Mục lục
- Why forklift safety matters
- Forklift safety rules BEFORE operation (daily inspection)
- Forklift safety rules DURING operation
- Forklift safety rules for LIFTING and STACKING loads
- Forklift safety rules AFTER operation (parking and shutdown)
- The three most common forklift accident types and how to prevent them
- Required PPE by truck type
- International standards to reference
- Related articles
- Frequently asked questions about forklift safety
- Contact and forklift advice from ICD
Forklift safety rules fall into three stages: before operation (the daily pre-shift inspection), during operation (speed, blind spots, ramps, load handling), and after operation (safe parking and shutdown). Following them protects people and stock, since a forklift weighing several tonnes carries enormous risk. This guide gives an operator checklist to international standards, the three most common accident types with specific controls, and PPE requirements by truck type.
Why forklift safety matters
A forklift, whether electric or diesel, is a powerful machine that can weigh several tonnes. When it moves, it carries a large amount of energy and risk, so any complacency can lead to severe consequences. Following safe operating rules is not only the driver’s responsibility but the safety culture of the whole business, and it is the foundation for protecting its most valuable asset: people.
The first principle is training: only personnel who are professionally trained, hold a valid certificate, and are authorised by the company may operate a forklift. Under OSHA 1910.178(l), operators must be trained and evaluated before driving, with re-evaluation at least every three years and refresher training after any accident or near miss.
Forklift safety rules BEFORE operation (daily inspection)
Every shift should start with an inspection routine. A five-minute daily check can prevent a large share of technical failures before the truck moves.
| Check item | What to look for |
|---|---|
| Walk-around | Inspect for oil or hydraulic leaks around the truck |
| Tyres | Pneumatic tyres correctly inflated; solid tyres free of cracks or splits |
| Forks | Straight, not bent or warped, with no cracks |
| Controls | Brakes, horn, lights, and lift/lower levers all operating smoothly |
| Fuel / battery | Enough fuel or charge for the whole shift |
| Visibility | Cab and any glass clean, with a clear line of sight |
If any item fails, tag the truck out of service and report it. Never operate a forklift with a known defect.
Forklift safety rules DURING operation
This is where the operator’s focus and discipline matter most.
| Rule | Detail |
|---|---|
| Seat belt | Always fasten the seat belt before starting the engine |
| Control speed | Stay within the permitted speed, especially at corners, doorways, and busy areas |
| Keep distance | Maintain a safe gap of about three truck lengths from other forklifts |
| Watch blind spots | Stay alert to hidden corners; sound the horn at intersections and doorways |
| On ramps | With a load, keep the load pointed uphill: drive forward up the ramp and in reverse down it |
| No passengers | Never let anyone ride on the forks or in the cab |
Forklift safety rules for LIFTING and STACKING loads
| Rule | Detail |
|---|---|
| Respect capacity | Know the load weight and never lift beyond the truck’s rated capacity |
| Balance the load | Centre the load on both forks and push it back against the fork carriage |
| Lift when stationary | Only raise or lower a load when the truck is fully stopped |
| Travel low | Keep the forks as low as practical (about 15-20 cm off the ground) and tilt the mast slightly back |
| Never travel high | Travelling with a raised load destabilises the truck and greatly raises the risk of tipping |
Forklift safety rules AFTER operation (parking and shutdown)
| Step | Detail |
|---|---|
| Lower the forks | Bring the forks fully down to the floor |
| Apply the brake | Set the parking brake before leaving the seat |
| Shut down | Switch off the engine and remove the key |
| Charging / refuelling | Keep the area ventilated, free of flammable material, and equipped with fire extinguishers |
The three most common forklift accident types and how to prevent them
Top guides list general rules but rarely break down where accidents actually come from. The three leading categories and their specific controls:
Tipping: around 42% of forklift accidents
Causes: off-centre loads, travelling with a raised pallet, uneven floors, and sudden turns. Controls: lower the pallet below 30 cm before moving; cap speed at 5 km/h when the load is over 70% of capacity; and never push or pull objects with the forks.
