Forklifts Injuring
Transcript of Forklifts Injuring
-
7/30/2019 Forklifts Injuring
1/14
Preventing forkli
people during lounloading of truc
A guide to effective pr
VWA5
32/02/04
.02
WorkSafe Victoria is a division of the Vic torian WorkCover Authority
-
7/30/2019 Forklifts Injuring
2/14
Contents
Introduction 1
Legal obligations 1
How to use this guide 1
Key elements of effective forklift traffic management systems
Comparative chart of tasks and issues 2
Key elements of effective forklift traffic management systems
Dos and Donts 9
1. Example of an effective forklift traffic management system for loading
and unloading vehicles 10
2. Example of an implemented effective forklift traffic management system
for loading and unloading vehicles 11
Some other important facts to consider 12
WorkSafe Victoria Offices 13
WorkSafe Victoria O
WorkSafe Victoria offers a complete
range of health and safety services:
Emergency response
Advice, information and education
Inspections
Licencing and certification
Publications
Head Office
Victorian WorkCover Authority
Level 24, 222 Exhibition Street
Melbourne Victoria 3000
GPO Box 4306
Melbourne Victoria 3001
Telephone 9641 1555
Fax 9641 1222
Toll-free 1800 136 089
Local offices
Ballarat 5337 1400
Bendigo 5443 8866
Dandenong 8792 9000
Geelong 5226 1200
Melbourne 9628 8115
Mildura 5021 4001
Mulgrave 9565 9444
Preston 9485 4555
Shepparton 5831 8260
Traralgon 5174 8900
Wangaratta 5721 8588
Warrnambool 5562 5600
-
7/30/2019 Forklifts Injuring
3/14
Introduction
In Victoria, a worker dies on average every week and over half of the forklift related fatalities
have been caused by people being hit by a moving forklift. This impact is felt by everyonearound them. Families, loved ones, work colleagues, employers and mates. The reality is that
almost every one of these deaths could have been prevented if proper forklift operating safety
procedures like those outlined in this guide were implemented and followed.
No one should die at work.
The purpose of this guide is to help employers implement safe and effective forklift traffic
management systems, and in doing so to comply with the relevant aspects of the Victorian
Occupational Health and Safety Act 1985 and the Occupational Health and Safety (Plant)
Regulations 1995.
This booklet helps to identify some of the potential risks and provides solutions and tips to help
reduce injuries and fatalities resulting from unsafe forklift operations during the loading and
unloading of heavy goods vehicles.
Legal obligations
The employers main duty under the Victorian Occupational Health and Safety Act 1985 (OHS
Act) is contained in Section 21(1). This section provides that employers (including contractors)
are required to:
provide and maintain so far as is practicable for employees a working environment that
is safe and without risks to health
Employers and employees responsible for the safe use of forklifts must be familiar and meet the
requirements of the OHS Act along with the Occupational Health & Safety (Plant) Regulations
1995 (particularly regulation 711 714).
How to use this guide
This guide lists effective ways to reduce risks to safety when vehicles are being loaded or
unloaded by forklifts. This will help you identify dangerous work practices and provide clear
advice on safer work practices.
As you read this guide, take a walk around your workplace to look for potential hazards.
Then find ways to fix the problem in the short term while you work at long term solutions.
1
-
7/30/2019 Forklifts Injuring
4/14
2
Key elements of effective forklift trafficmanagement systems
Comparative chart of tasks and issues
A comparative chart has been developed to help you. The practices in the green column should
be regarded as the target for all workplaces. The practices in the amber column are less
effective in reducing risk and should only be treated as an interim solution. Whilst the practices
in the red column involve high risk and should not be used in workplaces; an employer who
allows high risk practices to be used is almost invariably going to be in breach of Occupational
Health & Safety Legislation.
High Risk- Unacceptable Work Practices
Medium Risk- Interim solution only
Low Risk- Target for all workplaces
Find long term solutions
Find ways to fix the problem in the short term
Only acceptable aspermanent practices if its
clearly not PRACTICABLE to
implement higher standardpractices in your workplace
Breach of OHSLegislation
Please Note:
The OHS Act does not allow a person to avoid putting a risk control measure in place purely
on the basis of the cost of the control measure.
The term forklift, as used in this guide, applies to counterbalanced industrial trucks that are
designed to lift and move loads and typically used to load and unload vehicles.
