Safe forklift operation requires proper training, daily inspections, and consistent adherence to established safety procedures. OSHA estimates that roughly 100 U.S. workers die and 36,340 suffer serious injuries in forklift accidents each year. At least 20% to 25% of these accidents occur because the operator was not adequately trained. The following do's and don'ts are based on OSHA regulations (29 CFR 1910.178) and industry best practices.
DO's – Safe Operating Practices
Before Operation
Conduct a visual and operational inspection of the forklift at the start of each shift.
Check tires for damage and correct air pressure, test brakes, warning signals, and lights.
Remove any forklift found to be in unsafe operating condition from service immediately.
Ensure you are properly trained and authorized to operate the specific type of forklift.
Wear appropriate PPE, including safety footwear and hardhat.
Traveling and Maneuvering
Always look in the direction you are traveling.
Operate the forklift at speeds safe for the particular operation and worksite conditions.
Sound the horn at cross aisles, doorways, and other locations where vision is obstructed.
Keep a clear view of the path of travel at all times.
Slow down for wet and slippery floors.
Travel in reverse when the load blocks your forward vision.
Keep forks pointed uphill when traveling with a load on an incline.
Keep forks pointed downhill when traveling without a load on an incline.
Maintain a safe distance from platform and ramp edges.
Always wear the seatbelt when the forklift has one.
Load Handling
Place forks under the load as far as possible.
Carry loads within 4 to 6 inches of the ground while traveling.
Tilt the mast back slightly while driving to stabilize the load.
Only raise or lower loads when the forklift is completely stopped.
Ensure the load is stable and balanced before moving.
Check for adequate overhead clearance before raising the load.
Parking and Shutdown
Park in authorized areas only.
Park a safe distance from fire aisles, stairways, or fire equipment.
Lower forks fully to the ground, neutralize controls, apply the parking brake, and turn off the engine.
Block the wheels if parking on an incline.
Refueling and Battery Charging
Turn off the engine before refueling the forklift.
Charge batteries only in designated areas with proper ventilation.
DON'Ts – Practices to Avoid
Training and Authorization
Never operate a forklift without proper training and authorization – OSHA requires that operators be trained and evaluated before operating a powered industrial truck.
Do not allow anyone under 18 years of age to operate a forklift in non-agricultural operations.
Passengers and Lifting People
Never carry passengers or give rides.
Never use the forklift to lift a person standing on a pallet or the forks.
Only use approved personnel platforms securely fastened to the forks to elevate anyone.
Overloading and Improper Loads
Never exceed the rated load capacity.
Do not move loads that are piled or stacked poorly.
Do not raise or lower a load while traveling.
Do not carry loads that block your view without traveling in reverse.
Unsafe Driving Practices
Never make sharp turns with elevated loads.
Do not operate a forklift with any malfunction.
Do not handle the steering wheel if your hands or gloves are greasy or slippery.
Do not drive up to anyone standing in front of a bench or other fixed object.
Do not leave forklifts running inside for long periods without ventilation.
Unsafe Parking and Idling
Never leave a forklift unattended with forks raised and engine running.
Do not block aisles or exits when parking.
Do not park on an incline unless the wheels are safely blocked.
General Prohibitions
Never allow anyone to stand or pass under the elevated portion of any forklift, whether loaded or empty.
Do not operate forklift loads directly over personnel or unprotected work areas.
Do not smoke when near a fuel source or while fueling the forklift.
Summary
Safe forklift operation begins with proper training and daily inspections, followed by consistent adherence to speed limits, load capacity, and visibility rules. Operators must always wear seatbelts, keep loads low while traveling, and never carry passengers or lift people. Parking requires lowered forks, neutralized controls, and the parking brake engaged. Following these OSHA-based do's and don'ts significantly reduces the risk of forklift-related fatalities and injuries.