The purpose of this document is to
define the requirements for safe operations of low lift and high lift forklifts
used on behalf of Jefferson Lab.
This
document provides Jefferson Lab’s minimum requirements for safe operation of
forklifts and attachments.
Requirements
are provided in coordination with ES&H Manual Chapter 6140 Material Handling Equipment Program
and ES&H Manual Chapter 6145 Material
Handling Equipment – Forklifts and Attachments.
3.0
Responsibilities
NOTE: Management authority may be delegated at the
discretion of the responsible manager.
3.1
Qualified Forklift Operators
·
Perform a Pre-Work Analysis prior to forklift operations.
·
Determine the need for Guides or Signalers
·
Perform work in accordance with Forklift Operations
Guidelines listed below including:
o
Rigging loads from the tines of a forklift
o
Attaching rigging to the forks to support a suspended load
o
Performing Critical
Lifts
o
Operating in tunnels and halls or other tight-clearance areas
Refer to ES&H Manual Chapter 6140
Material Handling Equipment Program and ES&H Manual Chapter 6145
Material Handling Equipment – Forklifts and Attachments for overall
responsibilities.
· Familiarize yourself with the area of operation
noting any unusual conditions by performing a Task Hazard Analysis and documenting unusual conditions as
required.
· Select the proper forklift for the job, diesel/propane or electric
powered forklift. (For example: Indoor
use of diesel/propane forklifts is kept to a minimum. They may be used to move a load in or out of
a building, but not within a building.)
·
Evaluate the driving surface and tire-type:
o Pneumatic-type tires: asphalt, concrete, or improved (graveled).
o Solid-type tires: asphalt or concrete surfaces.
· The need for guides and
signalers is identified through the Task
Hazard Analysis, and is determined by load size or
proximity of hazards. However an
operator can request this type of assistance at any time.
· Must be in the operator’s view at all times.
· Remain away from the raised load.
Guides and signalers maintain a distance of at least one foot from the
load for every foot the load is raised.
·
Hardhats are worn by operators, guides, and
signalers when the forklift operation involves lifting the load more than
six-feet above the floor.
· Forklifts are not operated on public highways beyond the Jefferson
Lab site boundaries.
·
Operators, guides and signalers concentrate on the operation of the forklift and the load. The work must be stopped if a distraction is
present.
· Electric forklifts
are charged in approved charging areas which have an eye wash station located
nearby.
·
At the conclusion of the forklift operation, the operator
immediately restores the work area to its pre-work condition, replacing
barriers, ropes, or other items moved for travel or delivery of the load.
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The following sections are transcribed from DOE
Standard 1090-2007; Hoisting and Rigging Standard, Chapter 10 Forklift
Trucks. Paragraph numbering used in
this Reference has been retained for ease of future updates. Portions of the Operators Conduct that do
not apply at Jefferson Lab have been omitted as noted.
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“The
following shall apply to all personnel involved in forklift operations. At the
initial stage of the planning process, an appointed person shall classify each
lift into one of the DOE-specified categories (ordinary, critical, or
preengineered production).
Note:
Preengineered Production lifts are not defined for Jefferson Lab material
handling operations. A Standard
Operating Procedure or Temporary Operational Safety Procedure will be used as
apropriate for forklift operations that are beyond the scope of an ordinary
lift.
10.5.1 CONDUCT OF OPERATOR
The following requirements shall be
observed by the operator when operating forklift trucks.
10.5.1.1
General
a. Safe operation
is the responsibility of the operator. Report all accidents and “near misses”
promptly.
b. The operator
shall develop safe working habits and also be aware of hazardous conditions in
order to protect himself, other personnel, the truck, and other material.
c. The operator
shall be familiar with the operation and function of all controls and
instruments before operating the truck.
d. Before operating
any truck, the operator shall be familiar with unusual operating conditions
which may require additional safety precautions or special operating
instructions.
e. Be certain the
truck has successfully passed a preuse inspection.
f. Do not start or
operate the truck, any of its functions or attachments, from any place other
than from the designated operator’s position.
g. Keep hands and
feet inside the operator’s designated area or compartment. Do not put any part
of the body outside the operator compartment of the truck.
h. Never put any
part of the body within the reach mechanism of the truck or other attachments.
i. Avoid reaching
through the mast for any purpose.
j. To safeguard
pedestrians, understand the truck’s limitations and observe the following
precautions:
1. Do not drive a
truck up to anyone standing in front of an object.
2. Ensure that
personnel stand clear of the rear swing area before conducting turning
maneuvers.
3. Exercise
particular care at cross aisles, doorways, and other locations where
pedestrians may step into the path of travel of the truck.
4. Do not allow
anyone to stand or pass under the elevated portion of any truck, whether empty
or loaded.
k. Do not permit
passengers to ride on powered industrial trucks unless a safe place to ride has
been provided by the manufacturer.
l. Ensure that fire
aisles, access to stairways, and fire equipment is
kept clear.
m. A powered
industrial truck is considered unattended when the operator is more than 25 ft.
(7.6 m) from the truck, which remains in his view, or whenever the operator
leaves the truck and it is not in his view.
n. Before leaving
the operator’s position, the operator shall perform the following:
1. Bring truck to a
complete stop.
2. Place
directional controls in neutral.
3. Apply the
parking brake.
4. Fully lower
load-engaging means, unless supporting an elevated platform.
o. In addition,
when leaving the truck unattended the operator shall perform the following:
1. Stop the engine
or turn off the controls.
2. If the truck
must be left on an incline, block the wheels.
