Lower Your Risk

Forklifts play a vital role in lifting and transporting heavy loads across all industries, but in the hands of unprepared or inattentive operators, they also carry serious risks. By understanding the most common and completely preventable OSHA violations involving forklifts, you can significantly lower your operational and financial exposure. In this guide, we’ll walk through these risks and show you how a proactive training approach can safeguard your workplace.

Forklift Violations: What to Watch For and How to Respond

When OSHA cites forklift-related issues, the costs can exceed $9,600, with penalties climbing to $13,500 or more. Beyond financial impact, safety remains the priority. Notably, forklift violations consistently rank among OSHA’s top ten. 

When you drill down in their data, the following forklift-related violations stand out as the most common—and, we like to add, the most avoidable. We’ve included the OSHA regulation(s) for each violation in the article for your convenience!

1. Unsafe operation

This category includes some of the most common reasons for citations, such as:

• Driving with an elevated load (Loads should be carried no more than 8 inches off the ground. An elevated load poses a hazard to pedestrians should it fall. Plus, an elevated load may block the driver’s line of sight.)

  1910.178(n)(7)(iii) On all grades the load and load engaging means shall be tilted back if applicable and raised only as far as necessary to clear the road surface.

• Driving too fast (Common sense must apply here since conditions vary.)

  1910.178(n)(8) Under all travel conditions the truck shall be operated at a speed that will permit it to be brought to a stop in a safe manner.

  1910.178(n)(10) The driver shall be required to slow down for wet and slippery floors.

• Driving too close to platform edges (This is a significant cause of tip-over accidents.)

  1910.178(m)(6) A safe distance shall be maintained from the edge of ramps or platforms while on any elevated dock, or platform or freight car. Trucks shall not be used for opening or closing freight doors.

• Not following loading dock safety protocols (Trailers that need to be loaded or unloaded must be secured to prevent accidental movement, that is, have their parking brake on and wheel-chocks in place.)

  1910.178(m)(7) Brakes shall be set and wheel blocks shall be in place to prevent movement of trucks, trailers, or railroad cars while loading or unloading. Fixed jacks may be necessary to support a semitrailer during loading or unloading when the trailer is not coupled to a tractor. The flooring of trucks, trailers, and railroad cars shall be checked for breaks and weakness before they are driven onto.

2. Failure to provide refresher training

Every forklift operator must receive refresher training every three years, and sooner if they are involved in an accident, or if they’re reported for reckless behavior. Forklift operators also need additional training when they must operate a different class of forklift or if a change in the workplace has created a new hazard.

1910.178(l)(1)(i) The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph (l).

1910.178(l)(4)(iii) An evaluation of each powered industrial truck operator’s performance shall be conducted at least once every three years.

3. Missing/inadequate operator certification

Operators must be certified for the specific class of forklift they use. Certification needs to include operator identity, training and evaluation dates, and who conducted them.

1910.178(l)(6) Certification. The employer shall certify that each operator has been trained and evaluated as required by this paragraph (l). The certification shall include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation.

4. Not taking unsafe forklifts out of service

If a forklift needs fixing, it shouldn’t be used until it’s repaired.

1910.178(p)(1) If at any time a powered industrial truck is found to be in need of repair, defective, or in any way unsafe, the truck shall be taken out of service until it has been restored to safe operating condition.

5. Not doing a pre-operation inspection

Use a daily inspection checklist to ensure the safety of your operators and detect minor issues before they become expensive repairs.

1910.178(q)(7) Industrial trucks shall be examined before being placed in service and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily.

Where industrial trucks are used on a round-the-clock basis, they shall be examined after each shift. Defects when found shall be immediately reported and corrected.

Effective Operator Training reduces OSHA citations

Minimizing OSHA citations is simple (and smart) with the right training approach. A comprehensive program, tailored to your specific fleet and environment, makes all the difference. Beyond training, fostering a safety culture is essential. That means:

• Setting and enforcing clear, OSHA-aligned rules

• Empowering operator role models to lead by example

• Recognizing and reinforcing safe behaviors

• Addressing violations with prompt and decisive action

• Tracking retraining schedules with precision

 

When operators are trained, vigilant, and equipped (and equipment itself is maintained with care) the result is fewer injuries, less damage, and a safer, more efficient workplace.

Rely on TrainMOR

When safety matters, rely on TrainMOR. Our training is built around the principles of being Mobile, Memorable, and Measurable, whether delivered online, in the classroom, or on-site.