The Basics of Forklift Safety (Part 3)

Forklift speed

It is important, when discussing speed and stopping distances as it applies to forklifts, to remember what we observed earlier, namely that a normal forklift is about the same weight as a medium-sized dump truck.

Because forklift are so much smaller than a dump truck, we tend not to think of it in the same way but when it comes to stopping distances, not understanding this similarity can be dangerous. Let’s take a quick look at speeds and stopping distances for a typical forklift.

If a forklift is going 4 mph, it’s going to need about 17 feet or more to stop. The driver will usually travel about 7 feet before he or she has time to apply the brakes (and that’s assuming that the driver is paying close attention to his surroundings, which is not usually the case). It will take another 10 feet for the forklift to come to a full-stop.

If the forklift is going 8 mph, the distance jumps to 42 feet. At a speed of 9 mph the distance jumps up to 51 or more feet.

When we start to look at the numbers the severity of speeding on a forklift begins to become apparent. That rack of pallets is not going to escape unscathed at best and will topple over and/or dump its’ content at worse when impacted by a forklift. What about the load on the forks? At maximum stopping speed, the load will fly off, no if and or buts about it.

In addition, a forklift is much, much more unstable than a dump truck which greatly increases the danger. Tipping over, flipping, etc… are a very real and serious threat.

Employers need to determine what a safe speed is depending on the working conditions, amount of space, turn radius, etc… and post the speed limit accordingly. Forklift drivers need to know what the speed limit is and know that it will be enforced. They need to know that there will be repercussions if they are caught speeding.

If companies are serious about avoiding forklift injuries, this must be a clear policy in the workplace.

Ergonomics Tip of the Week # 6

Avoid any lifting while seated. Always try to stand up. If an object is heavy, get help to lift it!

The Basics of Forklift Safety (Part 2)

Understanding the basics of forklift stability

1. Forklifts are designed to carry loads. When a forklift moves without a load it is much more unstable than one with a load carried low to the ground.
2. Because loads are not fastened down, applying the brakes often causes the load to shift, causing additional instability.
3. Loads are intended to be carried low. When a load is raised the stability of the forklift drops substantially. This becomes even more dangerous if the forklift is moving.
4. Uneven ground, especially when going downhill with the load in the front, is extremely unstable.
5. Because of the narrow wheel base of a forklift design (designed that way intentionally in order to allow the lift to go into narrow spaces and still be maneuverable), the forklift is extremely unstable when the operator takes a sharp turn.
6. Uneven loads on a forklift can add tremendously to the instability.
7. It takes very little to flip a forklift if the upper part (top of the cab or raised forklifts) comes into contact with an overhead structure.

Measures to be taken in order to compensate for forklift instability

• Set and enforce low speed limits for forklifts. Do not allow reckless driving.
• Delineate pedestrian zones in the warehouse using floor marking tape and enforce it.
• Make sure that forklifts have seatbelts and make sure that the operator wears it. When an operator jumps off a tipping or falling forklift the odds are very good that he will get seriously hurt or killed.
• Remove incentives and such that encourage operators to speed in order to get the work done. Instead, give incentives for operators who demonstrate safety in the way that they do the work.
• Always check the distribution of the load to make sure it is properly distributed.

The Basics of Forklift Safety (Part 1)

Do you remember the movie “Christine”, the 1958 Plymouth fury with attitude based on a book by Stephen King?

You may not have a killer car in your warehouse out for revenge but chances are you’ve got one or more forklifts in it with the same destructive power. The fact is that the average forklift weighs as much as a medium-sized dump truck and, because it’s small and most often a lot quieter than a dump truck, it can become a very real source of danger to your employees. Additionally, because forklifts are used to transport heavy and bulky loads, its potential for injury goes up even more.

Forklifts are also used to load content onto trucks and semis which means that they are often working on docks and crossing spans between the dock and the truck bed, furthering the changes of an accident. Because forklifts are built to be more maneuverable than other vehicles (they usually have to get into very tight spaces, turn on a dime, etc…) they are more prone to stability issues and can be more easily flipped and tipped.

This writer has personally been involved in a forklift injury when a truck driver who had not checked to make sure that the back of the truck was closed and the steel plate removed, assumed all the loading was done and drove away suddenly leaving the back end of the forklift on the dock and the front end hanging in mid-air. I was fortunately younger and more agile than I am now (some 28 years ago now) and managed to jump clear before the forks planted in the asphalt and the forklift flipped over on its side (it fortunately tipped the opposite way from the way that I jumped). I came away unscathed. All over the county each year there are many others who aren’t so fortunate.

