TITLE:	ES&H Manual
DOCUMENT ID:	6145 Forklift Safety

1.0 Purpose

This document defines Jefferson Lab’s policy regarding the purchase and use of powered industrial trucks (forklifts). Jefferson Lab recognizes that safe operation of forklifts depends on the skills of the operator and the condition of the vehicle, therefore, only qualified personnel purchase, operate, and maintain forklifts which are inspected and maintained to enhance safety.

Jefferson Lab bases its forklift program using 29 CFR 1910.178 “Powered Industrial Trucks” and American National Standards Institute (ANSI)/ITSDF B56.1 – 2005 Safety Standard for Low Lift and High Lift Trucks.

2.0 Scope

This chapter and its appendices apply to forklift use and operators qualified by Jefferson Lab.

3.0 Responsibilities

NOTE: Management authority may be delegated at the discretion of the responsible manager.

3.1 Material Handling Equipment Representative (MHER)

· Considered the Jefferson Lab subject matter expert (SME) for forklifts.

· Provides oversight of forklift attachment adequacy, annual inspection, and operator training.

3.2 Material Handling Safety Representative (MHSR)

· Ensures operators are trained and qualified in accordance with Jefferson Lab’s requirements.

· Reviews Lift Plans and observes all critical lifts

· Provides oversight of the Jefferson Lab forklift program including:

o Approval of purchase requests for vehicles and attachments.

o Manages the inspections, maintenance, and repair requirements and maintains these records on file.

o Conducts initial safety inspections of forklifts.

o Authorizes repairs and maintenance requirements to forklifts.

o Maintains the list of qualified operators.

o Maintains the vehicle and attachment key distribution system.

o Coordinates forklift safety documentation through the construction project Subcontracting Officer’s Technical Representative (SOTR) on access restricted construction sites.

3.3 Supervisor/SOTR:

· Acknowledges that an employee needs to operate a forklift prior to commencement of training.

o Inclusion of SAF502 Forklift/Forktruck Operator Training in an employee’s Skills Requirements List (SRL) constitutes supervisory approval.

· Acknowledges that an employee needs to use a forklift attachment prior to commencement of training.

o Inclusion of SAF 502B in an employee’s SRL constitutes supervisory approval.

3.4 Forklift Operators – Includes anyone (staff; users; service and construction subcontractors) using a forklift.

Requirements:

· Possess a valid State Motor Vehicle Driver’s License and carry it while operating the forklift.

· Completes classroom and practical training through SAF502 Forklift/Forktruck Operator Training or equivalent as determined by the MHSR.

Responsibilities:

· Inspect the forklift before use in accordance with the forklift manufacturer’s operators manual and ES&H Manual Chapter 6145 Appendix T1 Use of Forklifts.

3.5 Jefferson Lab Qualified Operators:

· Report forklift damage or malfunctions to the MHSR.

· When using a forklift at another facility to conduct Jefferson Lab business:

o Reviews the facilities forklift policies and procedures.

o Follows the more stringent safety procedures.

3.6 Subcontracting Officer Technical Representative (SOTR)

· Monitors subcontractor’s work to ensure compliance with Jefferson Lab requirements.

o Informs subcontractors that forklifts and attachments are to be inspected by the MHSR upon arrival at Jefferson Lab.

o Notifies the MHSR when subcontractors will bring forklift equipment on site and coordinates inspections.

o Notifies the MHSR and coordinates critical lifts.

o Ensures subcontractor’s operators are adequately trained and qualified minimally to Jefferson Lab policies and procedures.

o Monitors the performance of subcontractor employees forklift operations and notifies MHSR of any concerns.

· Coordinates with MHSR on access restricted construction sites to ensure the requirements of the referenced standards are satisfied.

o The MHSR must acknowledge, in writing, that “the evaluated knowledge and capabilities of the SOTR and project support staff are adequate” along with providing the level of responsibility to be assumed.

3.7 Procurement Department

· Ensures MHSR approval prior to purchasing forklift equipment.

· Ensures material handling safety requirements are included in subcontract document when forklift operation is anticipated.

3.8 Occupational Medicine

· Evaluates forklift operators in accordance with ES&H Manual 6820 Medical Monitoring to ensure they are physical capable of operating a forklift safely.

4.0 Expectations

4.1 Forklift Equipment Purchase, Lease, and Maintenance:

· Purchases or lease of: forklifts, forklift attachments, and maintenance services are reviewed and approved by the MHSR.

· Purchases Request using an account code of 043-028 – Material Handling Supplies & Equipment, are used for these types of procurement.

· The use of P-Cards is not permitted for material handling supplies and equipment.

4.2 Receipt Inspection

· New purchase of forklifts, other powered industrial vehicles, and attachments are inspected by the MHSR upon arrival per Jefferson Lab’s Receiving Inspection and Acceptance Testing Procedure.

o Equipment that does not comply with Jefferson Lab standards is tagged and quarantined to prevent inadvertent use using the Control of Nonconforming Material or Products Procedure.

