The Occupational Safety and Health Administration (OSHA) significantly revised the standards for powered industrial trucks by adding extensive new requirements to improve the training of operators of those trucks. The current rules became effective on March 1, 1999.
According to OSHA, the previous requirement was "very general," and the revisions were needed to reduce the number of injuries and fatalities that occur because of inadequate operator training. The standard increased substantially the amount of time and cost of training operators. A non-mandatory appendix was also included in the new standard to provide guidance on understanding the basic principles of stability for powered industrial trucks.
Coverage
The rule covers employees who operate powered industrial trucks in the general industry, construction, and maritime sectors. It also covers employees who might operate such vehicles as part of another job.
The Standard Industrial Classification (SIC) Codes now covered by the rule include:
- Agricultural services (SIC 07);
- Oil and gas extraction segment of mining industry (SIC 13);
- Construction (SICs 15-17);
- Manufacturing (SICs 20-39);
- Transportation and utilities (SICs 41-49);
- Longshoring and marine terminals (SIC 4491)
- Wholesale and retail trade (SICs 50-59);
- Finance, insurance and real estate (SICs 60-67); and
- Services sectors (SICs 70-89)
Scope
All types of powered industrial trucks are covered. Such vehicles are defined as "mobile, power-driven vehicle[s] used to carry, push, pull, lift, stack or tier material." They are commonly known as forklifts, pallet trucks, rider trucks, forktrucks, or lift trucks. The rule does not apply to vehicles used for earth moving or over-the-road hauling.
Training Requirements
Employers must ensure that each operator of powered industrial trucks is competent in the operation of such vehicles before being allowed to operate them independently. More specific requirements are shown, as follows:
Training Program
The rule includes a list of subjects that must be mastered in order to operate the vehicle safely.
The training program must consist of a combination of:
- formal (classroom-type) instruction, as well as practical, hands-on training in proper vehicle operation;
- the hazards of operating the vehicle in the workplace;
- the requirements of the OSHA standard for powered industrial trucks; and
- an evaluation of the employee's ability to handle the vehicle safely in the workplace.
Training Program Content:
The initial training must cover truck-related and work-related topics.
Truck-related Topics
- Operating instructions;
- Warnings and precautions for the types of vehicle the employee will be operating;
- Differences between the powered industrial truck and an automobile;
- Truck controls and instrumentation;
- Engine or motor operation;
- Steering and maneuvering;
- Visibility (including restrictions due to loading);
- Fork and attachment adaptation operation, and use limitations;
- Vehicle capacity;
- Vehicle stability;
- Any vehicle inspection and maintenance the operator will be required to perform;
- Refueling and/or charging and recharging of batteries;
- Operating limitations; and
- Any other operating instructions, warnings or precautions listed in the operator's manual for the types of vehicle the employee is being trained to operate.
Work-related Topics
- Surface conditions where the vehicle will be operated;
- Composition of loads to be carried and load stability;
- Load manipulation, stacking and unstacking;
- Pedestrian traffic in areas where the vehicle will be operated;
- Narrow aisles and other restricted places where the vehicle will be operated;
- Hazardous (classified) locations where the vehicle will be operated;
- Ramps and other sloped surfaces that could affect the vehicle's stability;
- Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust; and
- Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.
Who Must be Trained and When:
Employees hired before December 1, 1999, must be trained by that date, and employees hired after that date must be trained and evaluated before being assigned to operate a powered industrial truck.
Operators must be evaluated periodically (at least once every three years), to ensure their skills remain at a high level, and must receive refresher training whenever there is a demonstrated need. The rule contains triggers for refresher training and evaluation, such as an operator's involvement in an accident or "near miss."
Operators with prior training do not have to be trained in topics for which they have previously received training, if the operator's performance has been evaluated as competent.
Who Does The Training:
All operator training must be conducted by persons who have the knowledge, training and experience to train and evaluate the competence of powered industrial truck operators. Another employee with the requisite knowledge, training and experience could conduct the training and evaluations. The employer may contract with an outside training organization to conduct the training and evaluations.