A forklift operator sees the job from the seat. The person walking across the aisle sees it from the floor. Most forklift-pedestrian incidents happen where those two views don't meet: at a blind corner, behind a load that blocks the operator's view, or in the swing of the truck's rear end.
OSHA's Powered Industrial Trucks eTool puts it plainly: many pedestrians and bystanders are injured in forklift accidents, either struck by the truck or by falling loads. This guide covers what OSHA requires, how to set up a facility so trucks and people cross paths less often, and the habits operators and pedestrians both need.
What OSHA requires
Several parts of OSHA's powered industrial truck standard, 29 CFR 1910.178, protect people on foot.
Operators:
- Must slow down and sound the horn at cross aisles and anywhere vision is obstructed (1910.178(n)(4)).
- Must travel with the load trailing if it blocks the forward view (1910.178(n)(4)).
- Must look in the direction of travel and keep a clear view of the path (1910.178(n)(6)).
- Must follow traffic rules, including plant speed limits. Operators must keep about three truck lengths from the truck ahead (1910.178(n)(1)).
- May not drive a truck up to anyone standing in front of a bench or other fixed object (1910.178(m)(1)).
Everyone:
- No one may stand or pass under the elevated portion of any truck, loaded or empty (1910.178(m)(2)).
- Unauthorized people may not ride on a truck (1910.178(m)(3)).
The facility:
- Where mechanical handling equipment is used, aisles, loading docks, doorways and turning areas need enough safe clearance. Aisles must be kept clear, and permanent aisles and passageways must be appropriately marked (29 CFR 1910.176(a)).
Training:
- "Pedestrian traffic in areas where the vehicle will be operated" is one of the workplace topics every operator's training must cover (1910.178(l)(3)(ii)(D)).
Designing pedestrians out of the truck's path
The most effective protection is distance. OSHA's eTool says forklift traffic should be separated from other workers and pedestrians where possible, and it suggests:
- Dedicated pedestrian walkways, kept out of truck aisles wherever the layout allows
- Permanent railings or other barriers between walkways and truck traffic
- Painted walkway striping on the floor where barriers aren't practical
- Enough walking space on at least one side of any equipment aisle pedestrians must use
- Convex mirrors at blind aisle intersections
- Traffic control signs and posted speed limits
A few layout questions are worth walking through with a floor plan:
- Where do people actually walk? Break rooms, restrooms, time clocks and exits create foot traffic across truck aisles at shift change. Route walkways to them, not through the busiest aisles.
- Where are the blind spots? End-of-aisle intersections, doorways, rack ends and the spots beside dock doors are the usual places. Add mirrors, signs or a stop line.
- Where do trucks back up? Loading docks and staging lanes see constant reversing. Keep walkways out of the reversing zone.
- Are crossings marked? Where a walkway must cross a truck aisle, make it a marked crossing, and train operators to stop there.
Habits for operators
OSHA's eTool lists these reminders for drivers:
- Yield the right of way to pedestrians. When someone crosses your route, stop, wait for them to pass, then proceed with care.
- Slow down, stop and sound the horn at intersections, corners and anywhere your view is blocked.
- Sound the horn or another alarm when backing up, and use the flashing light or backup alarm if the truck has one.
- Don't move the truck without a clear view of your path. Use a spotter for blind spots.
- If an area is cluttered, walk the route first to spot problems.
- Make eye contact with pedestrians and other operators when you can.
- Start, stop, travel, steer and brake smoothly.
- Never let anyone stand or walk under the load or the lifting mechanism.
- No riders, unless the truck is designed for them and riding is authorized.
Habits for people on foot
Pedestrians need to know how forklifts behave, too. OSHA's eTool lists these reminders:
- Forklifts can't stop suddenly. They're designed to stop gradually to protect the load and stay stable.
- Stand clear of trucks in operation. The operator's view may be limited by blind spots.
- Watch the rear swing. Most forklifts steer with the rear wheels, so the back end swings wide in a turn.
- Use the walkways, or stay to one side of an equipment aisle.
- Never ride on a forklift unless you're authorized and it's designed for riders.
- Never walk under a raised load.
A short briefing for everyone who works near forklifts is a good idea: temps, visitors, maintenance staff and office staff who walk the floor. It isn't operator training, but it teaches them how to be seen and where not to stand.
Warning devices help, but don't replace the basics
Horns, backup alarms, flashing strobes and projected floor lights all help pedestrians notice a truck. In a busy building, though, constant beeping soon gets tuned out. Devices work best on top of separated walkways, marked crossings, sensible speed limits and operators who stop and look. They don't replace those things.
Pedestrian safety starts with operator training
Every operator's training has to cover pedestrian traffic in the areas where they'll drive. That training works best in the real building, where operators can see the actual blind corners, crossings and dock areas they'll deal with every shift. It also connects to the other skills that protect people nearby: a proper daily inspection catches a dead horn or backup alarm before the shift starts, and understanding load stability keeps loads from falling where people walk.
How BHG Forklift Training helps
We train operators at your facility, so pedestrian safety is taught in your own aisles, crossings and docks, not in a classroom diagram. We cover every truck your operators run, from Class 1 electric riders to Class 2 reach trucks in narrow aisles and Class 3 pallet jacks in busy pick areas. The evaluation includes how each operator handles pedestrians on a real route. Training is available in English and Spanish.
See our forklift classes or schedule training at your facility.