Forklift & Pallet Jack Safety Policy

EHS Home Issued: June 13, 1996 Revised: July 23, 2010
PURPOSE RECORDKEEPING
RESPONSIBILITIES REFERENCES
TRAINING & CERTIFICATION DEFINITIONS
INSPECTIONS & MAINTENANCE Att. A: REQUIRED TRAINING TOPICS
Att. B: FORKLIFT TRUCK OPERATOR
TRUCK SAFEGUARDS
CERTIFICATION FORM
Att. C: FORKLIFT/PALLET JACK DAILY
SAFE OPERATING PRACTICES
INSPECTION CHECKLIST
WORK PLATFORMS FOR PERSONNEL Att. D: FORKLIFT TRUCK SPECIFICATIONS
BATTERY CHARGING STATIONS

PURPOSE

To provide information and guidance for the safe operation, maintenance, and selection of powered industrial
forklift trucks & motorized pallet jacks.

RESPONSIBILITIES

Production Manager/Director

• Review the program periodically for compliance and effectiveness

• Make recommendations for program revisions if necessary
• Maintain documentation for training & inspections in EHS filing system/server
• Discipline operators for rule violations as necessary

Department Supervisors/Forepersons

• Review and understand the rules and procedures in this program

• Periodically verify that all employees who operate trucks or pallet jacks are properly trained
• Coordinate employee training with in-house or outside trainers
• For supervisors who are certified as trainers, certify all applicable operators
• Ensure that only trained and qualified individuals use forklift trucks and pallet jacks
• Observe the operation of trucks/pallet jacks in your department, and correct unsafe practices

Maintenance Supervisor/Manager

• Maintain written records of all periodic and annual inspections of the equipment, including the date any
problems found, the date when fixed, and the person/company performing the repairs.

Operators
• Ensure you have a valid forklift license/certification before operating any equipment
• Complete the Daily Inspection Checklist before operating any truck/pallet jack
• Follow all safety precautions and rules learned from your training session
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 • Observe the operation of powered industrial trucks in your department, and report unsafe practices to
your supervisor

EHS Director
• Periodically review and update this program as necessary
• Maintain a database of employees who were trained
• Periodically observe the operation of trucks/pallet jacks, and report unsafe practices to the appropriate
supervisor

TRAINING & CERTIFICATION

1) All forklift truck and motorized pallet truck operators are required to be trained and evaluated:

• Initially, before operating a forklift truck

• Every 2 years after initial training & certification

2) Training must be provided by a Certified Forklift/Pallet Jack Truck Trainer and must include:

a. Classroom Instruction – a review of operating conditions and the specific type of trucks/jacks and
attachments used, safe operating practices, etc., including a review of this program.
b. Hands-on Review of Actual Truck(s) - demonstrations by the trainer and practical hands-on exercises
performed by the trainee.
c. Road Test Evaluation – each operator must be given an individual road test and his or her performance
evaluated. This road test must demonstrate proficiency in (as a minimum):

1. Removing rolls/pallets from the top stack and transporting over to the lay down/storage area
2. Removing rolls/pallets from a delivery truck at the dock and placing the roll on the top stack
3. Maneuvering around the warehouse & roll stack aisles while carrying a roll (for those handling
rolls)

3) The certified forklift trainer must provide written certification that each operator has been trained and
evaluated as required by paragraph (l) of the revised OSHA standard 1910.178. See the list of "Required
Training Topics" (Attachment A) that the certified trainer must cover.

The operator certification document must include the following:

• Operator name(s)
• Date of training
• Date of evaluation
• Printed name and signature of the certified forklift trainer
• A statement that the training and evaluation complies with OSHA’s paragraph (l) requirements

For those sites that may be using employees as trainers via a “train-the-trainer’ course, the Forklift Truck
Operator Certification Form (Attachment B) can be used to document both the training and certification
of each forklift truck operator. In-house trainers must also receive refresher "train-the-trainer" training every
2 years.

For the Bronx plant, forklift licenses are also provided (in addition to the certification) to trained employees,
under the control of certified trainers from the DOT department.