The term loading refers to both the unloading and loading of vehicles unless otherwise
specified.
-
7/30/2019 Forklifts Injuring
5/14
3
Key elements of effective forklift trafficmanagement systems
Comparative chart of tasks and issues
Trafficmanagement
plan
There is no trafficmanagement plan. Trafficmanagement is dealt within an ad hoc way. Nosafe work procedures arein place.
Traffic is managed byindividual safe workprocedures at each areaof the workplace.
A comprehensive trafficmanagement plan, dealingwith all likely traffic controlissues, has been preparedand documented. Everyoneaffected by the planunderstands and applies
the traffic managementprinciples. The effectivenessof the plan is regularlyreviewed in collaborationwith workers.
High Risk Medium Risk Low Risk
Signage forfrequently
usedpedestrianroutes and
forkliftoperating
areas
No signs or if there aresigns they are not inprominent areas or whereforklifts are operating.Signs and markings areinconsistent across theworkplace and provideinsufficient informationabout intended use.
Signs prominentlydisplayed at entrance toworkplace and forkliftareas warning ofpresence of forklifts: Forexample Forkliftsoperating in thisarea. There are nosigns specific to theworkplaces own trafficmanagement system.Pedestrian walkways andforklift operating areasare marked to show theirintended use.
Signs conforming toAustralian Standard AS1319 are prominentlydisplayed at entrance toworkplace and in forkliftoperating areasreminding pedestriansand forklifts drivers aboutcritical parts of theworkplaces trafficmanagement system. Forexample
Pedestrian Prohibited Forklift OperatingArea;
Speed Limited Area.Pedestrian walkways,roadways and forklift
operating areas areclearly marked with highvisibility self evidentlines and signs
Speed limits No speed limits enforcedor speed limits fail toconsider load stability andstopping distance factors.
Speed limits have beendetermined through acomprehensive riskassessment taking accountof stability under brakingand stopping distances.Speed limits are enforcedthrough supervision or
speed monitoring.
Speed limits have beendetermined through acomprehensive riskassessment takingaccount of stability underbraking and stoppingdistances. Forklifts arefitted with speed limiting
devices.
-
7/30/2019 Forklifts Injuring
6/14
4
No information isprovided to visiting driverson safe loading
procedures.
Staff not trained inloading operations.
All visiting transportdrivers are fully briefedand provided with written
information/instructionsregarding the loadingprocedures used at work.
Staff involved in loadingoperations are trained inthe workplaces loadingprocedures only.
All visiting transportdrivers are fully briefedand provided with written
information/instructionsregarding the loadingprocedures used at work.
Everyone involved inloading operations aretrained in safe loadingoperations including:
the use of correctequipment to performthe task safely;
the use of alternative
load shifting equipmentand methods; and
knowing when use of aforklift is notappropriate for the task.
The training aims toimprove skills to allow staffto make contributions toenhancing safe workpractices.
High Risk Medium Risk Low Risk
No systems in place forpedestrian crossing areas.
A priority or give wayprocedure applies to
pedestrian crossings.Prominent signs specifywho must give way.
Forklift proximity warningdevices only.
Pedestrian crossings arecarefully planned, clearly
marked, clear ofobstructions and speedsare limited to suit requiredstopping distances andload stability.
A priority or give wayprocedure applies topedestrian crossings.Prominent signs specifywho must give way.
Forklift proximity warningsystems incorporating
temporary pedestrianbarriers such as boomgates etc. at crossings.
No physical barriers at
high risk areas. Noproper risk assessmentcarried out.
Physical barriers at high
risk areas e.g. blindcorners or places whereforklifts are close topedestrian areas.
Physical barriers protect
all marked pedestrianwalkways.
In addition to physicalbarriers in areas wherepedestrian traffic iscommon there are largefixed bollards set out fromblind corners to protectpedestrians in all areas.
Informingvisitingdrivers
Forklift
barriers
Pedestriancrossings
-
7/30/2019 Forklifts Injuring
7/14
5
No markings, bollards, orsafety zones for the driveror loading crew.
A clearly defined safetyzone protected by largeportable bollards/barriers
is provided so that thedriver or loading crewcan supervise loading ata safe distance frommoving forklifts.
There are specifiedexclusion zones aroundvehicle trailers and forkliftoperating areas.
