by Roger Andrews

Each year more than 60,000 forklift accidents occur in the United States, causing almost 35,000 serious injuries and approximately 85 deaths. OSHA has documented that about 20 percent of these accidents involve pedestrians either being struck by forklifts or struck by objects that are dropped/knocked over by forklifts. With proper awareness and pedestrian safety training, the rate of accidents can be significantly reduced.

OSHA requires formal forklift training for an operator; however, it does not specifically address pedestrian training for those employees who work around forklifts. The OSHA General Duty Clause requires that an employer “furnish to each of his employees’ employment and a place of employment which are free from recognized hazards that are causing or likely to cause death or serious physical harm to his employees.” This includes ensuring that workers who are exposed to forklifts in operation receive the instruction necessary to preserve their safety on the job.

Very often management does not realize the significance of training pedestrians exposed to any kind of lifting operation. The chances of an accident involving a forklift and pedestrian increase when the pedestrian is ignorant of basic safety precautions around forklifts.

COMMON FORKLIFT/PEDESTRIAN ACCIDENT SITUATIONS

1. 1. 1. Pedestrian comes too close to forklift: There is no way a collision involving a pedestrian can take place if the pedestrian does not come within close proximity of a forklift. Maintaining at least a four-foot safety zone is highly recommended when the forklift is running (the actual safety zone can be much more than four feet). This precaution can lessen the risk of the forklift hitting the pedestrian. Employers must make pedestrians aware that the back end of forklifts can swing very quickly to the side. In addition, oversized length or width loads may require a much larger safety zone.
      2. Pedestrian did not notice the forklift in operation: In many cases, pedestrians do not see the forklift in operation at blind corners and intersections. Pedestrians must be taught to be aware when approaching these areas. Electric forklifts can be very quiet, and pedestrians may not hear them approaching. Additionally, pedestrians may not hear internal combustion forklifts because of the ambient noise in the facility.

WAYS TO INCREASE PEDESTRIAN SAFETY IN FORKLIFT OPERATIONS

1. 1. 1. Training awareness for pedestrians: Proper pedestrian awareness training does not take much time or effort. Pedestrians need to be aware that forklifts can suddenly appear around blind corners. Training can work as a reminder to the pedestrians to stop, listen and look carefully when working or walking around blind corners. Pedestrians must always expect the sudden appearance of a forklift. Painting warnings in pedestrian walkways provides a reminder to be aware of the presence of forklifts. Before crossing a forklift’s path, the pedestrian must maintain eye contact with the forklift operator. When eye contact is not possible or difficult, like when crossing the path behind the forklift, giving the driver a verbal alert is mandatory. Alertness and communication are crucial. A pedestrian should never ride on a forklift—either on the side or on the forks. If a forklift is stopped and raising or lowering a load, the pedestrian should keep well away from the forklift and never, ever, walk under a load.

1. 1. 2. Traffic management: Safety professionals recommend the creation of separate pedestrian routes made easily noticeable through painted lines and signage. Having physical barriers to keep forklifts from entering pedestrian-only routes can be a very effective solution. If having physical barriers is difficult or not possible, avoiding forklift use in areas with high levels of pedestrian activity can be a good solution. Having and maintaining safety rules for both pedestrians and forklifts is very important.

1. 1. 3. Safety equipment: Best Management Practices dictate those pedestrians should wear a highly visible vest or shirt for improving visibility. Ensure that the forklift operators use horns frequently. Adding warning lights and travel alarms are good measures as well. The use of convex mirrors at intersections can improve pedestrian safety by providing the pedestrians with better chances of seeing the forklifts in operation.

1. 1. 4. Proper safety practices for forklift operators: It is the operator’s responsibility to ensure the safety of pedestrians. Here are some simple suggestions to keep pedestrians safe:
         1. Stop and sound the horn at intersections and corners.
         2. When traveling in reverse, use flashing lights or backup alarms.
         3. Use a spotter for blind spots.
         4. Look in the direction of travel, even when backing up. Never trust only your mirrors.
         5. Keep a clear view.
         6. Signal to pedestrians to stand clear.
         7. Don’t allow anyone to stand or pass under the load or lifting mechanism.
         8. Make eye contact with pedestrians and other forklift operators.
         9. Never carry people on the forks.
         10. In areas with lots of clutter, walk the route first to spot potential problem areas.
         11. Stop and wait for pedestrians, then proceed cautiously through congested areas.

The most important thing is for the forklift operator to maintain good situational awareness. Keep your head on a swivel while operating the forklift.

While the training of forklift operators is mandatory, employers are also required to protect the safety of pedestrians who travel in and around forklifts. You should also consider the safety of pedestrians who are not around forklifts often, such as sales, clerical staff or visitors.

Further Information

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Roger Andrews is the Director of Training Services for Cornerstone Environmental, Health and Safety. He regularly consults with clients in all areas of OSHA, EPA Hazardous Waste Training, Storm Water Training, Spill Prevention Control and Countermeasures Training and DOT Transportation of Hazardous Materials Training.