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4) Refresher training and re-evaluation must be provided to an operator when:

• Initial evaluation shows that the operator is not operating the truck safely

• Operator has been observed operating the truck in an unsafe manner

• Operator has been involved in an accident or near-miss incident (Bronx operators must also have
mandatory alcohol & drug testing immediately after an accident involving injury or property damage)

• Operator is assigned to a different type of truck or a truck modification has been made

• Workplace conditions have changed in a manner that could affect the safe operation

NOTE: Efforts should be made to ensure only trained employees operate forklift trucks. However, if contractors
must be used to operator our forklift trucks, they must provide management with written proof that they have
been trained and certified to operate our type of forklift trucks in accordance with OSHA's regulations.

INSPECTIONS & MAINTENANCE

Daily Inspections

• Prior to use each day, all operators must inspect each forklift truck and motorized pallet truck to ensure the
vehicle is in safe working order.

• Complete the Forklift/Pallet Jack Daily Inspection Checklist (Attachment C) and maintain completed
checklists in the site EHS filing system. Motorized pallet trucks should be inspected for controls, brakes,
tires, and other moving parts.

• The night shift should conduct a visual inspection of the vehicle prior to use to ensure no additional safety
hazards have occurred since the full inspection earlier that day.

Note: Vehicles in need of repair must be immediately taken out of service and not operated until proper repairs
are made.

Annual Preventative Maintenance

Thorough annual PMs must be scheduled with a representative of the forklift truck manufacturer/supplier or
contractor knowledgeable on the specific trucks used, and include a thorough check for mechanical or structural
problems (i.e. stress fractures along load bearing components) to determine if repairs (i.e. magna-fluxing) are
necessary.

TRUCK SAFEGUARDS

Operator Safety Restraint System

• All forklift trucks must be equipped with seat belts and must be worn by drivers at all times while
operating the vehicle.

Note: Restraint seat belt systems must be installed by the manufacturer or a factory authorized service
company for older trucks that are not equipped with this safety feature (the forklift vendor may be able
to provide this service).
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Other Safety Features Required of Trucks

• Overhead Guard Cage - Forklift trucks capable of lifting loads higher than the operators head must be
equipped with an overhead guard cage and must not obstruct vision.

• Load Back Rest - Loads must never exceed the height of the back rest.

• Warning devices - Riding type forklift trucks must be equipped with a standard horn in the center of the
steering column and a strobe and/or alarm that is activated when backing-up.

• Nameplates - Every forklift truck must be equipped with a nameplate showing the weight of the truck
and its rated capacity.

• Mast Tilt – Mast tilt should be adjusted to prevent the truck from tipping over in the forward position
with the paper roll extended full height over head – 2 degrees forward and 3 degrees back is acceptable.
Manufacturers can place restrictions on the mast to limit tilt.

A list of recommended forklift truck specifications can be found in Attachment D.

SAFE OPERATING PRACTICES

General

• Do not allow anyone to stand or pass under the forks, loaded or empty.
• Do not drive up to anyone standing in front of a fixed object
• Maintain sufficient clearance to keep mast under lowest obstacle in storage area (i.e. under overhead
installations, lighting, sprinkler piping, manifolds, doorways, etc.)
• Do not block aisles and access to stairways, fire equipment, and electrical panels
• Never drive trucks onto elevators unless authorized to do so and make sure the combined weight does
not exceed the rated capacity of the elevator.
• Forklift modifications that affect capacity and safe operation must not be performed without the
manufacturer’s prior written approval.

Travel

• Operate the forklift truck at a slow, steady speed (i.e. quick walking pace)
• Wear seatbelts
• Carry forks as low as possible, but high enough not to strike any raised or uneven surface
• Keep a clear view of the path of travel and always look out for obstacles
• Stop and sound horn at all blind corners, intersections, doorways, and places with limited view
*Safety Tip: Overhead mirrors can be utilized to improve operator visibility in blind spots
• Avoid quick starts/stops and quick turns
• Keep hands and legs inside the truck at all times
• Never permit rides or let anyone stand on the forks
• Be aware of pedestrian traffic areas and be prepared to stop -- yield to pedestrians

Parking

• Bring forklift truck to a complete stop

• Place controls in neutral
• Apply the parking brake
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 • Lower forks / clamps completely to ground
• Stop motor and turn off controls
• If the truck is equipped with LPG fuel supply, close the fuel valve at the tank