If there is no risk of thecabin being damaged bya load or the forklift, thedriver remains in the truckcabin during loading andunloading operations.
A clearly defined safetyzone protected by largefixed bollards/barriers is
provided so that the driveror loading crew cansupervise loading at asafe distance frommoving forklifts andfalling loads; or
Loading supervision isachieved via remotemeans such as closedcircuit TV and/or radiocommunications; or
The loading supervisorsobservation post iselevated and visible to theforklift operator at alltimes.
If there is no risk of thecabin being damaged bya load or the forklift, thedriver remains in the truckcabin during loading andunloading operations.
High Risk Medium Risk Low Risk
Pedestrian
ExclusionZones
Loading crew or other
pedestrians are permittedto move in close proximityto working forklifts or thevehicle loading activity.
There is no acceptable
interim alternative.
A clearly defined
pedestrian exclusion zoneis designated around thevehicle being loaded. Theextent of the exclusionzone is determined from acomprehensive riskassessment of all loadingoperations. A minimumexclusion zone size shouldbe established for adistance equal to theheight of the load fromthe ground plus anadditional allowance forthe nature of the load e.g.potential to bounce, rollor splash contents.
Lines or large bollardsdelineate the exclusionzone.
All forklift movements arestopped if pedestrians e.g.loading crew need toenter the exclusion zone.
Safety zonesfor drivers of
trucks and
loading crew
-
7/30/2019 Forklifts Injuring
8/14
6
Number ofloading crew
and
monitoringof their
location
Large number of peoplein the loading crewaround the loading area
and there is no system tomonitor their presence.
There is no acceptableinterim alternative.
Loading crew is limited tominimal numbers to keepcommunications simple
and make it easier tomonitor where the crew islocated.
Where there has to be alarge number of people inthe loading crew, specificmonitoring systems are inplace so that forkliftoperator is certain of thelocation of any memberof the crew while theforklift is in operation.
High Risk Medium Risk Low Risk
Loading crew Personnel are permittedon the vehicle tray whenthe forklift is moving theload.
There is no acceptableinterim alternative.
No personnel are on thevehicle tray during anymovement of the load bya forklift.
Visibility ofpeople near
workingforklifts
No procedure in placerelated to visibility ofpeople near workingforklifts. Loading crewmay not always be inview of forklift operator.High visibility clothing is
not worn or is ineffective.
There is no acceptableinterim alternative.
The forklift driver checksthat loading crew and thetruck driver are in the safetyzone before entering thepedestrian exclusion zone.Forklift drivers stop workimmediately if the location
of the truck driver or anymember of the loadingcrew cannot be confirmedor any pedestrian enters theexclusion zone.
High visibility clothing isworn by anyone required tomove or work in the vicinityof forklifts or other traffic.
No special arrangementsin place when more than
one vehicle is beingloaded.
Portable physical barriersused around forklift
operating zones wheremore than one vehicle isbeing loaded.
Warning systems are usedto alert forklift drivers ifthey have moved intoanother exclusion zone.
Fixed physical barriers orscheduling of operations
make it impossible for aforklift that is notsupposed to be involvedin a loading operation tointrude into anotherdesignated exclusion zonewhile loading operationsare underway.
Loading operations arenot supervised orplanned.
Supervision of loadingoperation occurs on aneeds only basis.
Loading operators areunder constantsupervision and loadingprocedures are enforced.
Parking areasfor multiple
vehicles
Supervision
-
7/30/2019 Forklifts Injuring
9/14
High Risk Medium Risk Low Risk
7
Trainingforklift
operators
Forklift operators are notlicensed and trainees arenot constantly and directly
supervised.
Operators have not beenspecifically trained in allactivities undertaken.
There is no acceptableinterim alternative.
Forklift operators arelicensed or they are traineesunder constant direct
supervision. Competenciesare regularly reviewed andupdated.
Task (workplace) specifictraining is provided on allactivities to be undertaken.
Using aforklift to lift
people
People are lifted on thetynes of a forklift withouta safety cage.
Forklifts are only used tolift people where no othermethod is practicable.People are only lifted insafety cages that comply
with the AustralianStandard.
Forklifts (other thanspecialised order pickingforklifts) are not used tolift people.
Controllingwho uses
forklifts
There is no specificprocedure or control ofwho operates the forklift.
