Overview and Objective

This article provides agencies with the tools necessary to review the safe use of powered industrial trucks, commonly referred to as "PITs", in accordance with the Occupational Safety and Health Administration (OSHA) 29 CFR 1910.178 guidelines. Operator training, operator evaluation and operator certification are reviewed.

The article also includes information on where to obtain forms and materials to assist agencies in complying with the OSHA Powered Industrial Truck Standard such as:

• Sample performance test for forklift operators
  
  http://www.osha.gov/dcsp/ote/trng-materials/pit/test.pdf


• Sample Daily Checklists for Powered Industrial Trucks
  
  http://www.osha.gov/dcsp/ote/trng-materials/pit/pit_checklist.html


• PowerPoint Presentation for Operator Training
  
  http://www.osha.gov/dcsp/ote/trng-materials/pit/ppt/pit-pp97.ppt


• Sample Training Program Outline
  
  http://www.osha.gov/dcsp/ote/trng-materials/pit/trg_outline.pdf

Background

A powered industrial truck is a mobile, power-propelled truck that is used to carry, push, pull, lift, stack or tier materials. There is a wide range of equipment, each designed for specific industries and uses. Manufacturers classify powered industrial trucks according to each truck's individual characteristics. There are seven classes of trucks:

• Class One: Electric motor, sit-down rider, counter-balanced trucks with either pneumatic or solid tires;


• Class Two: Electric motor, narrow aisle trucks that use solid tires;


• Class Three: Electric motor hand or hand/rider trucks that use solid tires, commonly referred to as electric pallet jacks;


• Class Four: Internal combustion trucks, using solid tires. These are the most common types of forklift. They can be gas, diesel or propane powered;


• Class Five: Internal combustion engine trucks, using pneumatic tires;


• Class Six: Electric and internal combustion engine tractors with pneumatic tires;


• Class Seven: Rough terrain forklift trucks that use pneumatic tires, more commonly used in construction.

Powered industrial truck accidents cause approximately 100 fatalities and 20,000 serious accidents in general industry and construction annually.¹ Inadequate training, at least in part, causes 20 - 25 percent of the accidents, according to estimates.²

OSHA published operator-training requirements for powered industrial trucks on December 1, 1998. The operator training section applies to all industries except agricultural operations. OSHA estimates that the new rule will prevent 11 deaths and 9,422 injuries each year.³

The powered industrial truck operator training requirements are performance-oriented. Employers must customize their training program to the characteristics of the workplace and the particular type of powered industrial trucks operated. The training must be specific to the type of forklift at your facility, the layout and design of the facility, and the materials being handled.

Operator Training

Only trained and authorized personnel are permitted to operate a powered industrial truck. OSHA 1910.178(l)(1)(i) states, "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 the paragraph (l)."

Individuals who have the knowledge, training and experience to train and evaluate potential operators must conduct all operator training and evaluation. Trainers can attend a train-the-trainer program offered by forklift manufacturers, consulting companies, or by the Office of Workers' Compensation.

Manufacturers produce many different models of powered industrial trucks. The training program must be specific to the operating characteristics of the specific truck the employee will be using. Trainees must be initially trained in the following truck-related topics:

• Operating instructions, warnings, and precautions for the type of truck


• Similarities and differences to automobiles


• Control and instrumentation location and use


• Engine or motor operation


• Steering and maneuvering


• Visibility


• Fork and attachment limitations and use


• Vehicle capacity


• Vehicle stability


• Vehicle inspection and maintenance


• Refueling and battery charging


• Operating limitations


• Other operating instructions, warnings, or precautions listed in the operator's manual

In addition to the above truck-related topics, the training program must review the specific workplace conditions the operator may encounter. Trainees must be initially trained in the following workplace-related topics:

• Surface conditions where the truck is used


• Load composition and stability


• Load stacking, unstacking, and transport


• Pedestrian traffic


• Narrow aisle and restricted area operation


• Operation in hazardous locations


• Ramp and sloped surface operation


• Unique or potentially hazardous conditions


• Operating the vehicle in closed environments

The training program must review the requirements of the OSHA standard on powered industrial trucks in the initial operator-training program. Once the operator training is completed, it is a best practice to review any facility specific operating procedures, operators' daily checklists, and powered industrial truck safety rules.