Pedestrian struck-by: around 25%
Causes: a high pallet blocking the line of sight and pedestrians in the operating zone. Controls: paint segregated lanes (one colour for pedestrians, another for trucks); fit a reversing alarm and warning light; and place convex mirrors at blind corners.
Crushing or falling load: around 20%
Causes: damaged pallets, poorly secured loads, and forks not inserted deep enough. Controls: inspect the pallet before lifting (no cracks, all feet intact); insert the forks the full length of the pallet; and strap or stretch-wrap any load over 1 m tall.
Required PPE by truck type
General guides treat PPE as one-size-fits-all. Requirements vary by truck:
| PPE | Hand pallet truck | Walkie / pedestrian electric | Counterbalance forklift |
|---|---|---|---|
| Hard hat | Recommended | Required | Required |
| Steel-toe safety boots | Required | Required | Required |
| Hi-vis vest | Recommended (busy warehouse) | Required | Required |
| Cut-resistant gloves | Required | Recommended | Recommended |
| Safety glasses | - | Recommended | Required when lifting above 2 m |
| Ear protection | - | - | Required (diesel trucks over 85 dB) |
International standards to reference
| Standard | Region | Key requirement |
|---|---|---|
| OSHA 1910.178 | United States | Operator training and evaluation before use; re-evaluation every 3 years; refresher after an accident or near miss |
| ISO 3691-1:2024 | International | Safety requirements for industrial trucks, including load-centre calculation |
| EN 1726-1 | Europe | Stability testing and tipping limits |
| TCVN 9396:2012 | Vietnam | Aligned with ISO 3691: daily checks plus periodic maintenance |
Related articles
| Xilin forklifts: full range and load capacities | Contact ICD for forklift advice and a quote |
Frequently asked questions about forklift safety
1. Who is allowed to operate a forklift?
Only personnel who are professionally trained, hold a valid operator certificate, and are authorised by the company. Under OSHA 1910.178(l), training and a performance evaluation must be completed before driving, with re-evaluation at least every three years.
2. What should I do if a forklift shows signs of a fault?
Stop operating immediately, tag the truck out of service, and report it to a supervisor or the maintenance team. Never attempt a repair yourself without the proper qualification.
3. What is the most common cause of forklift accidents?
Tipping accounts for roughly 42% of accidents, usually from off-centre loads, travelling with a raised pallet, uneven floors, or sudden turns. Lowering the load below 30 cm before moving and limiting speed under heavy loads are the key controls.
4. What are the safety rules for pedestrians near forklifts?
Always stay within marked pedestrian walkways, never cut through a forklift operating area, assume the operator may not see you, and keep a safe distance at all times.
5. How high should the forks be when travelling?
Keep the forks about 15-20 cm off the floor with the mast tilted slightly back. Never travel with a raised load, as it destabilises the truck and greatly increases the tipping risk.
6. Is a certificate required to operate a forklift?
Hand pallet trucks generally do not require a certificate. Seated counterbalance forklifts rated above 1 tonne require a valid operating certificate under local labour-safety regulations, alongside the employer’s own authorisation and training.
Contact and forklift advice from ICD
ICD Viet Nam Industrial Production Company Limited
North: Floor 3, Thang Long A1 Building, Bau Hamlet, Thien Loc Commune, Hanoi - 0983 797 186 / 090 345 9186 / 090 5859 186
South: 551/212 Le Van Khuong, Tan Thoi Hiep, District 12, Ho Chi Minh City - 098 6784 186
Email: sales@icdvietnam.com.vn · Zalo: Chat on Zalo now
ICD is the exclusive distributor of Xilin (Ningbo Ruyi) forklifts in Vietnam, with a 2-year manufacturer warranty and on-site technical support. Tell us your load and rack height, and we will recommend the right truck and quote right away.
