Safe Use of Forklift Work Platforms

A forklift work platform is a safety cage or unit that securely attaches to the forks of a forklift, allowing workers to perform tasks at elevated heights. Sometimes used in place of scissor or boom lifts, work platforms are versatile and portable units that may provide a safer way to conduct tasks above ground level than ladders or makeshift lifting solutions.

Forklift work platforms typically include specific safety features, such as entry gates with locks, nonslip floors, fork securing mechanisms, harness anchor points, and guardrails and toe boards. These platforms provide a solid footing and enable workers to use both hands for tasks.

Forklift work platforms are common in several industries, including construction (e.g., used for light-duty elevated tasks, such as painting, repairs and electrical installations), manufacturing (e.g., used for overhead facility work such as servicing HVAC components or lighting systems), and warehousing and distribution (e.g., used for inventory inspections, stocktaking and routine maintenance).

Forklift-mounted work platforms can be deployed quickly, offering a safe, efficient and cost-effective solution for companies performing time-sensitive tasks. However, when used improperly, forklift work platforms can pose significant hazards to both the operator and individuals working on the platform. If your work requires you to operate or use a forklift work platform, it’s imperative to understand the potential risks involved and related safety precautions.

Hazards of Using Forklift Work Platforms

Forklift work platforms can pose several hazards to employees, including the following:

• Falls from height—Workers could slip and fall from the platform due to incorrect use of fall protection equipment or sudden or unplanned movement of the forklift (e.g., abrupt turns, especially on inclines or uneven surfaces).
• Tip-overs—The work platform could tip over and eject workers if the weight capacity of the platform is exceeded or if the forklift suddenly brakes, accelerates or tilts.
• Platform attachment failures—The work platform could suddenly slide off the forklift’s forks if improperly attached or poorly secured.
• Collision with objects—The work platform could obstruct the forklift operator’s view, resulting in collisions with vehicles, pedestrians or overhead obstructions (e.g., beams or ceilings).
• Contact with unguarded parts of the forklift—Workers could come into contact with unguarded moving parts of the forklift (e.g., chains, gears or lift mechanisms), especially if the work platforms’ guardrails are not high enough to discourage leaning out.

These and other hazards can result in crushing and pinching injuries, cuts and lacerations, sprains, fractures, spinal injuries or even death.

Forklift Work Platform Setup and Safe Use Best Practices

Considering the risks associated with forklift work platforms, it’s critical to take precautions when using this type of equipment. Ensure you have received adequate training to operate or work on a forklift work platform, and always follow all safety procedures. Additionally, consider the following steps to set up a forklift work platform safely:

• Prepare the area. Cordon off the area with safety cones or other physical barriers to alert nearby personnel. Verify the forklift is positioned on a flat, level surface with a firm footing.
• Assess the surroundings. Scan for overhead obstructions and check that there is ample space to perform the task safely. Ensure that workers can’t make contact with any pinch or shear points.
• Adhere to the manufacturer’s instructions. Attach the platform securely to the forklift’s forks or mast according to the manufacturer’s instructions. Check that the platform is horizontal and centered, and that the combined weight of the platform and its load remains well within the forklift’s recommended capacity limits.
• Inspect equipment. Perform a visual check of all workplace equipment and confirm the forklift’s lifting and locking mechanisms, horn and brakes are working as expected. Ensure the work platform has proper guardrails and a toe board, and check for damaged welds or any other signs of structural issues.
• Conduct a test run. Undertake a trial lift with the platform empty to verify that it reaches the correct height and travels smoothly and safely, with adequate clearance from its surroundings.

Once the task commences, forklift operators should keep the following safety tips in mind:

• Lower the work platform to floor level for the safe entry and exit of employees.
• Lift the work platform smoothly and cautiously, and always lower the platform before adjusting the forklift’s position or moving it to a new location.
• Always stay at the forklift controls and maintain constant communication with employees on the platform (e.g., through radios or hand signals).
• Wear appropriate personal protective equipment (PPE), such as a hard hat, high-visibility clothing and safety gloves. Consult your supervisor to confirm the specific PPE requirements for the task at hand. Ensure that your equipment fits properly and that you are familiar with its use.

Employees working on the platform should follow these safety measures:

• Use designated gates to access the platform and maintain three-point contact (two feet and one hand, or two hands and one foot) to steady yourself when entering or exiting. Keep all body parts inside the platform when it’s being raised or lowered.
• When using a fall restraint system, always check that your harness is securely attached to the platform’s designated anchor points. Keep both feet on the platform at all times to reduce the likelihood of falls.
• Wear appropriate PPE, such as a full-body harness, a hard hat, high visibility clothing, safety-toed footwear and safety glasses. Check with your supervisor which PPE is required and ensure you’ve been trained in its use.

What Not to Do

In addition to understanding the appropriate safety measures to adopt, it’s critical to understand what not to do.

Forklift operators must not:

• Operate the forklift if the work platform’s guards are missing or fault.
• Operate the forklift if individuals working on the platform aren’t wearing the appropriate PPE or if it’s not safe and effective for the job (e.g., their fall arrest lanyard is frayed or worn).
• Let anything interfere with the fall-arrest system used by employees on the platform (e.g., get too close to tools or equipment that could tangle or snag the harness).

• Tilt the mast or move the forklift suddenly or abruptly, because instability can lead to tip-overs.
• Travel with individuals on the platform.
• Lift workers on the forklift’s forks or use pallets, plywood sheets or other makeshift solutions instead of an OSHA-compliant work platform.
• Leave the forklift unattended for any reason. 

Workers on the work platform must not:

• Work on a platform that lacks guardrails or an appropriate fall-arresting system.
• Work on a platform if the forklift is on an unstable surface and the operator can’t raise it smoothly and safely.
• Step on the platform’s railings to reach something, as this could lead to falls.
• Overcrowd the platform or ignore the manufacturer’s capacity guidelines.
• Climb on any part of the forklift while entering or exiting the platform.
• Climb onto a pallet, board or any makeshift surface on a forklift.

Regardless of whether you operate the forklift or work on the platform, never undertake any work task that you have not been sufficiently trained for.

Conclusion

While forklift work platforms can be helpful for conducting tasks at heights, they also pose significant safety hazards. You can stay safe at work by understanding the risks associated with using work platforms with forklifts and closely following all safe working practices. For more safety information, contact your supervisor.

Article Published By: Zywave, Inc.