When an operator jumps or is thrown from an overturning forklift, more often than not they end up trapped under the overturned forklift and a fatality occurs.

There are several instances where a forklift can tip over; these include rolling or overturning the forklift sideways or by pitching forward when the back wheels lift off the ground.

According to a guide on forklift safety from Workplace Health and Safety Queensland, forklifts can tip over if you:

• collide with another vehicle

• brake too quickly, especially with a loaded forklift

• brake or accelerate while cornering

• accelerate quickly in reverse

• carry a load facing down a slope

• brake or accelerate down a slope

• carry an unevenly balanced load

• drive with the tines raised too high (loaded or unloaded)

• strike low doors or overhead structures

• drive across inclines or uneven ground such as potholes (particularly with a height difference greater than 20mm across the front wheels)

• turn too fast

Information for this article was sourced from www.worksafe.qld.gov.au. For further forklift safety information contact MLA Holdings on 131 652 or www.mlaholdings.com.au.

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What is a forklift’s rated load capacity?

Australian Standard AS2359.1:2015 clause 2.2 states ‘The rated capacity is the maximum capacity established by the manufacturer based on component strength and truck stability’. A forklift’s rated load capacity is the maximum weight in kilograms that a forklift can safely lift and transport at a specified load centre distance in millimetres. This rated load capacity is listed on the forklifts name plate or load capacity data plate.

What is a load capacity data plate?

A forklift’s load capacity data plate is a notice plate on the forklift visible to the operator from the operating position that displays the rated load capacity taking into account the lift height, mast tilt angles, tyre specifications, forklift attachments and load centre distances. Other safety information and relevant data is also listed on the load capacity data plate.

Consider the following tips to increase your forklift safety:  

1.       Identify which forklift best suits your workplace’s needs, keeping in mind load capacity and safety features

2.       Provide forklift operators with the adequate training and knowledge to interpret the load capacity plates

3.       Purchase or hire forklifts with slightly larger load capacities then what is actually needed

4.       Be aware of operating conditions and your forklift load capacity and ensure that it is never exceeded

5.       Ensure that load capacity data plate is correct and readable

6.       Evaluate the safe load capacity with oversized loads

7.       Use a scale to check the weight of an object or check the marked weight of an object

8.       If the stated load centre distance is exceeded then counteract this by reducing the weight of the load accordingly.

MLA is able to assess material handling applications and provide advice regarding the safest and most efficient forklifts and attachments. Information for this article was sourced from Australian Standard 2359.1:2015

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1. Boosting productivity

When your drivers are uncomfortable, it's a big distraction – and they tire more quickly, too. That lack of focus reduces performance, while increasing the risk of accidents.A well thought-out cab puts all the controls within arm's reach, allowing the driver to keep their mind on the job and their eyes on the environment. It also reduces the need for unnecessary movements keeping the driver feeling fresher for longer.

2. Eliminating strain

Strain-related injuries suffered by drivers can have long-term impact on their health. The neck, shoulders, upper back and forearms are all particularly susceptible, mainly through overstretching for levers and excessive cab vibration. With sick pay and potentially compensation, good ergonomic design makes sound economic sense.

Pay special attention to reach trucks - where mounting and dismounting the truck over 100 times in a shift can really take its toll on the operator's joints. Simple touches like wide, non-slip steps, good grab handles and a lower seat position can reduce the strain enormously... And some trucks go further still. When Mitsubishi designed the SENSiA range of reach trucks, we even created a console that folds away to make things as easy as possible.

3. Reducing damage

Visibility is a factor in up to 80% of accidents, so look for a cabin design that gives clear, wide open views all around – as well as a high vision mast.Good ergonomics helps here, too. Obviously, a tired or distracted driver is not going to be at their sharpest – and that makes accidents more likely. Since two-thirds of forklift accident victims are colleagues on foot, helping the driver to focus makes work safer for everyone.But reducing accident risk doesn't just protect your workforce. If it happens often enough, minor damage to trucks, racking and stock can quickly add up to a huge – and largely uninsured – expense.

4. Protecting limbs

Working in very tight and confined spaces, it is vital to consider the space within a reach truck's compartment to ensure it is big enough to protect all of your driver. A compartment which is too small could result in an operator's shoulder, arm or leg protruding from the compartment... creating a very real danger of trapping or scraping a limb against racking walls. In developing SENSiA, Mitsubishi designers looked to maximise the space available within the compartment itself – ensuring operators' limbs are protected against injuries during narrow aisle operations.

Information for this article was sourced from www.forkliftbriefing.com.

