Document No: Page:

HSE Procedure 1 of 7
Supersedes: Revision:
Forklifts Rev. 4
Issuing Department: Approval: Issue Date: Effective Date:
Corporate HSE

Table of Contents
1.0 PURPOSE AND SCOPE......................................................................................................................................................1
2.0 RESPONSIBILITIES...........................................................................................................................................................1
2.1. Site Manager................................................................................................................................................... 1
2.2. Supervisor....................................................................................................................................................... 1
2.3. Employee......................................................................................................................................................... 2
2.4. Designated Competent Person....................................................................................................................... 2
3.0 PROCEDURE....................................................................................................................................................................... 2
3.1. Operating Rules............................................................................................................................................... 2
3.2. Lifting and Transporting Loads........................................................................................................................ 3
3.3. Parking and Stopping...................................................................................................................................... 4
3.4. Personnel Basket and Platform Use With Forklifts..........................................................................................4
3.5. Forklift Refueling and Recharging...................................................................................................................4
3.6. Charging.......................................................................................................................................................... 4
3.7. Entering Process and Regulated Areas..........................................................................................................5
3.8. Inspection and Storage.................................................................................................................................... 5
3.9. Training............................................................................................................................................................ 5
3.10. Environmental.................................................................................................................................................. 6
4.0 REFERENCES AND RELATED DOCUMENTS............................................................................................................6
5.0 FIGURES.............................................................................................................................................................................. 6
Forklift Daily Safety Checklist...................................................................................................................................... 7

1.0 PURPOSE AND SCOPE

This HSEP provides the minimum procedures to be followed when employees operate forklifts. It
applies to all employees and on-site contractors operating forklifts and engaged in operations
covered by the Jacobs HSE Program
2.0 RESPONSIBILITIES
General responsibilities for HSE Program implementation are stated in HSEP 1.5. Additional
management, staff, employee, and subcontractor responsibilities that address duties specific to
this topic are stated in this procedure.
2.1. Site Manager
The Site Manager must assume ownership and responsibility for implementation of the policy and
procedures found in this HSEP.
The Site Manager, along with Corporate HSE shall facilitate the designation of a Competent
Person to conduct forklift training.
2.2. Supervisor
Supervisors responsible for employees operating forklifts shall:
 Ensure that forklift operators have been properly trained in accordance with this HSEP,
and
 Continuously monitor the work to assure all forklift operations are being conducted in
accordance with this HSEP.
2.3. Employee
Employees must
 receive forklift training prior to operation, and
HSEP 17.4 Page 2 of 8
Forklifts Rev. 4, 01-Sep-12

 operate forklifts within the procedures set forth in this HSEP and according to training
received.
2.4. Designated Competent Person
Competent Persons shall
 assist Site Management in compliance with this HSEP, and
 conduct Forklift Operator training.
3.0 PROCEDURE
3.1. Operating Rules
Only trained and certified operators may operate a forklift.
Supervisors shall assure that operators have reviewed the operating instructions, warnings, and
precautions for the type(s) of truck the operator will be authorized to operate.
The first person to use a forklift each day must thoroughly inspect the forklift prior to use.
Defective forklifts shall not be operated. Supervision must be notified immediately if damage or a
defect develops during operation.
All established traffic regulations shall be complied with by forklift operators.
Seatbelts must be worn during forklift operation. They must be inspected, properly maintained,
and replaced when defective.
When moving forward empty, always move at a moderate speed, avoiding sudden stops, starts,
and skidding. Avoid rough/uneven surfaces and debris. Travel slowly on slippery surfaces.
Horseplay, such as racing, traveling at high speeds, spinning, etc., is not permitted.
Never permit anyone to ride on any part of a forklift.
When backing, always proceed more slowly, since it is more awkward to operate the controls in
this position, and reaction time is increased.
The backup alarm should sound at all times when the unit is in reverse.
When moving, forks should be about 6” from the floor and tilted back slightly.
Before crossing railroad tracks, stop and make sure the way is clear. Hold the steering wheel
firmly and cross the tracks diagonally.
Never use reverse as a brake. Stop the vehicle with the brakes before changing your direction of
travel.
Always sound horn before rounding corners, entering or exiting doorways, and to warn
pedestrians that may not see you of your approach.
When it is necessary to use the forklift for towing, be sure the forklift was designed for this
purpose, and use only the attachments designed for towing.
Never tow rail cars or attempt to open rail car or trailer doors with forklift.
Pushing a forklift with another forklift or any other vehicle to get it started is prohibited.
Always know the position of the rear wheels, as they tend to swing outward during turning.
When traveling between indoors and outdoors, allow your eyes time to adjust to the lighting
differences.
Never wear sunglasses indoors when operating a forklift.
Never use a gasoline or diesel powered forklifts inside buildings, trucks, trailers, or railcars
without proper ventilation. Carbon monoxide can accumulate which has the potential to result in
serious injury or death.
HSEP 17.4 Page 3 of 8
Forklifts Rev. 4, 01-Sep-12

