Forklift hazards can be found on safety inspector's hot lists throughout the world. In an inspection these trucks are in the top five on the checklist. The first item is the current safety sticker followed by policies on safety controls. Drivers of these trucks will be checked for training; then personnel working in the areas of forklift operation. Here are some hazards to consider when developing policies on forklift operation.

Accident Hazards

Fall of truck operator, due to slip or incautious step, while climbing to or descending from the operator's seat

Fall of truck from an upper level to a lower level, due to careless driving, slip or collapse

Fall of improperly loaded cargo

Overturning of truck due to overload or incorrect positioning of the center of gravity

Overturning due to cargo lifting to an excessive height, or due to careless steering

Overturning of truck, especially 3-wheel, while making an extremely sharp and speedy turn

Overturning due to driving on a too steep slope, or at excessive driving speed, or loss of traction, or due to use of improper equipment or even forklift attachments

Rolling-down of truck due to insufficiently applied handbrake

Injury from rotating parts of the truck, not fully protected against accidental contact

Collision with a stationary, such as a wall or moving object especially when view is obstructed by the loaded cargo

Collapse of a stack of cargo

Electric shock resulting from contact with overhead electric cables

Possible exposure to hazardous chemicals as a result of fall and crush of the loaded cargo

Spill of acid during battery charging

Physical hazards

Exposure to excessive noise levels with resulting hearing impairment

Exposure to whole-body vibration caused by rigid construction of truck, inadequate shock-absorbing properties of operator's seat, and prolonged driving on rough grounds

Exposure to harsh climatic conditions such as heat while working outdoors

Chemical hazards

Allergic skin reactions as a result of contact with fuel and/or solvents

Eye injury due to splashes of corrosive materials

Intoxication by exhaust gases, fuel, which are emitted from the exhaust pipe. The concentration will rise rapidly inside closed and inadequately ventilated structures

Exposure to nitrogen oxides (NOX) emitted together with the exhaust gases inside relatively closed and inadequately ventilated structures

While charging electric truck batteries, hydrogen gas is giving off

Biological hazards

Exposure to dust and other contaminants as result of truck movement

Ergonomics and Stress

Cumulative trauma disorders of hands and arms pains resulting from their overexertion while driving a non-laden truck presenting higher resistance to steering

Low-back pain, muscle contraction and other disorders caused by prolonged seating in an inadequate seat

Neck pains as a result of frequent back-turning of head and neck stretching during reverse driving and while transporting bulky load obstructing operator's field of vision

Vision problems due to prolonged work in insufficient lighting

Psychological stress associated with increased risk of accidents involving other vehicles and suddenly appearing pedestrians

Psychological problems with time constraints