3. Fully lower the
load-engaging means.
p. Maintain a safe
distance from the edge of ramps, platforms, and other similar working surfaces.
q. intentionally ommitted for JLab
r. intentionally ommitted for JLab
s. intentionally ommitted for JLab
t. intentionally ommitted for JLab
u. intentionally ommitted for JLab
v. intentionally ommitted for JLab
w. intentionally ommitted for JLab
x. Care shall be
taken to not contact overhead installations such as lights, wiring, pipes,
sprinkler systems, etc. If in doubt,
measure.
y. Motorized hand
trucks shall not be ridden unless they are of the hand/rider design.
10.5.1.2
Traveling
a. Observe all
traffic regulations and under all travel conditions, operate the truck at a
speed that will permit it to be brought to a stop in a safe manner. Unless
facility specific procedures state otherwise, the guideline is: within plant
buildings – 5 mph; on plant roads – 15 mph. Drive slowly around curves.
b. Yield the right
of way to pedestrians and emergency vehicles. Whenever possible, establish eye
contact with approaching pedestrians or vehicle drivers before continuing.
c. Do not pass
another truck traveling in the same direction at intersections, blind spots, or
at other locations where vision is obstructed.
d. Slow down and
sound horn at cross aisles and other locations where vision is obstructed.
e. Intentionally ommitted for JLab
f. Never travel
with forks raised to unnecessary heights.
Approximately 4 to 6 inches (10 to 15 cm) above floor level is adequate.
g. Intentionally ommitted for JLab
h. Face in the
direction of travel, except if the load being carried obstructs forward view.
In such cases, travel with the load trailing.
i. When ascending
or descending grades, ramps, and inclines:
1. In excess of 5
percent grade, drive loaded rider trucks with the load upgrade.
2. Use low gear or
slowest speed control.
3. Operate unloaded
trucks with the loadengaging means downgrade.
4. The load and
load-engaging means shall be tilted back, if applicable and raised only as far
as necessary to clear the road surface.
5. Avoid turning if
possible, and normally travel straight up and down.
j. While turning,
be cautious of rear end swing and keep clear of the edge of loading docks.
k. Make starts,
stops, turns, or direction reversals in a smooth manner s as not to shift load
and/or overturn the truck.
l. Do no indulge in
stunt driving or horseplay.
m. Slow down for
wet and slippery floors.
n. Before driving
over a dockboard or bridge plate, be sure that it is properly secured.
o. Drive carefully
and slowly across the dockboard or bridge plate, and never exceed its rated
capacity.
p. Intentionally omitted for JLab
q. Unless a towing
hitch is supplied by the manufacturer, do not use forklift trucks as tow
trucks. When a towing hitch is provided, use tow bars rather than wire rope for
towing.
r. At the end of
the operator’s shift, return the forklift truck to its assigned parking place,
set brakes, fully lower load-engaging means, place controls in neutral
position, turn ignition off, and secure the key.
s. If the truck is
equipped with a seat belt, use it.
10.5.1.3 Loading
a. Since the load
rating for forklifts may be based on stability or hydraulic or structural
competence, do not exceed the rated capacity in operational application.
b. The designated
person shall ensure that the weight of a load approaching the rated capacity
(combination of weight and location of the center of gravity) has been
determined within –10 percent, +0 percent before it is lifted.
c. Only stable,
safely arranged loads shall be handled. Block and secure them if necessary.
d. Caution shall be
exercised when handling off-center loads which cannot be centered.
e. Always spread
the forks to suit the load width.
f. Extra caution s
required when handling loads exceeding the dimensions used to establish truck
capacity. Stability and maneuverability may be adversely affected.
g. The forks shall
be placed under the load as far as possible; the mast shall be carefully tilted
backward to stabilize the load.
h. Do not transport
loads or miscellaneous items within the operator’s compartment or other areas
of the truck, unless a secure area has been provided and designated by the
user.
i. A load backrest
extension shall be used whenever necessary to minimize the possibility of the
load or part of it from falling rearward.
j. Do not attach or
operate any attachment on a forklift truck that has not been approved for use
by forklift truck manufacturer or a qualified engineer in the absence of
manufacturer approval.
k. When attachments
are used, extra care shall be taken in securing, manipulating, positioning, and
transporting the load.
l. Operate trucks
equipped with attachments as partially loaded trucks when not handling a load.
m. Fork length
should be at least two thirds of the load length.
n. Use extreme care
when tilting load forward or backward, particularly when high tiering.
o. Do not tilt
forward with forks elevated except to pick up or deposit a load over a rack or
stack.
p. When stacking or
tiering, use only enough backward tilt to stabilize the load.
q. Rigging loads
from the tines of a forklift, (attaching rigging to the forks to support a
suspended load) shall only be performed by qualified personnel in accordance
with approved site procedures.
r. Never lift with
one fork without an engineering analysis and approval.
s. Use guides and
signalers as necessary. If in doubt, check the conditions personally before
proceeding. Standard hand signals are shown in Figure 10.5, “Hand Signals.”
t. Do not block
fire extinguishers, fire protection sprinklers, or alarm stations when stacking
loads.
10.5.2 Intentionally omitted for JLab
10.5.3 STANDARD
HAND SIGNALS
a. Standard hand
signals for use at DOE locations shall be as specified in the latest edition of
the ANSI standards for the particular forklift being used (see Figure 10-5).
b. The operator
shall recognize signals only from the designated signaler. However Obey a STOP
signal no matter who gives it.
c. For operations
not covered by standard hand signals, special signals shall be agreed on in
advance by both the operator and the signal person, and should not conflict
with the standard signals.
