Understanding safe load truck capacity requirements can be difficult. Not only do you have to worry about ever-shifting OSHA regulations, but the various modifications that take place over the life of your forklift equipment will also come into play. Having access to the most up-to-date regulations is essential, if you are going to maintain acceptable capacities for the use of your truck. OSHA provides many of these requirements on their website, as well as mailing them out to those who request them. The following pieces of information will help you ensure that use of your truck stays within mandated regulations.
Be wary of the following potential hazards when it comes to safe load truck capacity:
• Be aware of potential tip-overs when arranging your load. With too much weight on the forks, you can easily tip the truck forward, losing steering control when the back wheels lose contact with the ground. This could lead to a collision, or the load could fall from the fork lift.
• Make sure you don't exceed the capacity of the forklift as printed on the nameplate.
• Make sure that the data plate or nameplate stays up to date. Attempting to do so with manual calculations is not only time consuming, but prone to human error. Instead, use a tool, such as that located at lifttruckcapacitycalculator.com where you can get approval from a registered professional engineer. This tool maintains up-to-date specifications as provided by the manufacturer, as well as an easy to use interface for adding custom modifications and attachments.
• Minimize the distance between the load center and the front wheels. This will avoid potential tip-overs.
• Ensure safe load truck capacity when moving multiple loads by positioning smaller loads closest to the front wheels. Do not put larger loads behind smaller loads during transport.
• Be extra cautious when moving oversized loads. Laying them flat can result in load center that cannot be balanced on the fork, resulting in a tip-over or losing the load off of the forks.
• Never attempt to transport a load that exceeds the stated capacity of the truck, as indicated by the nameplate or data plate.
• When transporting a load close to the maximum allowable capacity, be extra careful of tip-overs, losing the load, and the danger of striking a passerby with a falling load. If possible, reduce the size of the load before transporting, if it is close to the maximum stated capacity.
• Be sure to regularly compensate for wear on the forks, as this alters the safe load truck capacity.
• When moving an oversized load, be extra careful to turn slowly to avoid shifting the center of balance. This, in turn, will minimize the likelihood of spilling a load or tipping the forklift.
• Make sure to always wear proper safety gear when transporting a load.
Update the data plate regularly to accommodate changes in the equipment, including wear on the forks and modifications to the truck. Using a tool such as that provided at LiftTruckCapacityCalculator.com can make the process easier, eliminate errors introduced by manual calculations and allow you to obtain an OSHA compliant data plate from a professional engineer. This calculator also maintains up-to-date information provided by manufacturers that is useful in calculating safe load truck capacity.
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There are a multitude of factors that affect the lifting capacity of a forklift and these parameters, which are indicated on the capacity data plate, include:
- Make or Manufacturer
- Model
- Power Source
- Battery Weight (for electrics)
- Tire Type
- Tire Size
- Mast Lift Height
- Mast Carriage Type
- Attachment(s) Type
- Attachment(s) model
- Load Center of Gravity (CG or LC)
If any of these parameters are changed, particularly the attachments on the forklift carriage or the load center, the capacity plate should be checked for accuracy to ensure safe load handling.
Forklift attachments include anything that is attached to the front carriage of a forklift or is attached to an attachment on the forklift. A typical forklift attachment configuration might include a hang-on side shifter and two forks. In this case, if the forks are removed and longer forks are added, the capacity of the machine could be drastically reduced. Or if the forklift is used to pick up a fork mounted attachment, such as a drum handler or fork extensions, then a capacity data plate must be changed or added to reflect the new configuration. OSHA forklift safety regulations state that a forklift must have a legible capacity plate to reflect any attachment used on the lift.
Lift height or maximum fork height (MFH) has a significant effect on a forklift’s load carrying capacity, and forklifts with high masts will have a greater carrying capacity at lower lift heights than at the maximum lift height. For this reason forklifts with very high masts may have a dual capacity rating on the data plate; a maximum capacity up to a mid level lift height, and a lower capacity rating at the maximum lift height. This allows the forklift operator to work with heavier loads at low heights, i.e. loading and unloading trucks, cross-docking, etc., while using the same forklift to put away lighter loads to high storage locations.
