Stand-up forklifts have a unique and significant safety risk called under-riding. This occurs when the forklift operator, with forks trailing, backs into a storage rack with a crossbar slightly taller than the truck cab. If there is nothing to stop the forklift, the operator can be hit or crushed. This is what happened twice within six months at a warehouse fulfillment center in Florida in 2018. Even though the facility had extra wide aisles and a requirement to look in the direction of travel, one driver was injured, the second died, and OSHA assessed a significant penalty for both (Chewy, Inc. v. U.S. Department of Labor, 11th Cir, May 2023). To prevent under-riding injuries at your facility, consider the following:
- Ensure comprehensive operator training that includes specific instruction on under-riding hazards. Vigilant’s powered industrial truck training is being modified to address under-riding.
- Enhance visibility by equipping forklifts with additional mirrors, cameras, or proximity warning systems. If you install additional safety features on your stand-up forklifts, contact the manufacturer and obtain written approval.
- Enforce safety rules, including reduced speeds and keeping a safe distance from objects.
- Regularly inspect and maintain forklifts to ensure all safety features are in working order.
- Adjust shelf heights or install barriers to prevent potential under-rides.
- Invest in forklifts with rear post guards or other features designed to prevent under-rides.
Review OSHA’s Safety and Health Information Bulletin, Standup Forklift Under-ride Hazards, for additional recommendations. For questions on this or Vigilant’s powered industrial truck training, contact your Vigilant safety professional.