Most of us understand that forklift operators need to receive proper training and be certified. Few of us think about the fact that the forklift operators aren’t the only ones at risk.

Types of accidents caused by forklifts

1. Pedestrians hit by moving forklift (This includes pedestrians hit by any part of the forklift, whether while the operator is driving or while the operator is maneuvering)
2. Unstable loads that fall on pedestrians
3. Danger of impalement to pedestrians
4. Injuries to operators because of tipping over or rolling over
5. Injuries to workers improperly standing on or working on the fork arms or loads.
6. Operators falling off the forklift
7. Person(s) being overcome by the exhaust fumes from a forklift
8. Injury from shelving or other objects that are hit by forklifts

Free Beta Software for Calculating Arc Flash

If you are involved with electrical work you need to check out the arcadvisor.com blog at http://arcadvisor.blogspot.com/

It focuses exclusively on arc flash, its dangers, prevention, etc… Additionally, they’ve got a free beta version of an arc flash calculation software that you can download free in exchange for feedback.

Arcad, the company that provides this blog and free software “helps facilities create safer working environments for individuals who service electrical systems by providing On-Line and PC based software tools for Short Circuit and Arc Flash Hazard Analysis. NFPA requires that any panel likely to be serviced by a worker be surveyed and labeled. ARCAD service includes resources and tools allowing plant and facility managers and personnel to perform short circuit, incident energy, arc flash protection boundary, level of PPE calculations, and create customized arc flash warning labels themselves drastically reducing the cost of getting in compliance with OSHA & NFPA 70E”

Have a look around (It’s a Canadian company but the information applies here in the U.S. as well), and download the free software. Don’t forget to go back and give them feedback, it’s the least you can do to thank them for the free download.

FR clothing… all the way or not at all!

You’d have to be living somewhere in upper Mongolia in a cave for the past decade not to know about the new standards and safety measures concerning Flame Retardant clothing that have been enacted and which are still in the works.

Being aware of the changes and standards is one thing, understanding them properly is quite another. I’m referring specifically to the issue of FR underclothing.

Many people don’t realize that, when dealing with arc flash, it isn’t enough to wear FR outerwear only. In case of the type of electrical power involved in an arc flash, your underclothing is just as much an issue as your outerwear. The outerwear may not catch fire and/or continue burning but the energy will go through to the underclothing. If you are wearing cotton or polyester under the outerwear, especially right up against the skin, these garments can ignite and/or melt and cause serious burns.

For this reason, it is important to dress appropriately if you are dressing to protect against arc flash.

Fortunately, there are FR underclothing options. Clothing such as the 5 cal flame retardant 2^nd Skin by Benchmark is a great, comfortable solution to the problem.

There are also FR bras available online for the ladies.

With FR clothing, its about protection all the way down, through all the layers, not just the outerwear.

Ergonomic Tip of the Week # 5

Eye Exercises. Rest your eyes routinely by focusing on objects at different distances. Look at an object far away (at least 20 feet) for a count of 20, then look at an object close for a count of 20. Repeat this 5 times

Safely handling Cement

Cement and concrete are an inescapable element of modern life. From the basic foundations to whole buildings, to sidewalks and streets, concrete is everywhere and the amount is increasing daily. Cement, however, can be a health hazard. Between 5% to 10% of construction workers may have cement sensitivity and, even the rest of the workers are still at risk on a number of levels. Being aware of the hazards is important in order to handle it correctly and avoid injury.

What are the hazards?

1. Dermatitis and Burning from skin contact
   
   1. Dermatitis is a rash or irritation that results when a worker who has an allergy or sensitivity comes in contact with cement. The skin will itch and get irritated and sore. It will look red, cracked and/or scabby. Even those without an allergy to cement can develop irritant dermatitis which is a chaffing or irritation of the skin that is simply due to the basic nature of cement. Allergic dermatitis is an allergic reaction to the hexavalent chromium in cement. Allergic dermatitis can develop over time, much like a latex allergy. The more a worker is exposed to cement the more likely he or she is to developing an allergy.
   2. Cement burns result because of the alkaline content in wet cement. Prolonged exposure to wet cement can result in serious burns and ulcers. Untreated burns can get worse and worse and eventually get bad enough to require skin grafts. Seek medical attention right away.
2. Inhalation of cement dust
   When handling and pouring cement, the fine dust can be a hazard to the lungs. A dust mask should be used. When grinding concrete, workers might want to step up to a half-mask in order to provide a higher level of protection from the silica.
   
