Session: 15-06-01: Reliability and Safety in Transportation Systems I

Paper Number: 166664

Review of Risk and Safety Assessments for Powered Industrial Trucks 

Powered industrial trucks (PIT), often referred to as forklifts or lift trucks, are “mobile, power propelled trucks used to carry, push, pull, lift, stack, or tier material”[1] across various industries such as manufacturing, construction, mining and agriculture. Each type of PIT has distinct characteristics and associated hazards. Additionally, workplaces where PITs are used, present a variety of different hazards such as rough, uneven, or sloped surfaces. Many incidents have occurred because of unsafe truck operation or improper maintenance. The Occupational Safety and Health Administration (OSHA) estimated that there are approximately 1.5 million workers in the United States who operate approximately 850,000 PITs.[2] Associated with PIT operation and use, OSHA estimated that annually 35,000 serious injuries, considered to be those that require hospitalization, and 62,000 non-serious injuries occur. According to the Bureau of Labor Statistics (BLS), nearly one hundred workers were fatally injured in 2015. Data analysis has found that the leading cause of fatalities is pedestrians struck by vehicles.[3] In 2018, OSHA established a Local Emphasis Program intended to reduce the number of fatal and nonfatal injuries related to PITs in construction and general industry.

 

OSHA regulations on PITs are found in 29 CFR 1910.178[4] for general industry and 29 CFR 1926.602(c)[5] for construction. These regulations address requirements for design, maintenance and use of PITs including extensive requirements for operator training. There are also several industry standards for powered industrial trucks. For example, for rough terrain forklift trucks, ANSI/ITSDF B56.6, Safety Standard for Rough Terrain Forklift Trucks, provides safety requirements relating to design, operation, and maintenance of these vehicles. These trucks are intended for operation on unimproved natural terrain as well as the disturbed terrain of construction sites. ANSI/ITSDF B56.1, Safety Standard for Low Lift and High Lift Trucks, addresses the design, construction, application, operation and maintenance of low lift and high lift powered trucks. In this industry standard, low lift vehicles are considered trucks equipped with an elevating mechanism to raise a load for horizontal movement such as a low lift order picker truck and high lift vehicles are trucks equipped with an elevating mechanism to permit tiering such as a sit-down four-wheel rider. In all cases, these vehicles are equipped with various safety features intended to protect the operator and nearby personnel.

 

This paper will focus on identifying and defining the hazards and safety mitigation measures associated with the use of PITs. It will review PIT injury data to better understand trends, quantify the risks related to PIT usage, and explore the engineering and administrative controls currently available to address these hazards. Additionally, a brief overview of recent updates to relevant standards will be included.

 

[1] ASME B56.1-1969, Safety Standard for Low Lift and High Lift Trucks

[2] https://www.osha.gov/sites/default/files/enforcement/directives/CPL_04-00-023F.pdf

[3] https://www.osha.gov/sites/default/files/enforcement/directives/CPL_04-00-023F.pdf

[4] https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.178

[5] https://www.osha.gov/laws-regs/regulations/standardnumber/1926/1926.60

Presenting Author: Okanmisope Fashanu Exponent

Presenting Author Biography: Dr. Fashanu is a senior mechanical engineer. His expertise includes failure analysis, mechanical testing and analysis, industrial accident investigations, machine safety, quality reviews, and compliance and safety investigations.

Authors:

Okanmisope Fashanu Exponent
Amin Ajdari Exponent
Eugenia Kennedy Exponent