Powered Industrial Trucks (PIT)
A forklift (PIT) is shown.
Date Posted: 05/30/2024
Powered industrial trucks (PIT) are essential material handling tools, better known in the work environment as forklifts. PITs help save time and reduce material handling efforts when maintained and used safely. However, according to the Bureau of Labor Statistics (BLS), from 2011 to 2017, 614 workers lost their lives in forklift-related incidents, and more than 7,000 nonfatal injuries with days away from work occurred every year.
Does an Operator Need to be Certified to Operate a PIT?
PITs are divided into seven classifications. Two factors determine how a truck is classified – the fuel used and the intended use of the truck. Businesses must choose the appropriate class of truck for their purposes. All forklift operators must be trained and qualified for the type of PIT they will operate.
Before Operating, Inspect the PIT
Each powered industrial truck must be inspected at the beginning of each shift.
A PIT that needs repair is defective or unsafe should be removed from service. The problem should be recorded on a log and reported to a supervisor immediately. The truck should also be taken out of service and locked out/tagged until the repairs have been made and the truck is safe to operate.
PIT must not be altered so that the relative positions of the various parts are different from what they were when originally received from the manufacturer, nor will they be changed by eliminating any parts.
Adding additional counterweights to fork trucks may not be done unless the PIT manufacturer approves.
Hazards for PIT Operation
Untrained PIT Operators: In accordance with WAC 296-863-30010, PIT operators must be trained in the safe operation of the equipment and be competent. Only trained and authorized operators are permitted to operate PIT. An evaluation of PIT operator performance must be conducted, at minimum, every three years.
Unsafe Operation: Speeding or dangerous turning while operating a PIT poses a significant risk to operators, loads, and the PIT itself. Accidents such as collisions or unit tip-overs, which can result in injuries, fatalities, and product and equipment damage, are much more likely to occur if you operate them inappropriately. PITs should only be used for their designed purposes, safely lifting and moving large, palletized products. Seatbelts must always be worn when operating a PIT.
Loading/Lifting Beyond PIT Capacity: Always be aware of the PIT’s maximum load capacity prior to operation by checking the PIT’s data plate or load chart provided by the manufacturer. The size and weight of the load to be transported always significantly impact the forklift’s stability - it makes the truck unstable. Transporting heavy loads more than the forklift’s maximum load capacity is a definite way to make the truck unstable during travel. This situation could become more dangerous when the surface where the truck is driven is wet, on an incline, or in rough terrain.
A PIT depiction is shown describing the relationship between the load and the PIT counterweight.
Traveling with a Load Elevated: The forks should be just below the front axle height or at a minimum distance from the floor surface. If the load is too bulky or blocking the forward view, travel in reverse and ensure that the mast is tilted back against the backrest to stabilize the load to transport. Keep the load pointed uphill when the forklift travels up or down a ramp with a load. When going up an incline, the load should face uphill, and when going down, travel in reverse instead.
Unsafe or Uneven Terrain: Debris, poor housekeeping, puddles, uneven ground, and any other floor obstructions can all be hazardous when the PIT working area’s floor is in poor condition. A PIT can skid over wet and slick surfaces, while fissures and potholes in the ground might cause the unit to topple over.
Fueling: The gas or other chemicals in refueling or recharging a forklift present possible safety hazards. Both diesel and propane are highly combustible and can create fires or explosions if not handled properly. Recharging batteries can result in a fire hazard due to the fumes produced and an electrocution hazard if they are wet or wires are exposed. Potential ignition sources, such as cigarettes or tools that create sparks, should be kept from refueling sites.
Poor Maintenance: A PIT requires regular maintenance to function safely like any other machine or equipment. In accordance with WAC 296-863-30010, all PITs must be inspected prior to use according to manufacturers’ instructions.
Overhead Obstructions: PITs can face overhead obstructions such as overhead powerlines, mezzanine levels, and low-hanging ceilings. If the loads are raised too high, a collision with obstruction may occur, damaging the load, the PIT, and the overhead obstruction.
What is “Free Rigging,” and is it Permitted?
“Free rigging” is the direct attachment to or placement of rigging equipment (slings, shackles, rings, etc.) onto the tines of a PIT for a below-the-tines lift. This lift type does not use an approved lifting attachment (shown below).
A forklift is shown transporting a load that is rigged below the forklift tines by chain rigging.
Although free rigging is common, it could affect a PIT’s capacity and safe operation. Employers must seek written approval from PIT manufacturers when modifications and additions affect powered industrial trucks' capacity and safe operation. When using a forklift (classifications don’t matter) to perform construction work by lifting with a winch or hook, then 296-155 Part L applies. This adds the requirement for a lift director, qualified rigger, and qualified signal person (when needed) along with the power line rules, etc., all applying.
Resources
Chapter 296-863 WAC-Forklifts and Other Powered Industrial Trucks
WAC 296-863-60005 - PIT Operator Training Requirements
Workers Who Operate or Work Near Forklifts | NIOSH | CDC
Conducting a Daily Inspection of Powered Industrial Trucks | NIOSH | CDC
