How to Prep for Forklift Work: 5 Essential Measures
Written by Staff Writer
Imagine stepping onto a busy warehouse floor or a bustling construction site without fully knowing what lurks around each corner. Forklifts, also known as powered industrial trucks (PITs), are indispensable in these fast-paced environments — yet their immense power and size can pose significant risks if you’re not properly prepared.
According to the Occupational Safety and Health Administration (OSHA), forklift-related accidents are a leading cause of workplace injuries, and many of these incidents happen because operators skip essential pre-operation steps.
Below, we outline the five must-do actions before turning the ignition on any forklift. By following these crucial steps, you’ll be well on your way to fostering a safer workplace, meeting legal requirements and ensuring that operations go as smoothly as possible. Whether you’re new to forklift operation or an experienced driver in need of a refresher, these guidelines will help you maintain compliance with OSHA standards and protect both people and property.
1. Obtain the Right Forklift Certification
The first, and arguably most important, step before getting behind the controls of a forklift is ensuring you have the proper training and certification. OSHA requires that all forklift operators complete formal instruction, hands-on practice and an evaluation of their performance.
Why Certification Is Key
Legal Compliance: Under OSHA standard 1910.178(I), employers must certify that workers can safely operate powered industrial trucks. Without a recognized certification, you — and your employer — risk costly penalties and potential liability.
Safe Operation: Properly trained drivers are less likely to cause accidents. Knowing how to handle loads, turn corners and navigate tight spaces can drastically reduce workplace injuries.
Versatile Skill Set: Completing an OSHA-compliant forklift certification course means you’re prepared to operate multiple classes of forklifts, including Class I through VII models.
Are you interested in stand-up forklift training? Visit our stand-up forklift certification training to learn more about specialized courses for these maneuverable, space-saving machines. Or, if you’re ready to prove your expertise, check out our forklift driver certification card process to see how quickly you can start working on the warehouse floor.
2. Conduct a Comprehensive Equipment Inspection
A thorough daily inspection is mandatory before operating any forklift. This step ensures you catch mechanical issues, fluid leaks or other potential hazards that might lead to accidents. OSHA requires that if a forklift is used throughout multiple shifts, it should be inspected before each shift begins.
What to Look For
Pre-Operational Checks: Inspect fluid levels, tires, forks, seatbelts and the overall integrity of the machine. Walk around the forklift to look for cracks, leaks or any visible damage.
Operational Checks: Once the pre-operational inspection passes, start the engine and test the brakes, accelerator, horn and steering. Listen for odd sounds and feel for vibrations that could indicate mechanical trouble.
Model-Specific Components: Electric forklifts will require battery and cable checks, while internal combustion trucks demand scrutiny of the radiator, belts and oil levels. Liquid propane models call for verifying the condition of tanks, hoses and connectors.
Learn more about daily inspections and the different types of hazards you might encounter by visiting these additional resources:
By performing daily inspections, you not only ensure compliance but also keep everyone on the job safer. For a more in-depth understanding of forklift inspection requirements, explore our PIT certification training programs to see how OSHA Education Center can help you master this crucial step.
3. Verify a Safe Work Environment
Before you start moving loads, make sure the environment around you is primed for safe forklift operation. In warehouses, distribution centers or construction sites, hazards range from cluttered aisles and uneven floors to poor lighting and congested walkways.
Setting the Stage for Safety
Clear Aisles: Remove obstructions that could cause collisions or prompt you to swerve at high speeds.
Mark Pedestrian Lanes: If possible, set clear boundaries where pedestrians can walk without coming into direct contact with forklift routes.
Adequate Lighting: Dim or flickering lights hamper visibility, increasing the risk of accidents.
Warehouse Safety Protocols: Follow site-specific rules and use safety aids like mirrors and signage.
For more detailed guidance on how to ensure a hazard-free environment, consider compliance training for warehouse safety. You’ll learn to address everything from safe floor design to proper load stacking. Additionally, check out the top 10 OSHA violations to see how forklift operations commonly factor into OSHA citations and how you can avoid becoming part of that statistic.
4. Prepare Yourself: Personal Safety and Readiness
Your personal preparedness is just as important as the condition of the forklift and environment. Operating a forklift requires focus, awareness and the right protective gear.
Key Considerations
Dress Appropriately: Wear steel-toed shoes, fitted clothing that won’t get caught in machinery, and a hard hat if required. Reflective vests also increase visibility in busy settings.