   
3. Ergonomic and physical Issues related to working with cement
   Cement bags can be heavy, pouring concrete can be back breaking work and because of this it is important to know your limitations and to stretch before starting work.

Precautions to be taken when handling cement:

1. Wear the appropriate personal protective equipment (Gloves, protective clothing, boots, gloves and eye protection)
2. In the event of contact with the skin, wash the area immediately
3. Do not leave wet cement on clothing, no matter how much you think your clothing is waterproof.
4. Use adequate protection when kneeling in concrete (kneepads or kneeboards)
5. Use Neutralite Solution for concrete burn to neutralize the Alkaline properties of cement and restore the pH balance.

How to wash contaminated clothing:

• Wash any and all contaminated clothing separately. DO NOT MIX WITH OTHER CLOTHING.
• Wash clothing as soon as possible.
• Wash in hot water for the longest normal wash cycle.
• Use 1.5 the normal amount of detergent
• Wear gloves when handling contaminated clothing in order to avoid skin contact
• Run an empty cycle with hot water and detergent after wash contaminated clothing in order to decontaminate the washing machine

The power of… and problem with… “routine”

The brain is an amazing tool. It has abilities that we are still far from completely understanding. One of these is the ability to function on a subconscious level so as to free up your conscious mind. That’s called habit and we spend a lot of our time doing things out of habit. We stumble out of bed and into the shower, make the coffee, get dressed, etc… almost without thinking about it. The way we’ve always functioned and done things is the most likely way that we’ll continue to do things… mostly out of habit.

When it comes to safety and the work place this can be a good thing or a bad thing. Routines and habits, especially if they are safe ones, save time and energy. Much of our work day is spent on “autopilot”. This is why it is important that proper training be instituted and that the habits that workers acquire be safe ones, right from the start.

The problem is that this often isn’t the case. We cut a corner, skip a step… and before we know it it’s become a habit and we’re doing it every time, most often without even thinking about it. As long as nothing goes wrong the negative habit doesn’t affect us but as soon as something goes wrong, we find ourselves in trouble.

The construction worker starts taking a step back to better see what he’s doing. Pretty soon he’s taking more than one step back, most often without even looking. He’s never needed to look behind him because there’s been no reason to. This time, however, he’s working on a ledge and when he steps back the floor isn’t there. He isn’t high off the ground (one would assume that he would then be safely tied off with fall protection) but the 6 inches is enough to send him head over heels and before you know it a serious injury has taken place.

Understanding the minds’ ability to slide into a habit in this way is important, both for workers and supervisors. Creating positive habits is what training is all about; it’s why it’s important to run safety drills and put together safety plans that everyone understands and buys into. Breaking negative habits is why it’s important to have everyone take responsibility for everyone else’s safety; it’s why a positive corrective attitude needs to be cultivated (one that says that it’s okay to point out negative habits and routines to fellow workers).

It’s all about tapping into and breaking… the power of the routine!

Housekeeping for safety

One of the best things that you can do to help prevent injuries in the workplace in this coming year is to clean house. Good housekeeping is key to keeping the accident rate low. Here is a quick “to do” list that should become standard practice in your workplace.

1. Everything has a place and everything goes where it should. Pallets in the aisles or stacked where they shouldn’t be is not only a bad idea when it comes to finding what you need, it’s also a bad practice with relation to safety.
2. Clean up trash, cartons and paper right away. Left laying around they are a fire hazard and a trip and fall hazard as well.
3. All flammable liquids should be stored in the proper cans and in an explosion-proof cabinet.
4. Keep wheeled equipment in a safe place and lock the wheels when possible and when not in use.
5. Stack and store all materials neatly. Don’t risk having materials fall on people.
6. Keep spill kits and pads handy and use them as soon as you have a spill.
7. Do regular inspections on hoses and pipes. Immediately replace used, cracked or broken hoses and pipes.
8. Use floor marking tape to clearly mark pedestrian traffic areas. Use Anti-Slip grit tape where needed.
9. Put up mirrors in areas where traffic might be difficult to see.
10. Post signs to let employees know of problems and hazards. Make sure that there are also signs that outline what PPE needs to be worn in each area.
11. Make sure that first aid kits are available and clearly marked.

The best safety plan is prevention. Keeping a neat and tidy area is the first and most important step and one that should never be ignored.