A key control procedureis implemented to ensurethat only competentforklift operators haveaccess to the keys andforklift. This procedure ismanaged by the forkliftoperators.
A key control procedure isimplemented to ensurethat only competentforklift operators haveaccess to the keys andforklift. Managers orsupervisors are in controlover access to keys to theforklift.
Maintenanceof forklifts
There is no regularmaintenance performedby suitably qualified orcompetent persons andno documentation is kept.
Forklifts are wellmaintained by competentstaff but information inmaintenance records andlogbooks are notintegrated into a riskcontrol system.
There is a daily pre-startup maintenance checkdone by the driver.Suitably qualified orcompetent personsperform regularinspections andmaintenance.Comprehensive record ofmaintenance is kept andis available to operators.Logbooks are maintainedby operators. Alldocumentation isregularly monitored andthe information from thedocuments is integratedinto a risk control system.
Fitting andwearing of
seat belts orother forms of
driverrestraint
Seat belts are not worn orare not fitted to forklifts,there is no driver restraintand no relatedsupervision.
Seat belts are fitted tonew forklifts but not toolder units.
Supervision isinconsistent.
Wearing of seat belts iscompulsory on new forkliftsbut not on older units.
Seat belts are fitted to newforklift vehicles and retro-fitted to older units.Wearing of seat belts iscompulsory and thepractice is supervised.
-
7/30/2019 Forklifts Injuring
10/14
8
Use ofalternativeload liftingequipment
Attachments
Appropriate loadshifting/handlingequipment is notavailable.
There is no acceptableinterim alternative.
Load shifting or handlingequipment is provided foruse as an alternativewhere the use of a forkliftmay be particularlyhazardous.
Appropriate load liftingattachments are notavailable for forkliftoperations or they are notengineered to appropriatestandards.
Purpose built liftingattachments are used andthese are marked with thesafe working load, anengineers report isavailable and theattachments are regularlyinspected for damage or
wear.
Only attachmentsconfirmed by themanufacturer as suitable forthe particular forklift andtasks are used. Safeworking load and radiuscharts for the forklift andattachment combination
are displayed on the forklift.The attachments areregularly inspected fordamage or wear.
High Risk Medium Risk Low Risk
Incidentreporting
Forklift related incidentsare not reported orinvestigated.
There is no acceptableinterim alternative.
All forklift relatedincidents are reported,investigated and actedupon to prevent futureincidents. Reporting andresponse involves healthand safety representatives.
Loadingdocks
Loading ramps aremanufactured without
obvious regard to loadingforces, necessary width oredge guarding.
Loading ramp notsecured to loading dockor trailer.
Trailer movementprevented only by parkingbrakes.
No edge marking ondocks or ramps.
Loading ramps (bridgingplates) properly
engineered, full width ofvehicle being loaded andfitted with raised edgeguarding having highvisibility markings.
Loading ramps locked toloading dock trailerbrakes applied andwheels chocked againstmovement.
Edges of loading docksclearly defined with high
visibility markings.
Automatic dock levellersused at all loading points.
Edges of loading docksclearly defined with highvisibility markings.
Automatic trailer brakingchocks and parkingbrakes used.
Dock designed to allowvehicle to drive throughrather than reverse in.
Use ofengineeringsolutions forcritical safety
controls
No use of engineering ortechnological safetyoriented systems.
Minimum engineeringand technology toimprove safety but not allavailable systems areexploited. e.g. onlyreversing warning systemsused.
Use of smart forkliftvehicles that utiliseengineering andtechnology to improvesafety e.g. use ofautomatic pedestrianproximity warning devicesand speed limiting devices.
-
7/30/2019 Forklifts Injuring
11/14
9
Key elements of effective forklift trafficmanagement systems Dos and Donts
Do
develop and implement traffic
management plans for both forklift and
heavy vehicle movements.
provide specified pedestrian exclusion
zones around vehicle tray or trailer and
forklift operating areas.
require the forklift driver to stop workimmediately if they lose sight of the
truck driver or any member of the
loading crew.
supervise work to ensure that
procedures are followed.
have specific workplace training in
competency in safe forklift operation,
use of attachments and safe loading
practice.
report and investigate all forklift related
incidents.
provide safety areas where pedestrians
involved in the loading activity are
clearly visible to the forklift driver.
instruct and brief all visitors, including
visiting truck drivers, on companyprocedures.