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Australian Standard AS 2359.12 –Powered industrial trucks: hazardous areas, defines hazardous areas as "areas that may be hazardous because of the presence of an explosive gas/vapour atmosphere or combustible dusts." AS2359.12 classifies hazardous areas in two groups. The first, known as Class I, is made up of flammable gases, vapours and liquids. The second group, consisting of combustible dusts, is known as Class II.

Modified forklifts that can operate in these areas are more commonly known as flameproof forklifts. AS2359.12 lists 26 relevant specific requirements of a flameproof vehicle. Depending on its classification, the vehicle may need to comply with one or more of these requirements, as illustrated in Table 1. For a full list of the relevant specific requirements, refer to Australian Standard AS 2359.12.

Flameproof forklifts must be clearly marked, as per Requirement 6 of AS 2359.12. Requirement 6 states: "Vehicles shall be permanently and clearly marked with a minimum of one label indicating the hazardous areas in which operation is permitted."

Operating flameproof forklifts in hazardous areas can be extremely dangerous. Operation, modifications, maintenance, and repairs must be fully compliant with Australian Standard AS 2359.12 –Powered industrial trucks: hazardous areas. Failure to do so is not only illegal, but may lead to serious consequences.

MLA Holdings has provided flameproof forklifts for use in hazardous areas to many of its clients. Information for this article was sourced from AS 2359.12 –Powered industrial trucks: hazardous areas.

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Driving with an elevated mast is dangerous. It makes the forklift less stable and leads to tipping over, particularly if the forklift is being driven at speed. When the mast is elevated and the forklift is in motion, the quicker it travels the higher the likelihood of the forklift tipping. Unfortunately driving fast with the mast elevated is common practice in some workplaces where operators drive recklessly, have inadequate training, or are under pressure to complete their workload as quickly as possible.

In June 2015 a revised version of the Australian Standard for forklifts (AS2359.1:2015) was released. This standard now requires specific model forklifts sold in the Australian market to be equipped with a travel speed / mast elevation interlock to positively prevent the operator from driving fast with the mast elevated.

Australian Standard AS 2359.1:2015 - Powered industrial trucks Clause 8.2.3 is titled: "Speed reduction for ride-on electric trucks with an elevated mast" and states: "For electric counterbalance and reach trucks, the truck speed
shall be reduced to a maximum speed of 3km/h when:

(i) The mast is above staging (maximum free lift) for trucks with a mast with full free lift.

Or

(ii) The forks are lifted more than 800mm from the ground for trucks with a mast that has limited free lift."

As of June 2015, all manufacturers are required to offer the travel speed reduction with mast elevated on new electric trucks they supply in Australia. Operators and supervisors are advised to ensure their new electric counterbalance and reach trucks have this feature and enquire if an upgrade for their existing fleet of trucks is available in order to help avoid tipping accidents.

Staying ahead of the game and the competition, MLA Holdings and Mitsubishi Forklifts began offering this feature on their electric counterbalance and reach trucks at the beginning of 2014. Every new electric Mitsubishi forklift and reach truck will be delivered with the travel speed reduction feature, ensuring maximum operator safety.

This feature is currently not available on LPG and diesel forklifts as the technology on these trucks does not permit manufacturers to make the modification. Information for this article was sourced from Australian Standard AS 2359.1:2015 and www.forkliftbriefing.com. For more information contact MLA Holdings.

WorkCover NSW states that; "Attachments include any side shift devices, jibs, extension tynes and specifically designed devices for load manipulation or carrying."

It is crucial to remember that if an attachment is fitted to a forklift, the dynamic and operating characteristics may change, making it necessary to de-rate the forklift capacity and restrict some operating controls. A change in a forklift's centre of gravity may make the forklift unstable and susceptible to tipping over incidents. All forklifts must have details of the attachments and the rated capacity when using the attachment listed on the forklift's load rating plate.

Attachments must be designed for the forklift that they are to be fitted to. Make sure the attachment is secured correctly and safely on the forklift. Because different attachments have a different effect on the forklift's capacity and stability, it is advised to always travel at a safe speed and take greater care when manoeuvring the forklift. When selecting an attachment, WorkCover NSW advises that attachments must be:

• Designed by a competent engineer
• Manufactured by competent people
• Safely used on the forklift

Specific skills require additional training and supervision. Employers must ensure that where attachments are used, further training is given to forklift operators and adequate supervision is provided. It's important that operators understand the effect attachments have on a forklift's capabilities before they operate it.

MLA Holdings are able to rate and fit a wide variety of attachments to its Mitsubishi forklifts. All attachments provided by MLA are manufactured by and sourced from competent suppliers.

Information for this article was sourced from WorkCover NSW.

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