3.2. Lifting and Transporting Loads

The capacity of forklifts shall not be exceeded.
When you approach the load, slow down gradually, stop, and adjust the forks to the proper height
and position them so that they are spread as wide as possible while maintaining firm contact with
the load, then slowly proceed under the load.
Be very cautious that the forks do not puncture the load due to improper positioning of the fork
height.
Be sure that all loads are properly stacked and arranged and that they are stable. Never attempt
to handle an unstable load.
Avoid carrying loose material on the forks; use pallets. Pallets should always be maintained in
good condition and replaced when necessary.
When traveling with a full load, forks should be adjusted to about 6” from the floor after picking up
the load.
Never travel while raising or lowering your forks. This practice greatly increases the chance of
overturning the forklift or toppling the load.
Always travel at a slow-to-moderate speed. Turn corners very slowly.
Be extremely careful with overhead clearance. This is difficult to judge if the load is being raised
very high. Contact with overhead objects is a common cause of forklift accidents that can result
in serious injury or death.
If the size of the load creates a problem with forward visibility, the load should be moved in
reverse. This should be done slowly. Greater visibility makes this desirable and safer.
When moving a load on an incline, always move down the incline in reverse and up the incline
going forward. In other words, always have the load on the upgrade side of the forklift. Never
allow anyone to walk ahead of the forklift or load while they are on an incline.
Do not stand or walk under elevated forks or loads.
Never raise the load while on the way to the destination. As you approach the destination, slow
down, stop, raise the load, and proceed to slowly set it in place.
Brakes should always be applied slowly except in emergencies.
After placing the load, slowly back up until the forks are clear of the stack, then stop and lower the
forks to within 6” of the floor.
Always look behind you before backing. Slowly back away from the stack and proceed to the
next destination.
Never move a load that is loosely stacked or poorly positioned. A load should be tied down if that
is the only way to secure it.
Before entering trucks, trailers, or rail cars, be sure chocks are secured to keep the vehicle
entered from movement. Assure that dock and bridge plates are firmly secured in place. Check
the flooring of the vehicle to be entered, and ensure that it is capable of supporting the weight of
the forklift.
Never overload floors or storage areas when stacking material.
Do not place material in roadways, aisles, exits, in front of emergency equipment, or in any other
location not designated for this purpose.
3.3. Parking and Stopping
When parking the forklift:
 Always set the hand brake.
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Forklifts Rev. 4, 01-Sep-12

 Lower the forks until they are flat on the floor. If these are raised at all, they are serious
tripping hazards.
 Always stop the engine when dismounting the forklift and remove the ignition key when
the forklift is left unattended.
 Set the brake and chock the wheels, if it becomes necessary to park on an incline.
Forklifts may not be left unattended while running. Unattended shall mean:
 The forklift is out of sight of the operator, or
 The operator is more than 25 feet from the forklift.
Park forklifts so they will not interfere with the passage of other vehicles or people.
Never park on or within eight feet of the center of railroad tracks.
3.4. Personnel Basket and Platform Use With Forklifts
Refer to HSEP 17.10 for requirements related to forklift-mounted work platforms.
3.5. Forklift Refueling and Recharging
Forklift refueling and recharging must be conducted in areas with good ventilation and away from
ignition sources, such as sparks, open flames, electrical arcs, etc.
Fire protection devices, such as fire extinguishers, must be readily available in refueling or
recharging areas.
Smoking is not permitted in refueling or recharging areas.
3.5.1. Gas and Diesel Engine Forklifts
Gas and diesel engine forklift refueling must be conducted outdoors due to the possibility
of spills and vapor accumulation.
Turn off the engine and set the parking brake before refueling.
To prevent static electricity that can cause a fire, always make sure the nozzle makes
contact the tank while filling. When possible, a bonding wire should be used between the
forklift’s tank and the source of the fuel.
Avoid overfilling the fuel tank. Clean any spills before starting forklift.
Utilize safety cans when carrying or storing gasoline or diesel fuel. Use a funnel to avoid
spills when cans are used to refuel the forklift.
3.5.2. Refueling LPG Forklifts
LPG forklift refueling must be conducted by trained and experienced personnel only.
Drive forklift to the refueling area, set parking brake, and close the LPG cylinder valve.
Allow the forklift to run out of fuel. This will remove LPG and pressure from the lines.
Once the engine has stopped, turn off the ignition, close the LPG valve, and disconnect
the cylinder form the forklift.
Remove the cylinder and replace with another.
Reconnect the hose lines, turn on the LPG valve, and restart your forklift.
3.6. Charging
Electric forklift recharging must be conducted by trained and experienced personnel only.
Emergency eye, face, and skin flushing and drenching facilities must be provided.
Facilities must be provided for flushing and neutralizing spilled electrolyte. Charging areas should
have a readily available supply of dry baking soda available to neutralize acid should a spill occur.
HSEP 17.4 Page 5 of 8
Forklifts Rev. 4, 01-Sep-12