Use Appropriate PPE: Depending on your worksite, you may need gloves, hearing protection or additional gear to safeguard against dust and debris.
Check Your Own Fitness: Avoid operating a forklift if you’re fatigued, ill or taking medications that impair alertness. You should also be at least 18 years old to legally drive a forklift, as OSHA mandates.
If lifting tasks are part of your daily routine, consider brushing up on ergonomics and best practices for manual handling. Our safe lifting techniques and training resources can help you reduce strain and prevent injuries — both on and off the forklift.
5. Plan Your Route and Load Carefully
Even the most robust forklifts have operational limits. Before driving, understand where you’re going and how you’ll handle each load. Poor planning often leads to tip-overs, spilled cargo or collisions with other vehicles and workers.
Load Management
Know the Load Capacity: Each forklift has a clearly marked load capacity plate. Overloading can destabilize the truck, leading to dangerous tip-overs.
Position the Forks Correctly: Make sure loads are centered on the forks and secured against a backrest if available.
Lift Smoothly: Sudden jerks can dislodge cargo. Always lift and lower loads at a steady pace, and keep them close to the ground while traveling.
Route Considerations
Avoid Slopes and Potholes: Traveling over uneven terrain at high speed can unbalance the forklift.
Maintain Safe Speeds: Sharp turns while carrying loads can cause rollovers. Drive cautiously, especially around corners and blind spots.
Communicate: Use your horn or alarms to alert pedestrians and other vehicles of your approach.
Following these steps goes hand in hand with building solid forklift operation habits and preventing accidents. If you’re working in tight or multi-story environments, you might also explore advanced training options such as becoming certified to use a stand-up forklift for narrow-aisle trucks.
Enroll in Our OSHA-Compliant Forklift Training
Fulfilling these five steps before operating a forklift will drastically reduce the risk of accidents, but preparedness doesn’t end here. True safety and compliance require ongoing education, adherence to best practices and a commitment to meeting OSHA’s standard for powered industrial trucks. When you choose the #1 trusted OSHA Training Provider, you benefit from:
100% Online Course: Complete training at your own pace.
Instantly Downloadable Forklift Certificate: Show proof of completion to your employer right away.
Plastic Wallet-Sized Certification Card: A convenient, durable way to demonstrate your qualifications on the job.
Bulk Discounts: Cost-effective for managers looking to train entire teams.
Guaranteed to Pass: Unlimited quiz and exam attempts ensure you master every lesson.
Not sure which training applies best to your specific worksite? Browse additional offerings, like our PIT Certification training, or extend your skills with specialized certifications for safe lifting, pallet jacks or telehandlers. Whatever your needs, OSHA Education Center’s training modules are designed to keep you up to date on the latest regulations and safe work procedures.
Take the First Step to Safe, Compliant Forklift Operation
Whether you’re a seasoned operator looking to renew your license or a complete newcomer eager to learn proper procedures, OSHA Education Center has the training programs you need. Our online courses are carefully structured to help you remain compliant with OSHA 1910.178(I), pass quizzes and final exams with confidence and, most importantly, operate forklifts safely.
Train on your own schedule
Gain official recognition with a plastic forklift certification card
Access expert-led modules, quizzes and unlimited practice exams
Protect yourself, your coworkers and your employer from the consequences of unsafe forklift operations
Don’t wait until an accident or inspection forces a change — take the initiative now. Enroll in our forklift certification course or one of our other specialized PIT training options. If you manage a team, consider purchasing in bulk to get everyone certified efficiently and consistently. Together, we can reduce hazards, boost productivity and keep the work environment aligned with OSHA’s vital standards for forklift operation.
Remember, safety isn’t just a checklist item — it’s a culture, a commitment and a responsibility shared by every member of your organization. Start your journey to safer forklift operations today!
Ensure Safety with Pre-Operation Checks and Daily Inspections
Before operating a forklift, it’s essential to understand what must be done to meet OSHA requirements. Daily inspections and safety procedures ensure that every forklift is safe to use, minimizing the risks of dangerous accidents.
Operators need to inspect critical systems and follow strict pre-operation checks and safety requirements for using a forklift. Remember, proper safety procedures can save lives. By adhering to OSHA requirements and daily inspection procedures for forklifts, you’re not just checking boxes — you’re prioritizing safety for everyone on the job.
Take the first step toward safer operations today. Enroll in our 100% online OSHA-compliant Forklift Certification Course and ensure you and your team are prepared to meet safety standards. Start now and make safety your priority!