· Leased and subcontractor provided powered industrial trucks and attachments used on Department of Energy (DOE) property or leased spaces will receive an initial inspection by the MHSR upon arrival. The equipment must comply with the requirements of the referenced Occupational Safety and Health Administration (OSHA) and ANSI standards. Equipment that does not comply with Jefferson Lab standards is tagged to prevent inadvertent use using the Control of Nonconforming Material or Products Procedure. The tag will remain in place until the equipment is removed from site or brought into compliance with the referenced standards to the satisfaction of the Jefferson Lab MHSR.

o The receipt inspection requirements and compliance with referenced standards applies to subcontractor owned and leased forklifts and forklift attachments.

4.3 Forklift Operator Training and Qualification Requirements:

· Medical monitoring per ES&H Manual Chapter 6820 Medical Monitoring Policy and Procedure.

· Employees and Service Subcontractors are trained for proper operation of forklifts upon request by the worker’s supervisor or SOTR.

o Initial Forklift Operator Training is SAF 502. This training is administered in a classroom setting followed by a practical skills exam conducted in the field using the forklift that the worker will be using to accomplish work requirements.

o Subsequent retraining is accomplished through SAF 502A at three-year intervals. This training is an internet accessed training conducted on a computer which includes an evaluation component to verify comprehension. Contact the Jefferson Lab Training Manager to obtain guidance and a password for this training.

o Additional training is required prior to the use of forklift attachments. SAF 502B – Forklift Attachment Training is an instructor-led training offered as needed for qualified forklift operators. Contact the MHER to arrange for the training.

o An instance of unsafe operation, or an accident, or a near-miss incident will result in disqualification of the employee or subcontractor’s privilege to operate a forklift or use of attachments until retraining is accomplished.

4.4 Avoidance of Duplicative Training:

· If an employee or subcontractor has previously received forklift operator training that satisfies Jefferson Lab training requirements and can demonstrate knowledge and skill to perform the duties of an operator, there is no reason to require the person to repeat that operator’s training. The MHSR may, at his discretion, accept a person’s previous training. The MHSR may also expand an existing operator’s access to additional types of forklifts with additional training in any element(s) that differ from previously trained types of equipment and/or changes in workplace conditions.

4.5 Restriction of Access to Forklifts:

· Access to forklifts is controlled through the use of electronic key boxes. Upon satisfactory completion of required training and medical surveillance, the MHSR provides qualified operators with access to specific keys.

· Unauthorized use of forklifts results in disciplinary action in accordance with Administrative Manual - 212 Voluntary & Involuntary Separations.

· At the completion of use operators return equipment to the appropriate garage and the key to the designated box.

4.6 Authorized Forklift Operation:

· Forklifts are operated in accordance with instructions contained in the manufacturer’s Operator’s Manual kept in the pocket behind the operator’s seat back.

o Refer to ES&H Manual Chapter 6145 Appendix T1 Use of Forklifts for additional/general and site specific operating instructions.

· If during operation the forklift becomes unsafe in any way, contact the MHSR immediately. Forklifts are not operated unless they are in safe operating condition.

· The MHSR authorizes all repairs to forklifts.

4.7 Authorized Use of a Forklift Attachment:

· Use of forklift attachments is restricted using ES&H Manual Chapter 6111 Administrative Control using Locks and Tags and a carbon fiber cable type lock. Access to keys for each attachment is controlled through the use of electronic key boxes. Upon satisfactory completion of Forklift Attachment Training the MHSR provides qualified operator with access to the specific keys.

o Operators are not authorized to share a forklift attachment key with anyone.

o At the completion of use the operator returns the attachment to appropriate garage and the key to the designated box.

· Attachments are only to be used on authorized forklifts.

· Forklift manufacturers evaluate any attachment and approve its use. Manufacturer’s approval of an attachment is listed on a load plate attached to the forklift.

· Refer to ES&H Manual Chapter 6145 Appendix T2 Forklift Attachments – Use and Inspection for forklift attachment inspection, use and maintenance instructions.

5.0 References

5.1 29 CFR 1910.178 Powered Industrial Trucks

5.2 29 CFR 1910.176 Handling Materials – General

5.3 ANSI B56.1 Powered Industrial Trucks

5.4 DOE Standard 1090-2007; Hoisting and Rigging Standard-Chapter 10 Forklift Trucks

5.5 ES&H Manual Chapter 6145 Appendix T1 Use of Forklifts

5.6 ES&H Manual Chapter 6145 Appendix T2 Forklift Attachments – Use and Inspection

5.7 ES&H Manual Chapter 6145 Appendix T3 Requisition Procedure for Forklifts

ISSUING AUTHORITY	CHAPTER AUTHOR	APPROVAL DATE	EFFECTIVE DATE	EXPIRATION DATE	REV.
ESH&Q Division	Dave Kausch	04/24/09	04/24/09	04/24/12	1

This document is controlled as an on line file. It may be printed but the print copy is not a controlled document. It is the user’s responsibility to ensure that the document is the same revision as the current on line file. This copy was printed on 9/3/2009.