Dont
allow pedestrians in forklift operating
areas.
allow drivers to supervise the loading
process while standing in the forklift
truck operating zone, including on the
opposite side of the vehicle and on the
tray.
lift people on the tynes of a forklift.
access pedestrian exclusion zones while
a forklift is moving in the area or moving
a load.
stand beside a vehicle on the opposite
side to where a forklift is moving or
adjusting a load.
stand on the tray of a vehicle while a
forklift is moving or adjusting a load.
-
7/30/2019 Forklifts Injuring
12/14
10
1. Example of an effective forklift trafficmanagement system for loading and unloading
vehiclesThe following example will assist you with developing an effective forklift traffic management
system.
Remember, keeping pedestrians and truck drivers at a safe distance from operating forklifts is
the only way to prevent death and injury.
Safety Zone for DriverThe driver must be in full view to a forklift operator. Allloading or unloading activity must stop if the drivercannot be seen or needs to enter exclusion zone toinspect load. Alternatively, if it is safe to do so, the
system of work can provide for the driver to stay in thetruck cabin during loading and unloading.
One way traffic is safer. Removable bollards in front ofthe truck enable it to move forward after being loading.
Bollards/Witches Hats/Paint marking the Pedestrian
Exclusion Zone.
Pedestrian Exclusion ZoneA minimum exclusion zone should beestablished for a distance equal to theheight of the load from the ground plus anadditional allowance for the nature of theload e.g. potential to bounce, roll or splashcontents. All forklift movements within thezone must be stopped before pedestriansenter this area.
Forklift
Truck loading/unloading - Exclusion Zones
Truckcabin
Trucktrailer
This is a total exclusionzone during loading or
unloading activity.
-
7/30/2019 Forklifts Injuring
13/14
11
2. Example of an implemented effective forklifttraffic management system for loading and
unloading vehiclesAs outlined in this guide the key to effective forklift traffic management systems is to separate
pedestrians and operating forklifts and to keep drivers in a safety zone.
The following is an example of how one operator has adapted the principles outlined in this
guide and implemented the following traffic management system. This system has significantly
reduced the level of risk and increased productivity.
Safety Zone for Driver
Pedestrian Exclusion Zone
Pedestrian Exclusion ZoneA pedestrian exclusion zone has been established for a distance equal to the height of the load from the ground plus anadditional allowance for the nature of the load. Forklift movements within this zone are stopped before pedestrians enter.
Forklift runners takepallets from edge ofexclusion zone totheir destinations.
Pallets are takento the edge ofexclusion zoneby a singleforklift.
Truckcabin
Trucktrailer
This is a total
exclusion zoneduring loadingor unloading
activity.
Forklift
Bollards/Witches Hats/PaintBollards marking the perimeter of the pedestrian exclusion zone have been installed.
Safety Zone for DriverThe driver must be in full view to a forklift operator. All loading or unloading activity must stop if the driver cannot be seen orneeds to enter exclusion zone to inspect load. Alternatively, if it is safe to do so, the system of work can provide for the driver tostay in the truck cabin during loading and unloading.
ForkliftsOnly one forklift operates in the pedestrian exclusion zone.
-
7/30/2019 Forklifts Injuring
14/14
Some other important facts to consider
Forklifts and the loads they carry are heavy; a laden forklift travelling at 15km/hr may take
12 metres or more to stop in an emergency.
Rear wheel steering can cause the rear of the forklift to swing out unexpectedly and crush or
run over the feet of bystanders.
Forklift wheels carry very high loads and will inflict serious injuries to feet.
Forklifts are designed to lift only palletised loads or equipment that has purpose-built slots
to engage the tynes. Talk to your supplier about special purpose attachments for safely lifting
other loads e.g. drum lifters, wide load spreader tynes. Loads that have steel to steel contact
with the tynes are especially dangerous as they slip unexpectedly during movement.
Forklifts can become unstable and roll over when turning or braking at speed, particularly if
travelling with the load raised.
Seatbelts or operator restraints should always be used. Drivers being thrown from the seat
and crushed by the forklift in a rollover has been the cause of many fatal injuries.
Forklifts placing or removing loads from other vehicles or material stacks can disturb
adjacent material causing these to fall on bystanders.
Remember keeping pedestrians at a safe distance from operating forklifts is the
only way to prevent death & injury.