EH-92-3 Worker Safety Compromised ENVIRONMENT, SAFETY & HEALTH BULLETIN Assistant Secretary for U. S. Department of Energy Environment, Safety & Health Washington, D.C. 20585 DOE/EH-0255 Issue No. 92-3 June 1992 WORKER SAFETY COMPROMISED WHEN OPERATING FORKLIFTS IN REVERSE Safety Issue A pedestrian was killed in May 1991, and a forklift operator was severely injured in March 1992 in accidents at DOE facilities. The accidents occurred when forklifts were driven in reverse. Incident Descriptions In May 1991, the operator of a rough-terrain forklift was carrying a trash dumpster when the fatal accident occurred. The mast of the forklift was tilted back for travel, and the dumpster was secured by its own weight and the angle of the forks. In accordance with proper procedures, the forklift was being operated in reverse because the dumpster completely blocked the driver's forward vision (Figure 1). The operator was driving with his left hand and looking backward over his right shoulder. The back-up alarm on the forklift was functioning. The pedestrian was walking on the right-hand side of an asphalt road. There were no sidewalks or walkways, and the pedestrian was walking in the path of the forklift with traffic. The forklift approached the pedestrian at a speed of less than 10 mph, and one or two of the tires struck and ran over him, causing fatal injuries. Figure 2 is a diagram of the accident scene. In March 1992, the operator of an electric stand-up counterbalance forklift was injured when he backed off the edge of a loading dock. He had been asked to take a forklift from one building to another. He conferred with a supervisor about the type of work to be done and the specific forklift to use. The path in front of the forklift was blocked by materials; and the operator decided to back toward the dock opening, pull forward, and proceed out of the area in another direction. He did not stop the forklift at the dock opening; and the forklift fell backward off the dock, pinning him under the vehicle. He received a severe cut on the back of his head, and his right foot was crushed, requiring partial amputation. Figure 3 is a photograph of the accident scene. Causal Factors Several factors probably contributed to the incidents. In particular, an operator's vision when driving in reverse is blocked by part of the forklift. Also, there were no established procedures for forklift operation in the dock area, and safety features there were inadequate to prevent the accident. Additional causes included a lack of sidewalks or designated pedestrian walkways in an area of construction traffic; the pedestrian walked on the wrong side of the road, with traffic instead of against it; and operator inexperience. Related Incidents Several other incidents involving forklifts occurred at DOE facilities in the last two years. Descriptions of some of the incidents follow. Most incidents were the result of operator error, including several that involved improper use of equipment or use of inadequate equipment. In these incidents, employees did not exercise caution or follow procedures. Operators sometimes used forklifts to transport material that should have been moved with other equipment. This resulted in the loads falling because they were not properly secured. In another case, an operator placed a load on inadequate cribbing, and the load fell when the forklift was backed clear of the cribbing. Employees replacing a heating/air conditioning unit at another site worked unsecured from a platform supported by a forklift. Although no accident occurred, procedures were violated and a report was filed. Several collisions occurred. In one incident, a vendor backed a forklift over an electrical junction box, tripping a breaker. In a second collision, an operator was unaware that the forks of the lift extended through the pallet he was transporting. He struck a battery on another pallet and punctured it, causing battery acid to leak. Another collision caused an electrical outage when the operator struck a power pole. There were no barriers around the pole, but the operator admitted his inattention contributed to the accident. In one incident, a forklift overturned because the operator was traveling too fast when he attempted to make a turn. He was thrown clear of the forklift and was not injured. Safety Implications All of these incidents demonstrate how easily worker safety can be compromised when proper precautions are not taken during forklift operation. Operators should be certain their path is clear before moving a forklift. Also, employees should not bypass established policies on proper use of equipment in an effort to perform a job more quickly. Recommendations Managers and supervisors should follow these procedures and practices in areas where forklifts are used: 1. Ensure that the forklift's rated capacity is adequate for the type of work being performed and that all forklift operators are trained and certified. Training should include the general equipment category, as well as instruction in how equipment will be used at the facility and how specific pieces of equipment should be operated. 2. Study vehicle and pedestrian traffic. Explore ways to separate the two in time and distance, and review compliance with existing traffic rules. Determine whether employee training programs on vehicle and pedestrian safety are adequate. Implement changes as necessary. 3. Make operators aware of the severely limited visibility in some models of forklifts, and instruct them to use extreme caution when driving in reverse. Consider the use of ground guides, rear-view mirrors, spotters, or other aids to increase visibility. 4. Determine whether an area should have physical barriers such as ramps, raised concrete staging areas,and/or heavy-gauge safety chains in front of dock openings. Add a "warning track" of yellow paint on the floor near dock openings. 5. Ensure electrical equipment is protected from physical damage by location or substantial guards. Operators of forklifts and other heavy industrial equipment should follow these procedures and practices in areas where forklifts are used: 1. Consider the noise level in the surrounding environment. Do not assume pedestrians or bystanders are able to hear the back-up alarm. In addition, never assume pedestrians or bystanders are aware of the presence of heavy equipment and/or the intended direction of travel. 2. Select and use proper equipment for material handling and elevating personnel. Verify material is secured properly. OSHA regulation 1910.178, "Powered Industrial Trucks," and American National Standards Institute (ANSI) standard B56.6, "Safety Standard for Rough Terrain Forklift Trucks," should be followed. 3. Use ground guides when visibility is limited. 4. Assure the path is clear prior to traveling. Note and take precautions near hazardous areas. This Bulletin is one in a series of publications issued by EH to share occupational safety information throughout the DOE complex. To be added to the Distribution List or to obtain copies of the publication, call (615) 576-3482. For additional information regarding the publications, call Eleanor Crampton, Safety Performance Indicator Division, Office of Environment, Safety and Health, U.S. Department of Energy, Washington, DC 20585, (301) 903-3732.  .