Loading and Unloading

• Make sure trucks and trailers are secure so they don’t roll forward when you drive on. Chock the wheels,
set the brakes, and engage the "Dok-Lok" system, if applicable.
• Whenever forklift trucks are driven on and off semi-trailers not coupled to a tractor, supports must be
utilized to prevent upending or corner dipping.
• Inspect the trailer floor to insure it is in good condition before entering with the forklift
• Bridge plates (dockboards) –

1. Must be secured in position by anchoring or other device

2. The rated carrying capacity should conspicuously be marked on bridge plate and should
never be exceeded
3. Should have a non-slip surface and kept dry

• Only handle stable or properly stacked loads that do not exceed the rated capacity of the truck
• Never travel or turn with the load elevated
• Don’t raise, lower or tilt a load while moving

Driving on Grades

• Trucks should ascend and descend slowly -- use low gear

• Stay well back from the edges of ramps and platforms
• Never turn around on the grade
• Drive with the load toward the upgrade; down slope in reverse with load in front (except for powered
pallet trucks)
• The load should be tilted back & only raised as far as necessary to clear the surface

WORK PLATFORMS FOR PERSONNEL

• An approved work platform (single level only, with standing area resting on forks) can be attached to a
forklift truck for overhead maintenance work, provided it is equipped with guardrails and toe boards,
and is securely fastened to the forks and mast.

• All work platforms must meet ANSI construction design standards and have a weight capacity plate
attached, in addition to nameplate on forklift. Pre-engineered work platforms meeting ANSI standards
are recommended for new purchases.

• Existing "in-house" work platforms designed and fabricated by on-site personnel must be certified by a
PE and weight capacity plate attached, before use.

• All work platforms must be inspected before each use, and preventive maintenance conducted annually
along with the annual PM of the truck in order to insure the structural integrity. These work platforms
can be inspected and documented by experienced in-house personnel.

• Operator must not leave the controls while the truck is being used to forklift a person.

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 • Person on platform must have fall protection (body belt with lanyard or deceleration device) if elevation
is more than 6 feet – the fall arrest system should be securely fastened to the platform railing.

• Apply parking brake or use wheel chocks to immobilize truck. Forklift truck must be on a level surface
and must not be moved, except for minor adjustments upon request.

• The combined weight of the platform, load, and personnel is not to exceed one-half of the truck capacity
as indicated on the nameplate of the forklift truck.

• Ladders, scaffolds, etc. are prohibited from use inside the platform.

• No overhead obstruction hazards can exist.

BATTERY CHARGING STATIONS

Each area designated as a battery charging station must have:

1. Eye wash station (and shower or drench hose if batteries are opened or serviced)
2. Neutralizing material (non baking soda type) or acid absorption pads for spilled electrolyte
3. PPE supplies (rubber gloves, safety glasses, goggles)
4. Fire extinguisher
5. Adequate ceiling ventilation (to prevent accumulation of explosive hydrogen gas)
6. Warning signs posted (i.e. "no smoking" and "gloves and eye protection required")

RECORDKEEPING

It is the responsibility of Production Management to assure personnel are adequately trained and inspections
maintained. The following documents must be kept on-site and available for possible inspection:

• Copies of operator training certifications/licenses

• Daily forklift truck inspection checklists
• Annual forklift truck preventative maintenance records
• Truck modification records

REFERENCES

OSHA 29 CFR 1910.178

ASME/ANSI B56.1

DEFINITIONS

Authorized forklift Truck Operator - A trained operator, who has retained and uses the knowledge
and skills that are necessary to safely operate a forklift truck.

Certified Forklift Truck Trainer - An individual knowledgeable with the equipment to a degree and
sufficiency as to convey the necessary operating procedures and safety precautions to the trainee (i.e.,
representative of equipment manufacturer, personnel successfully completing a "train the trainer"
course).

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Forklift Truck - Internal combustion engine or electric motor-powered forklift truck used for material
handling, including, sit-down forklift trucks, stand-up forklift trucks, scissor lifts and high-lift motorized
hand trucks.

Motorized Pallet Truck - A low-lift motorized hand truck with a powered platform to raise the load
only enough for horizontal movement and controlled by an operator who walks behind it.

