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Fork truck safety emphasized through rigorous training and routine inspections

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Fork truck safety emphasized through rigorous training and routine inspections
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Rebecca Kanable Assistant Editor | AviationPros

Ground handling operations at airports globally, particularly in cargo handling, rely heavily on powered industrial trucks (PITs), such as forklifts and fork trucks, for the movement of cargo, equipment, and materials. However, these vehicles are associated with numerous workplace incidents annually. The Occupational Safety and Health Administration (OSHA) reports that fatalities often result from truck overturns, workers being struck by trucks, or falling from them.

"Incidents can involve property damage," states Steven K. Fess, a Certified Industrial Hygienist. These damages include overhead sprinklers, racking systems, walls, floors, and other machinery. A significant number of these incidents stem from inadequate training and lack of safe operating procedures.

OSHA's Powered Industrial Trucks standard mandates safety requirements for various industrial trucks powered by electric motors or internal combustion engines. Revised in 1999 to reduce injuries and deaths due to insufficient operator training, the standards apply across multiple industries except agriculture.

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Training programs must be tailored based on the operator's prior knowledge and skill level and should include refresher courses if an accident occurs or unsafe operation is observed. Evaluations are required initially and at least once every three years.

Fess emphasizes the need for comprehensive PIT safety programs that include documented training protocols: "At minimum... ensure that workers do not operate a fork truck unless they have been trained." Training covers all aspects of vehicle operation including stability factors like driving behavior and load weight distribution.

Operator restraint systems are critical; since 1992 manufacturers have equipped new sit-down type fork trucks with these systems. Many older models can be retrofitted with restraint systems to prevent fatalities during tip-overs.

Douglas E. Roemer highlights the importance of practical experience alongside theoretical training: "All the training in the world is not a replacement for hands-on/practical experience."

Routine inspections and maintenance are essential for safe operation. Fork trucks should be inspected daily for defects such as tire wear or fluid levels.

When lifting personnel rather than materials, only approved lifting cages should be used according to manufacturer guidelines to ensure safety.

Separating pedestrian traffic from fork truck lanes wherever possible can reduce accidents. Installing physical barriers and using warning devices like horns or flashing lights also enhances safety around high-traffic areas.

Regular workplace inspections can identify potential hazards such as obstructions in aisles or blind corners which could pose risks to both workers on foot and equipment operators.

Fess concludes that workplace safety should be ingrained in company culture: "Safety is not a choice; it’s part of everyone’s job – and it starts with you."

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