Forklifts pose hazards to workers if they aren't properly maintained, and when operators aren't properly trained in their operation. OSHA forklift certification is no laughing matter, and OSHA takes their regulations very seriously. The regulations exist for good reason-to minimize safety hazards in the workplace without hindering productivity.
One of the requirements for OSHA forklift certification is to have every forklift and every attachment clearly labeled with an accurate and certified forklift capacity rating. Every forklift configuration is different, and it is important that the lift capacity of each configuration is calculated correctly. By knowing the lift capacity, lift truck operators can safely lift and transport products without worrying about causing equipment failure by exceeding capacity.
The OSHA forklift certification regulation is outlined in the regulations and standards documents, section 1910.178(a)(4): "Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without the manufacturer's prior written approval. Capacity, operation, and maintenance instruction plates, tags, or decals shall be changed accordingly." Recognizing that a manufacturer's written approval may be difficult if not impossible to obtain and in the interest of public safety, OSHA interpretation 07/03/2002 - Powered industrial truck addition/modification approval and marking requirements also allows a "written approval from a qualified Registered Professional Engineer" such as Professional Forklift Engineering Services and the Lift Truck Capacity Calculator website.
These regulations mean that all lift trucks must have a label or plate stating the certified forklift capacity rating for the forklift plus attachments. The label, sometimes called a "nameplate," should be easily found on the lift truck with the certified capacity rating stated.
Without knowledge of the lift capacity, not only is there a potential OSHA violation, but there is also the risks that the operator may exceed the maximum load. When this occurs, the lift truck can tip over, the lift mechanism may be damaged, or the load could spill, injuring the operator or nearby workers.
The dangers of incorrect OSHA forklift certification labels are real, which is why OSHA is so stringent on these guidelines. Sadly, there have been very serious injuries and even loss of life caused by lift trucks exceeding their maximum carry capacity. Forklift safety violations consistently fall in the "top ten most frequently cited standards" following an OSHA inspection of a facility (reference: http://www.osha.gov/Top_Ten_Standards.html)
When reviewing your lift trucks, take note of the OSHA required forklift certification plates and determine whether they need to be reviewed. Factors such as fork wear, configuration or attachment changes, lapses in maintenance, or other issues can affect the lift capacity rating for an individual lift truck.
Before second-guessing your lift capacity information, consider checking with a professional forklift engineering firm that can accurately certify your lift trucks and make sure they are in compliance with OSHA forklift regulations. The experts at Professional Forklift Engineering Services can help you with their Lift Truck Capacity Calculator. This tool will provide a certifiable capacity rating for any lift truck and attachment configuration. Before OSHA approaches, or before a problem occurs, check your forklifts to make sure they are compliant and safe.
Before second-guessing your lift capacity information, consider checking with a professional forklift engineering firm that can accurately certify your lift trucks and make sure they are in compliance with OSHA forklift regulations. The experts at Professional Forklift Engineering Services can help you with their Lift Truck Capacity Calculator. This tool will provide a certifiable capacity rating for any lift truck and attachment configuration. Before OSHA approaches, or before a problem occurs, check your forklifts to make sure they are compliant and safe.
|
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.