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Attachment A

REQUIRED TRAINING TOPICS

TRUCK-RELATED WORKPLACE-RELATED

Any operating instructions, warnings, and Surface conditions where the vehicle will
precautions for the specific truck used operate

Controls and instrumentation Types of loads to be carried and load stability

Engine or motor operation Moving loads, stacking and unstacking

Steering and maneuvering Pedestrian traffic in operating areas

Operating limitations Narrow aisles or other restricted places where

truck will operate

Visibility (including restrictions to loading) Hazardous locations where truck may operate

Fork and attachment adaptation, operation, and Ramps and other sloped surfaces that could
use limitations affect truck stability

Load capacity Closed environments and other areas where

insufficient ventilation could cause a buildup of
carbon monoxide or diesel exhaust

Truck stability Other unique hazards or hazardous conditions

that could affect safe operation.

Required operator inspection and maintenance

Refueling and /or battery charging procedures

Differences between truck and automobile

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Attachment B

FORKLIFT TRUCK OPERATOR CERTIFICATION FORM

EMPLOYEE NAME (print):

SITE LOCATION:
TRAINING DATE:
EVALUATION (ROAD TEST) DATE:
INSTRUCTOR NAME (print):
DESCRIPTION OF TRAINING (video, handouts, etc.):

DESCRIPTION OF EVALUATION (stacking, loading, transferring of paper rolls):

THIS DOCUMENT CERTIFIES THAT THE ABOVE EMPLOYEE

HAS BEEN TRAINED AND EVALUATED AS REQUIRED BY
PARAGRAPH (l) OF THE OSHA STANDARD 29 CFR 1910.178 (1998) –
POWERED INDUSTRIAL TRUCKS.

Employee Signature Instructor Signature

Send copy to [email protected]

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 Attachment C

FORKLIFT/PALLET JACK DAILY INSPECTION CHECKLIST

Instructions:
1. √ Check each box for each item that is OK, NA if not applicable, and circle box for items needing attention (use reverse side for comments)
2. Notify supervisor immediately if any item requires the truck/pallet jack to be removed from service.

Month/Year: Area: Equipment #:

GENERAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Drive Tires
Steer Tires
Horn
Warning Lights & Labels
Drive Lights
Battery Connector/Charge
Seat Belt
DRIVE TRAIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Engine Oil Level
Transmission Oil level
Coolant Level
Hydraulic Level
Fuel Level
Battery Fluid Level
FUNCTIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Service Brakes
Parking Brakes
Steering Movement
Hood/Seat Latches
Battery Restraint
Forward/Reverse Controls
HOIST 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Forks / Clamp
Fork Latches
Sideshift
Load Back Rest
Load Chains
Chain Attachment
Hydraulic Hoses / Leaks

Operator Signature:

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Attachment D

FORKLIFT TRUCK SPECIFICATIONS

• Manufacturer – Stay with a major manufacturer who has a good local dealer. Look for a popular size and model from a
manufacturer with a proven performance track record.

• Load Capacity – a minimum rated load capacity of 5,000 lbs. is recommended.

• Power Supply – Electric trucks are recommended for indoor use (over propane or gasoline) because they do not emit exhaust
fumes, but require a battery charging station and a hard-wired electrical supply. Batteries weigh between 2,500 to 4,000 lbs.
depending on service requirements and require a mechanical lifting device for battery change outs. Proper ceiling ventilation is
also required to prevent the accumulation of explosive hydrogen gas.

• Lifting Height – a 216 " maximum lifting height restriction is required so paper rolls could be stacked 4-high without striking
overhead obstacles, such as sprinkler heads, etc.

• Mast Height – Mast in retracted position should be low enough to fit through all building openings, such as doorways, etc. A
quad mast will provide a lower overall height.

• Mast Tilt - The tilt limitation should be designed to prohibit tilt of the mast at certain heights, although the operator with push-
button controls can override it if necessary.

• Tires - Cushion tires made of solid rubber, are good for smooth indoor surfaces and do not go flat.

• Lifting Attachments – Check if your existing paper roll clamp fits a newly purchased truck; past purchases have specified a
Cascade model 40D-RC-02A. If old forks can not be used, standard 42" forks are best for lifting pallets.

• Standard Safety Features – The truck should include, at a minimum, an overhead guard, backup audible warning device, fire
extinguisher, operator-controlled horn and seat belts.

• Travel Speed – Test the truck and determine if the top speed is satisfactory for the volume of newsprint being handled within
production time constraints. A single-speed transmission is better than having the vehicle shift.

• Side Shift – A side shifter is nice, but not always essential. Shifters add cost and slightly derate the lifting capacity. Make sure
your application requires this function.

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