section 16: aerial lifts, elevating work platforms, forklifts and...

UC System - Shop Safety Reference Manual Section 16 – Aerial Lifts, Forklifts and Lift Trucks February 2014

Section 16: Aerial Lifts, Elevating Work Platforms, Forklifts and Other Industrial Lift Trucks

OVERVIEW Cal/OSHA requires that all operators of aerial lifts, elevating work platforms, forklifts and other kinds of industrial lift trucks be trained and licensed to operate such equipment prior to the equipment-owner allowing the equipment to be used. The University of California extends this requirement to all personnel who may operate these kinds of equipment that are owned or leased by the University of California, regardless of the affiliation of the person with the University. Training must include either a class-room or on-line training portion where theory, loading, center-of-gravity, environmental hazard assessment, safe operating procedures, etc… are discussed. Then, a hands-on portion of training on each type of lift must be conducted where the operator demonstrates good judgment and operator skills to a skilled operator who will “license” the new operator for a 3-year period. Cal/OSHA requires that training and licensing be conducted initially of any operator using these kinds of equipment. Renewal of license must be completed every three-years for forklifts and industrial lift trucks. Aerial Lifts do not have a renewal requirement, however many campuses have included a 3-year renewal requirement for this equipment as a best-practice in safety management.

WHAT ARE ARIAL LIFTS AND ELEVATED WORK

PLATFORMS (AL/EWP)? Aerial Lift / Elevated Work Platform (AL/EWP) equipment is used to raise people from ground/floor level to conduct work aloft. They may be used indoors or outdoors and for any purpose when a person needs to work at an elevated location. There are many different kinds of AL/EWP equipment and are selected and used based upon work need and site conditions. Some are self-propelled, some are mounted on truck beds, some are towed behind a vehicle on a trailer, etc…. Power sources for the equipment include plug-in electric, on-board rechargeable battery packs, propane, gasoline, dual-power units, etc…. Common kinds of AL/EWP equipment include ‘Bucket Trucks’, Boom Trucks, Scissors Lifts, Extensible Boom Lifts, Articulating Arm Lifts, etc… While not exhaustive, below is a limited list showing various kinds of equipment affected by the Cal/OSHA codes / requirements:


Articulating Boom Lift –

An aerial device with two or more hinged boom sections. Fall Protection is required when operating this Lift.

Elevating Work Platform –

A device designed to elevate a platform in a substantially vertical axis. This device is stationary once setup and cannot be moved. Fall Protection is not required when operating this equipment, but is highly recommended.

Extensible Boom Platform –

An aerial device (except ladders) with an extensible boom. Telescopic booms with personnel platform attachments are considered to be extensible boom platforms. Fall Protection is required when operating this equipment.

Scissor Lift –

A device designed to elevate a platform in a substantially vertical axis. This device can also be driven by an operator inside the work platform and is generally designed to carry more than one person. Fall Protection is not required when operating this Lift, but is highly recommended.

Trailer Mounted Lift –

A device that can be towed by a vehicle to a work site, then un-hitched. These units have extendable or folding outriggers to give stability while being operated. Fall Protection is required when operating this Lift.


Vehicle Mounted Lift –

These devices typically have a Bucket in place of a basket, which is designed for one person. Vehicle must have the brakes set, wheels chocked, and outriggers in place while operating this device. Fall Protection is required when operating this Lift.

WHAT ARE FORKLIFTS AND INDUSTRIAL LIFT

TRUCKS? Forklift / Industrial Lift Truck equipment is used primarily to move palletized materials and equipment from one location to another. They may be used indoors or outdoors and for any purpose when materials must be moved, loaded, unloaded, stored on racks in an elevated location, etc... There are many different kinds of Forklift / Industrial Lift Truck equipment and are selected and used based upon work need and site conditions. All are self-propelled, but some such as a Pallet Jack or Walkie-Stacker are operated while walking behind the equipment. Power sources for the equipment include plug-in electric recharge of on-board battery packs, propane, gasoline, diesel fuel, dual-power units, etc…. Common kinds of Forklift / Industrial Lift Truck equipment include Pallet Trucks, Walkie-Stackers, High Lift “Common” Forklifts, Order Pickers, Peti-Bones, Rough Terrain Trucks, etc… While not exhaustive, below is a limited list showing various kinds of equipment affected by the Cal/OSHA codes / requirements:

Electric Pallet Jack –

An Electric Powered Lift that the operator walks behind that is made for carrying palletized material. It is designed to lift the load 6” or less, and not for stacking or placing the load up into storage racks. Requires a pre-operation safety inspection.

