs.

Powered Industrial Trucks (PITs) can incorporate many warning and safety devices to help protect operators, pedestrians, and other PIT operators. Some are required, some recommended, and some required only in certain instances.

The Occupational Safety and Health Administration (OSHA) specifically requires an operator-controlled horn for PITs.

OSHA also requires directional lighting when general lighting is less than two lumens per square foot. For example, the general lighting in an inspected warehouse where PITs were used was less than 1 lumen per square foot, and the trucks did not have directional lighting. OSHA cited the company for a willful violation, which brought a $62,537 penalty.

As far as other beepers/lights (such as backup warnings and strobe lights), there is no specific requirement, but OSHA has said that if these warnings are needed based on the specific operating conditions, then the Agency could cite employers under the General Duty Clause of the Occupational Safety and Health Act.

What about seat belts?

OSHA’s current enforcement policy is that employers must require operators of equipment that are equipped with operator restraint devices, including seat belts, to use the devices.

In addition, OSHA may also cite employers who do not take advantage of a manufacturer operator restraint system or seat belt retrofit program. Two enforcement cases illustrate this approach:

  • Case 1 — An OSHA inspector witnessed an employee operating a forklift without wearing the required seat belt that was provided. The employee was moving product around the refrigerated warehouse. The inspector cited the warehouse under the General Duty Clause (Section 5(a)(1) of the OSH Act). The citation explained that the employer did not ensure that employees operating PITs use seat belts, exposing employees to the hazard of falling out of and being struck by the PIT. The citation suggested that one feasible and acceptable abatement method to correct this hazard is to require all operators to read and follow the manufacturer’s operator manual and abide by the safety rules and practices, in accordance with ANSI B56.1, Safety Standard for Low Lift and High Lift Trucks.
  • Case 2 — In another case, a forklift collided with a concrete column, and the operator died after being thrown from the forklift. California OSHA says the worker was not wearing a seat belt. However, the agency also discovered that two safety devices were disabled. Proposed penalties climbed up over $205,000. The citations included four serious violations for the employer’s alleged: failure to ensure that forklift operators use seat belts; failure to properly maintain and inspect forklifts; failure to ensure operators were effectively trained; and improper alterations of forklift safety features. The company was also issued a citation for a willful violation for allegedly failing to ensure workers perform a forklift safety check at the beginning of each shift and report unsafe conditions, a violation the company was also cited for in a previous year.

Specialized equipment

  • OSHA’s PIT standard includes powered pallet jacks, requiring proper operator training and daily inspections.

Powered pallet jacks

Powered pallet jacks are a type of Powered Industrial Truck (PIT) used to move pallets. Pallet jacks are battery powered and are one of two designs: either walk-behind or ride-on. There are different types of pallet jacks as well, such as low lift or high lift. The controls for different designs may vary.

OSHA requires employers to:

  • Evaluate the workplace for motorized pallet jacks. OSHA’s PIT standard covers all types of powered pallet jacks and similar equipment. The key is “powered”; manually operated lifts are not covered.
  • Train all operators. All PIT operators must undergo a rigorous training that includes a combination of:
    • Formal instruction, such as:
      • lecture,
      • discussion,
      • interactive computer learning,
      • video, and
      • written material.
    • Practical training, including:
      • demonstrations performed by the trainer, and
      • practical exercises performed by the trainee.
    • Evaluation of the operator’s performance in the workplace.
  • Re-evaluate operators at least once every three years and document this evaluation.
  • Provide refresher training when operators are observed driving unsafely, involved in an incident or near miss, or are assigned a different type of equipment.
  • Allow only qualified persons to train operators. Persons wishing to train forklift operators must have the “knowledge, training, and experience” to train operators and evaluate their competence. The OSHA standard does not further define this requirement or set any specific certifications.
  • Ensure equipment is inspected at least daily. Where pallet jacks are used on a round-the-clock basis, they must be examined after each shift. OSHA does not require these inspections be documented; however, many companies keep a set number of inspections (e.g., “the most recent 2-month period”) as a way to prove to OSHA the inspections are being conducted.
  • Remove unsafe equipment from service immediately.
  • Only allow employees to operate correctly classified equipment in hazardous atmospheres to prevent explosion hazards.
  • Set and enforce operating rules. Employers should refer to the manufacturer’s safety instructions for procedures such as operating on ramps, function of controls, maintenance, etc.
  • Provide designated areas for battery charging/changing operations. This includes provisions for adequate ventilation, protection of the charging equipment, spill cleanup, and an eyewash/shower if workers could be exposed to the batteries’ dangerous substances (e.g., they open the caps).

