Forklifts are essential handling equipment in modern logistics and warehousing. Their operational safety is directly related to the safety of operators and the productivity of businesses. Below, we will explore in detail the safety guidelines for preventing tipovers and crush injuries during forklift operation.
Forklift tipovers and crush injuries are common, typically caused by a combination of violations or environmental factors. For example:
1.1 Improper Operation
Speeding, sudden braking, or sharp turns can easily cause the vehicle to tip sideways or forward or backward.
1.2 Loading Issues
Loading cargo exceeding the rated load, or unevenly distributed cargo or unstable suspension can shift the center of gravity and reduce vehicle stability.
1.3 Road Factors
Driving over the edge of a loading platform, on a slope, on soft or uneven surfaces, or with tires running over obstacles such as wood or rocks can all cause a forklift to become unstable and tip over.
1.4 Blind Spots
Cargo obstructing vision, or not paying attention to surrounding personnel when reversing or turning, can easily lead to crushing accidents.
1.5 Illegal Operations
Failure to wear a seat belt or leaving the driver's seat while operating, as well as unauthorized others riding the forks or standing on the forklift to direct operations, can all lead to accidental crushing injuries. These factors can all contribute to forklift tipping or crushing accidents.
In recent years, numerous forklift operating accidents have warned us that forklift tipping and crushing injuries can cause serious casualties.
For example, on June 29, 2016, a 25-year-old man was driving a forklift when it overturned at an intersection, crushing the driver to death under the collapsed forklift frame.
On March 4, 2018, a forklift operated by a Shanghai logistics company fell while unloading cargo on a platform. The driver's left leg was crushed and broken after he jumped out of the vehicle, and he later died from complications.
On February 28, 2020, a forklift overturned in Hebei, crushing the driver to death.
These tragic cases demonstrate that in the event of a forklift rollover, it is absolutely essential not to jump out. Instead, stay seated in the cab, lean forward, and hold onto the steering wheel. Wearing a seat belt significantly increases survival rates.
Strictly Regulated Operations: Forklift drivers must be certified and strictly adhere to national standards and company operating procedures, including the "Safety Specifications for the Use, Operation, and Maintenance of Industrial Trucks" (GB/T 36507-2023). Always drive slowly and steadily. Slow down when turning and going uphill or downhill. Reduce speed early when braking, and avoid sudden braking, swerving, or other dangerous maneuvers. Wear your seatbelt at all times while driving and lifting, treating it as a lifeline.
Load cargo appropriately: When loading, keep the forks within sight, keep the center of gravity as close to the center of the vehicle as possible, and avoid hanging or tilting long loads. Operate within the rated load capacity. Overloading or exceeding the reach can easily cause a tipping over. The loading and unloading area should be kept level and clearly marked to prevent approaching the edge of the platform or sand pits.
Strengthen vehicle inspection and maintenance: Daily check the function of key forklift components such as brakes, steering, hydraulics, and lighting; ensure the integrity of the frame, rearview mirrors, tires, and mast safety brackets; and promptly repair worn or damaged components. Focus on inspecting safety features such as seatbelts and alarms to ensure they are in effective condition.
Create a safe environment: Physical barriers or signs should be established between workshops and pedestrian walkways to prevent forklifts and pedestrians from crossing paths. When placing goods, avoid exceeding road height limits and occupying sidewalks. Install protective equipment and safety warnings in high-risk areas such as cargo platforms and slopes. Conduct regular road inspections to promptly remove obstacles and repair potholes.
Safety and technical protection: When purchasing a forklift, pay attention to the vehicle's stability design and safety features. Choosing forklifts equipped with intelligent systems such as front and rear cameras, speed alarms, and seatbelt reminders can improve operational safety. The use of safety technology such as vehicle rollover valves and electronic traction stabilizers is encouraged to prevent accidents.
4.1 Personnel Management
Certificate-based personnel are required. Untrained personnel are strictly prohibited from operating forklifts. Operators must maintain full focus during operation and avoid distractions such as using mobile phones or smoking. It is strictly prohibited to operate with passengers on board.
4.2 Work Environment Management
Maintain a clean and tidy work area, avoiding clutter or cramped spaces. Ensure adequate lighting, a dry and flat floor, and clearly display safety signs. Designate dedicated forklift lanes.
4.3 Cargo Handling Standards
Using a single forklift or lifting cargo by the fork tips is prohibited. When handling large loads, operate in reverse to ensure a clear view. When stacking, level the forks, advance slowly, and gently lift the mast.
4.4 Equipment Maintenance
Regularly inspect key components such as brakes, steering systems, and lift mechanisms, and promptly repair any faults. Operation with faulty equipment is prohibited. Maintain proper function of safety devices such as speed limiters and reverse alarms.
4.5 Management System and Regulatory Requirements
According to the "Special Equipment Safety Law of the People's Republic of China," forklifts, as specialized motor vehicles used within a factory, fall under the category of special equipment. Users must establish and implement a safety management system: appoint dedicated safety management personnel and inspection and maintenance personnel, provide pre-job safety education and skills training to forklift drivers, and ensure that they obtain a "Special Equipment Operator Certificate" before taking up their duties. Units should establish comprehensive maintenance and repair records and regular inspection plans, conduct timely self-inspections and undergo required safety inspections. The use of uninspected or unqualified equipment is strictly prohibited. Job responsibility systems, hazard detection and emergency response plans should be established, and regular emergency drills should be conducted to ensure timely and effective response to accidents.
Smooth Operation: Starting, steering, and braking should be smooth, avoiding sudden movements.
Visibility Priority: Maintain a good field of vision and reverse when necessary.
Anti-Danger Principle: Observe the work environment in advance to anticipate potential hazards.
Communication and Confirmation: Sound the horn to confirm safety at intersections or in areas with obstructed visibility.
Proper Parking: Always apply the parking brake and remove the key when exiting the forklift.
By following the above operating procedures and safety guidelines, forklift operators can significantly reduce the risk of tipping and crushing accidents, ensuring safe operation. Safe operation is not only a personal responsibility, but also a responsibility to colleagues and the company.
Companies should prioritize forklift safety investment and management, ensuring equipment compliance, standardized operation, and adequate training. Through comprehensive measures such as equipment selection, technology upgrades, training system development, and daily inspections, we can proactively prevent accidents, continuously improve safety management, and effectively protect personnel safety and stable production operations.
If you have any questions about the operation of forklifts, or want to buy a customized forklift, please contact us. We undertake customized forklift services.