Walkie-Stacker –

An electric powered device that the operator walks behind that is designed with a mast and is made for transporting palletized materials, with the option of stacking pallets up to four (4) high. Requires a pre-operation safety inspection.


High Lift Truck / “Common Forklift” –

The most commonly used Powered Industrial Lift. Also referred to as a cantilever type forklift, because it has a counter weight to offset the load it is designed to carry. Commonly operate on electric (batteries) and natural gas (CNG or Propane). Requires a pre-operation safety inspection.

Narrow Aisle Lift –

The Narrow Aisle Lift operates differently from other lifts in that the operator stands while riding on the lift, with a steering wheel and other controls located near their waist area on most models. The load scissors in and out of the racking system. Powered by CNG, propane or electricity / batteries depending upon design / use. Requires a pre-operation safety inspection.

Order Pickers and Stock Pickers –

A lift that the operator rides on and can be raised up/down on a platform adjacent to the forks to retrieve items from storage racks. Operators using this device must wear proper fall protection (Body-Harness and Lanyard) in compliance with Cal/OSHA Fall Protection codes. Powered by propane, CNG or electricity / batteries depending upon design / use. Requires a pre-operation safety inspection.

Peti-Bone –

Used to lift large/heavy loads, this lift is all-wheel drive and is made for rough, uneven or steep terrain. Powered by diesel or gasoline. Requires a pre-operation safety inspection.

Rough Terrain Lift –

These lifts are used mostly on construction sites for their ability to conquer rough terrain and telescope to reach high locations. Powered by diesel, gasoline, or propane depending upon design / use. Requires a pre-operation safety inspection.


MY DEPARTMENT USES THIS EQUIPMENT.

WHAT DO WE HAVE TO DO? Departments that own, rent and/or lease Aerial Lifts / Elevating Work Platforms (AL/EWP), forklifts or industrial lift trucks, or control property where this equipment is brought in and used by others, must:

• Select and then purchase, rent or lease appropriate equipment for job tasks based upon a work-environment and job-task hazard analysis,

• Train and license personnel who operate their specific type of owned / rented / leased equipment,

• Conduct documented safety inspections and preventive maintenance of the equipment,

• Assure operators of your equipment adhere to specific safe-work practices whenever using these types of powered industrial equipment, and

• Approve Contractors / Vendors to use AL/EWP / forklifts / industrial lift equipment on their premises, and only allow properly licensed contractor / vendor personnel to use Department-owned equipment.

• Ensure that contractors / vendors using their own such equipment on UC-property have proper licenses from their employers demonstrating safe-use proficiency of the equipment brought onto the UC-controlled site.

WHAT PERSONNEL DOES THIS APPLY TO? The requirements of operator licensing, equipment pre-use inspection, etc… applies to all University of California Faculty, Staff and Students who are required or request to operate Aerial Lift/Elevating Work Platform (AL/EWP), forklifts or other industrial lift trucks, or those personnel who must oversee persons operating such equipment. This requirement applies for any portion or aspect of research, instruction and/or facilities maintenance and other kinds work. It also applies to contractors and visitors using UC owned / leased / rented equipment. In all such situations, your campus EH&S is required to ensure that all users are appropriately licensed by the process your campus uses to do license personnel. Contact your EH&S department for further information and to arrange licensing of personnel as need may dictate. In situations where an outside contractor / vendor brings their own AL/EWP, forklift or other industrial lift equipment onto UC property, the owner-department of the UC property must ensure that all operators are properly licensed by the contractor / vendor prior to allowing such equipment use on the owner-department’s / UC property.


CONTRACTORS OR VENDORS USE AL/EWP,

FORKLIFTS, ETC… ON OUR PROPERTY. WHAT

DO WE HAVE TO DO? Departments hiring contractors or overseeing vendors that use their company’s AL/EWP, forklifts or industrial lift trucks on UC property, are NOT responsible to assure the contractor’s / vendor’s compliance with Cal/OSHA codes. However, Contractor or Vendor employees that have been trained under their company’s AL/EWP, Forklift and/or Industrial Lift Truck Safety program, and have your Department’s permission, may operate such equipment owned/leased/rented by their employer on UC premises. Contractors / Vendors who use AL/EWP, forklift or industrial lift equipment that is owned and/or rented/leased by a UC Department must demonstrate to the Department’s Safety Manager or other Responsible Person their current licensure for operation of the specific type of AL/EWP, forklift or industrial lift equipment before they are allowed to operate the UC owned / leased / rented equipment. Whether the operator is a vendor or contractor, or UC personnel, they may be required to show verification (an actual operator’s license kept in their wallet) that they have been trained and licensed on the specific AL/EWP, forklift or industrial lift equipment being operated on UC property. This request may be made by any UC Department representative at any time during work. If contractor / vendor employees are found to be unlicensed, all work using the AL/EWP, forklift or industrial lift equipment must stop immediately until properly licensed personnel are present to operate the equipment.