Because a forklift is using leverage to lift a load, any condition that adds weight to the front of the forklift and causes the load center (LC or CG) of the load to be moved further away from the forklift will contribute to a reduction in the residual carrying capacity of the machine. Forklift attachments can cause these reductions, as well as the dimensions of the load and the load handling conditions. Load center typically refers to the horizontal distance to the load CG and is typically half the length of the load for symmetrical objects. To illustrate how attachments and load CG’s can affect residual carrying capacity, consider for example that a particular forklift with only forks on the carriage is rated at 5,000 lb capacity @ 24” load center on the data plate. This forklift will only be rated at 1,270 lb when equipped with a particular 8 foot long fork mounted jib boom because the boom adds weight and moves the load center out to 96 inches. In this case the forklift may employ a dual load center capacity rating on the capacity plate indicating a greater lifting capacity (2,750 lb) at a 4 foot load center and a lower capacity (1,270 lb) at the 8 foot load center.
Small changes in load center can also greatly affect the carrying capacity. Consider the capacity of the same 5,000 lb forklift with 48” forks and rated at a 24” load center, drops to 3,660 lbs when 72” fork extensions are employed to lift a 6 foot long load.
The main thing to consider is that every forklift has a legible capacity plate that accurately reflects the attachment configuration being used at the correct load center for the load being lifted and contact Professional Forklift Engineering Services at www.LiftTruckCapacityCalculator.com to check your lift capacity and get a professional engineering (PE) certified capacity rating plate on your forklift today.
"Employers who are cited for repeat violations demonstrate a lack of commitment to workplace safety and health standards. Deficient forklifts and improperly handled chemicals can lead to serious injuries or death,"said Diane Turek, director of OSHA's Chicago North office in Des Plaines. "All employers must take the necessary steps to eliminate hazards from the workplace."
Four repeat violations with proposed penalties of $132,000 have been cited,including exposing workers to hazards by allowing them to operate forklifts that remained in service even after deficiencies were noted; exposing workers' eyes, faces and hands to corrosive chemicals without providing suitable eyewash facilities; and failing to develop an emergency response plan and conduct fire extinguisher training. A repeat violation exists when an employer previously has been cited for the same or a similar violation of a standard, regulation, rule or order at any other facility in federal enforcement states within the last five years. The company was cited for the same violations at numerous facilities between 2006 and 2011.
Central Transport also has been cited for eight serious violations with proposed penalties of $30,800, including failing to train and evaluate forklift drivers, maintain forklift name plates in legible condition, label hazardous material containers, maintain the mechanic shop maintenance area in a dry condition, provide workers with training on hazardous chemicals and provide material data safety sheets for workers' reference. A serious violation occurs when there is substantial probability that death or serious physical harm could result from a hazard about which the employer knew or should have known.
Finally, the company has been cited for five other-than-serious violations with $2,000 in proposed penalties for failing to maintain the OSHA 300 injury and illness log, maintain fire extinguishers, illuminate exit signs and unlock a fire exit door. An other-than-serious violation is one that has a direct relationship to job safety and health, but probably would not cause death or serious physical harm.
The citations can be viewed at http://www.osha.gov/ooc/citations/CentralTransport_77120_1205_11.pdf*.
Central Transport, a national freight company based in Warren, Mich., has 15 business days from receipt of the citations to comply, request an informal conference with OSHA's Chicago North area director in Des Plaines or contest the findings before the independent Occupational Safety and Health Review Commission.
To ask questions, obtain compliance assistance, file a complaint, or report workplace hospitalizations, fatalities or situations posing imminent danger to workers, the public should call OSHA's toll-free hotline at 800-321-OSHA (6742) or the agency's Chicago North office at 847-803-4800.
Under the Occupational Safety and Health Act of 1970, employers are responsible for providing safe and healthful workplaces for their employees. OSHA's role is to ensure these conditions for America's working men and women by setting and enforcing standards, and providing training, education and assistance. For more information, visit http://www.osha.gov.