Order pickers

  • Order pickers should only be used with the proper safety equipment.

Unlike forklifts, order pickers are designed to lift the operator to retrieve items. However, there are potential hazards from falling. The Occupational Safety and Health Administration (OSHA) requires that operators wear appropriate fall protection equipment that is properly fitted and adjusted unless guardrails are in place. OSHA strongly encourages the use of body harnesses, rather than belts, on elevated platforms of Powered Industrial Trucks (PITs).

A body belt is allowed to be used as part of a travel restraint system; however, it must eliminate the possibility of an employee going over the edge of a walking-working surface. A travel restraint system rigged to allow free fall even a small distance would not be an acceptable system under OSHA’s Subpart D Walking-Working Surfaces requirements. This is typically problematic with order pickers because of the size of a platform and the type of lanyard used.

A self-retracting lanyard does not eliminate the possibility of an employee going over the edge; therefore, it cannot be used as part of a travel restraint system. Self-retracting lanyards can only be used as part of a personal fall arrest system.

If a “static” lanyard and a body belt are used, the “static” lanyard must be short enough to prevent the employee from stepping off the edge. This means an employer would have to have multiple lanyard lengths to match the heights of all employees using them. Employers would also need to ensure the correct length is used by the correct employee.

Rough terrain forklifts

  • Rough terrain forklifts pose several unique challenges because they must operate on uneven surfaces.

Rough terrain forklifts are designed to operate on uneven and sometimes dirty surfaces. To do this, they are designed with larger tires. They also typically carry heavier loads, such as on construction sites, so their capacities are often higher.

Operators of these forklifts should be trained and evaluated with the environment to be operated in mind. They must understand the unique circumstances, including general hazards that may be on a construction site (e.g., falling objects, unexpected debris).

Personnel platforms/Manbaskets

  • When workers use a regular forklift to lift personnel, special safety precautions must be used.

There are many occasions when employees need to work at heights. Ideally, equipment designed for that specific purpose would be used (e.g., ladder or aerial lift), but there are times when it may be necessary to utilize a forklift to elevate personnel. There are only a few ways this can be done safely.

First, operators must never be allowed to lift workers who are standing on the forks, pallet, or load. Serious injury or fatality can occur, and the Occupational Safety and Health Administration (OSHA) prohibits this practice.

Instead, workers must turn to either manbaskets, order pickers, or similar solutions.

Manbaskets

When it comes to elevating personnel on a platform attached to a forklift, OSHA regulations do not specifically address the issue. However, OSHA does address forklift modifications/additions in general (which includes personnel platforms) by requiring that employers obtain the manufacturer’s prior written approval before making any modifications or additions that affect capacity and safe operation.

OSHA bulletin SHIB 06-03-2021, “Hazards of Using Job-Made Boxes/Baskets/Platforms,” alerts employers and employees about the sometimes-fatal fall, crush, and struck-by hazards associated with job-made boxes. Job-made boxes, baskets, and platforms are makeshift attachments for powered industrial trucks, such as forklifts. Since these makeshift aids for assisting with working at heights are not manufacturer-approved or stability/load tested, they are not permitted under 29 CFR 1910.178.

When either the manufacturer or a professional engineer has determined it is safe to lift personnel using a specifically designed platform, OSHA requires proper fall protection be provided, either built into the platform itself in the form of railing, or using personal fall arrest systems (e.g., lanyards, harnesses). For example, an employee was operating a platform when he fell approximately 16 feet to the floor, suffering a concussion. The employee was not tied off to the lift at the time of the incident.

In addition, the platform should be secured to the forks, and personnel protected from moving parts of the forklift.

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