Operator Evaluation

An obstacle course representing typical forklift activities is set up for each operator to complete. A facility-designated qualified trainer must set up the obstacle course and perform the evaluation. OSHA 1910.178(l)(2)(i)(A) states "Trainees may operate a powered industrial truck only: Under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence".

The qualified trainer must conduct an evaluation of each powered industrial truck operator's performance after initial training, after refresher training, and at least once every three years. The qualified trainer should document the evaluation and place it in the operator's training file.

Refresher training is also required when the qualified trainer observes or deems retraining based on:

• An unsafe operation


• Accident or near-miss


• Need identified in evaluation


• Introduction of different type of equipment


• Change in workplace conditions

Operator Certification

The last step in meeting the powered industrial truck requirements is to issue a certificate to each properly trained and evaluated operator. The powered industrial truck operator certificate must contain:

• The name of the operator


• The date of the training


• The date of the evaluation


• The identity of the person(s) performing the training or evaluation

This article has reviewed the compliance requirements for the safe operation of powered industrial trucks. Agencies without a powered industrial truck trainer have training resources available, including local forklift suppliers and the Office of Workers' Compensation. Forklift suppliers often offer operator training classes and train-the-trainer classes for free or for a nominal fee. The Office of Workers' Compensation periodically schedules classroom-only powered industrial truck train-the-trainer programs at no cost to state government agencies.

¹ National Institute for Occupational Safety and Health (NIOSH) (2001, June). NIOSH ALERT: Preventing Injuries and Deaths of Workers Who Operate or Work Near Forklifts. Retrieved July 23, 2004, from The Centers for Disease Control (CDC) at: http://www.cdc.gov/niosh/2001-109.html.

² National Institute for Occupational Safety and Health (NIOSH) (2001, June). NIOSH ALERT: Preventing Injuries and Deaths of Workers Who Operate or Work Near Forklifts. Retrieved July 23, 2004, from The Centers for Disease Control (CDC) at: http://www.cdc.gov/niosh/2001-109.html.

³ U.S. Department of Labor, Occupational Safety & Health Administration. Powered Industrial Trucks, Summary of Standards. Retrieved July 23, 2004, at: http://www.osha.gov/dcsp/ote/trng-materials/pit/std_summary.pdf.

Resources:

U. S. Department of Labor, Occupational Safety & Health Administration, 29 CFR 1910.178, Retrieved June 21, 2004, at
http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9828

Washington State Department of Labor and Industries. Forklift Safety Page, Retrieved July 23, 2004, at http://www.lni.wa.gov/Safety/Topics/AtoZ/Forklift/default.asp.

Illinois Onsite Safety and Health Consultation Program. Resources, Retrieved July 23, 2004, at http://www.illinoisbiz.biz/osha/resource.htm.

Sample performance test for forklift operators - U. S. Department of Labor, Occupational Safety & Health Administration, 29 CFR 1910.178, Retrieved July 23, 2004, at http://www.osha.gov/dcsp/ote/trng-materials/pit/test.pdf

Sample Daily Checklists for Powered Industrial Trucks - U. S. Department of Labor, Occupational Safety & Health Administration, 29 CFR 1910.178, Retrieved July 23, 2004, at http://www.osha.gov/dcsp/ote/trng-materials/pit/pit_checklist.html

PowerPoint Presentation for Operator Training - U. S. Department of Labor, Occupational Safety & Health Administration, 29 CFR 1910.178, Retrieved July 23, 2004, at http://www.osha.gov/dcsp/ote/trng-materials/pit/ppt/pit-pp97.ppt

Sample Training Program Outline- U. S. Department of Labor, Occupational Safety & Health Administration, 29 CFR 1910.178, Retrieved July 23, 2004, at
http://www.osha.gov/dcsp/ote/trng-materials/pit/trg_outline.pdf