An adequate lifting device, such as an overhead hoist or conveyor, must be available for battery
charging activities.
Batteries must be removed and installed in accordance with manufacturer’s recommendations.
Batteries must be charged in a well-ventilated area or in a battery charging room specifically
designed for this activity. Improper charging can result in the generation of hydrogen gas, which
is highly flammable.
For lead-acid batteries, cell caps must be removed prior to connecting the battery to the charger
to allow accumulated hydrogen gas to dissipate. Failure to remove caps can result in an
explosion and expulsion of acid from the battery.
3.7. Entering Process and Regulated Areas
Forklifts come in a number of classifications and designations based upon the type of energy
used to power the forklift. There are eleven designations, e.g., “G” represents gas, “LP”
represents liquid propane, “D” represents diesel, etc. Each designation is provided for fire safety
reasons. Only forklifts with the proper designations are allowed to operate in certain process or
regulated areas. The Corporate HSE should be consulted if there is doubt about whether the
forklift used is authorized to enter certain process or regulated areas.
In addition to ensuring that forklifts have the proper designation, they should not enter any
process or regulated areas until the proper authorization and permits are obtained. While in
these areas, if there are spills, emergencies, etc., follow evacuation procedures and notify
supervisor immediately.
3.8. Inspection and Storage
The first person to use a forklift each day must, prior to use:
 Inspect the motor, transmission, and hydraulic oil levels, water level, and the condition of
the battery,
 Tests of the light, horn, backup alarm, and both normal and emergency brakes,
 Make sure the operating controls function properly,
 Carefully look around and under the forklift for evidence of hydraulic oil or other fluid
leaks,
 Inspect the overhead guard, and make sure it appears stable and not altered or
damaged,
 Assure that tires are not excessively damaged or under-inflated to an extent that will
create a hazard, and
 Report problems or defects found during inspection to supervision immediately. Forklifts
in need of repair shall not be operated.
Use the form entitled “Forklift Daily Safety Checklist” (Figure 1) to document this inspection.
3.9. Training
Only properly trained and certified personnel shall operate a forklift.
Forklift training courses will be set up as needed through either the site manager, the designated
competent person, or Corporate HSE.
Reference HSEP 17.5 for specific training requirements related to forklift operator certification.
HSET Course Number 17.4, Powered Industrial Truck (Forklift) Operator Training, or equivalent,
which will be instructed by a designated competent person, is required for prospective forklift
operators. Complement this instruction with any additional training on regulatory and/or
consensus standard requirements, as appropriate.
Documentation will be maintained by the designated competent person at the jobsite or by
Corporate HSE.
HSEP 17.4 Page 6 of 8
Forklifts Rev. 4, 01-Sep-12

3.10. Environmental
Gasoline, diesel, LPG, and CNG fueled engines should receive periodic tune-ups and inspections
to ensure that they are operating properly and are not polluting. Air filters should be changed
routinely, especially in dusty work environments.
Check with local environmental staff to determine whether there are any special operating
conditions or constraints in effect on the project. Common examples include:
 Limiting or restricting the hours of equipment operation (construction-type projects),
 Limiting the number of diesel-fueled equipment that can operate at any given time
(construction-type projects),
 Retrofitting diesel engines with particulate traps on the exhaust, and
 Use of low sulfur (less than 500 ppm) or ultra low sulfur (less than 15 ppm) diesel fuel.
Hydraulic lines and hoses should be periodically inspected for leaks and repaired promptly when
a leak is found.
The accidental release of hydraulic fluid, lubricant, or diesel fuel from the crane must be reported
to environmental staff in accordance with client directives. Any release onto a waterway or body
of water must be reported to the appropriate agencies. Spilled or released fluid must be collected
immediately along with any impacted soil or water and be handled in accordance with Federal,
state, and local regulations.
Equipment service should be performed by certified mechanics. All removed fluids must be
disposed of or recycled in accordance with Federal, State, and local law. Use of spent oil for
weed control is a prohibited practice.
Dead or weak lead-acid and gel-cell batteries should be removed from service and be sent to a
qualified off-site recycler. The repair of lead acid batteries is not allowed unless the appropriate
facilities are available and the person engaged in the repair work is certified to work with lead and
covered by an exposure monitoring program.
4.0 REFERENCES AND RELATED DOCUMENTS
29 CFR 1910.178, Powered Industrial Trucks
HSEP 17.10, Forklift-Mounted Work Platforms
5.0 FIGURES
Figure 1: Forklift Daily Safety Checklist
HSEP 17.4 Page 7 of 8
Forklifts Rev. 4, 01-Sep-12

Figure 1
Forklift Daily Safety Checklist

Make: Capacity:

Equipment/Serial No.: Week of: to

ITEM Mon. Tues. Wed. Thurs. Fri.

Radiator, Engine Oil

Battery

Hydraulic Oil & Hydraulics

Hose Crimps, Leaks

Lights and Horn

Brakes

Back-up Signal

Operations Up-Down, Tilt,

Brake

Tire Appearance, Pressure

This is to certify that I have inspected this piece of equipment and it is in good condition, except
as noted:

Comments:

Operator’s Name Printed:

HSEP 17.4 Page 8 of 8
Forklifts Rev. 4, 01-Sep-12

Operator’s Signature: