At a metal fabricating shop, a worker was operating a forklift, moving a load of metal plates. The load — over 5½ feet (1½ metres) wide — weighed about 6,208 pounds (2,794 kilograms). The metal plates were
being carried on a custom-made load-handling rack attached to the forklift forks. This steel rack weighed
664 pounds (299 kilograms) and was so large that it affected safe operation. The forklift operator travelled
with the load elevated about 6 feet (2 metres) off the ground so that it could clear a welding shield set up
near a metal fabricator's workstation.
The forklift approached the workstation where the fabricator was welding with his back to the forklift.
The fabricator was wearing a welding helmet and hearing protection. He did not hear the forklift operator's
attempts to get his attention. Just as the forklift operator applied the brakes, the fabricator turned toward
the forklift with its elevated load. The metal plates slid off the forklift's load rack, the forklift tipped forward,
and the load rack itself slid off the forks. The fabricator was knocked to the ground and pinned underneath
the load rack with its remaining plates. He suffered fractured and broken bones.
Safe work practices:
- Consult the forklift manufacturer or a professional
engineer before using any custom-made load-handling
attachments, racks, or pallets that may affect the
stability and rated capacity of forklifts.
- Provide specific written safe work procedures
for the operation of forklifts. Train forklift
operators in these procedures. The
procedures should include — but are
not limited to — the following:
- Determine the load weight, load centre, and combined centre of gravity.
- Use an effective means of communication to alert workers who are in the vicinity of operating forklifts.
- Ensure a clear view of the work area before moving loads.
- Ensure that approved custom-made load-handling attachments, racks, or pallets and loads that could shift are properly secured.
- Do not travel with an elevated load.
- Keep forklift routes clear. If necessary, change workplace layout to keep forklift traffic away from
workstations and pedestrians.
- Do not operate a forklift unless all the safe work requirements listed here have been met.