IF I WANT TO PURCHASE OR LEASE AL/EWP,

FORKLIFT OR INDUSTRIAL LIFT EQUIPMENT,

WHAT DO I HAVE TO DO? Department Management is responsible for selecting, purchasing/leasing, owning and maintaining the AL/EWP, forklift and industrial lift equipment and must designate the person(s) responsible for implementing the following safety-program requirements including:

• Identify / Evaluate AL/EWP, forklift and/or industrial lift equipment requirements based upon a hazard assessment of the work environment, and work-task requirements. Your EH&S Department can help you conduct this assessment.

• Inventory and inspect Department AL/EWP, forklift and industrial lift equipment using specific program documentation for recordkeeping purposes. Samples are available in the Safety Management Tool Kit.

• Identify personnel requiring AL/EWP, forklift or industrial lift equipment training and licensure.

• Assure training, qualification and ongoing retraining and licensure of selected Department Personnel.


• Assure Department Operators are following AL/EWP, forklift and/or industrial lift truck safe-work operator procedures.

• Assure Contractors / Vendors operating UC Department owned equipment are licensed and authorized to operate the equipment.

• Assure Contractors / Vendors operating their own equipment on UC-owned property controlled by a host-department have operators who are licensed to operate their equipment by their employer (ask for evidence of operator licenses).

• Maintain records of program implementation, pre-use inspections and training / licensure of operators for UC personnel and equipment.

WHO MAY USE AL/EWP, FORKLIFTS AND

INDUSTRIAL LIFT EQUIPMENT, AND WHAT

TRAINING AND LICENSURE IS REQUIRED? Each Operator must successfully complete Operator Safety Training prior to operating AL/EWP, forklift or industrial lift equipment on UC property. Training can be provided by EH&S or an outside vendor with EH&S approval. Depending upon the type of AL/EWP, forklift or industrial lift equipment used, fall protection gear may need to be worn by the operator (see description of equipment above in the AL/EWP photo-table that requires fall protection gear to be worn). Additional “Fall Protection Training” may be required if this type of gear must be worn. Fall protection training can be done by your campus EH&S or outside vendor with EH&S approval. Anyone in the owner Department who has the work-need to operate a piece of AL/EWP, Forklift or Industrial Lift Truck equipment must be trained and licensed prior to allowing them to operate the Department’s equipment. An Operator’s License is issued by EH&S, or a certified vendor if your campus EH&S approves the use of vendors, is credit-card size, and is valid for three years. It must be carried by the Operator whenever he/she is operating an AL/EWP, forklift of Industrial Lift Truck on UC property. Within 90 days of expiration, the Operator is responsible to schedule re-training/licensure with EH&S through the LMS, or with their Department’s DSC/responsible person. Licensure is good for three (3) years. Operators must attend and successfully complete a ‘retraining’ within 90 days of the end of the 3-year licensure cycle to start the clock on the next 3-year cycle. It is highly recommended that all AL/EWP, forklift and industrial lift operators be held to this same training / retraining schedule by host Departments. While not required by law, many departments have both kinds of equipment used by the same operators, and conducting refresher training on AL/EWP equipment makes tracking and recordkeeping training easier for personnel managing the programs, and operators remembering when their training is needed.

Student Training Resource for AL/EWP Equipment


There is an excellent online-training-resource available for UC Departments who will have students using AL/EWP equipment. Offered through Notre Dame University, and the non-profit www.liftupright.org in response to the tragic death of a student that was elevated high-up in an aerial lift filming football-practice when it was blown-over by a wind-gust, the online-training is a great primmer for user and manager alike to understand the hazards associated with AL/EWP use, and how to prevent accidents. While watching this program would not complete training requirements, it’s a good “classroom” primmer for students learning to operate AL/EWP equipment, and may be used by UC departments to supplement the classroom-portion of the training for licensure for UC use. The hands-on portion of the training must still be conducted by UC Departments / EH&S and licensure must be completed prior to allowing work aloft. Please navigate to the link below for the “Lift Up Right” – Aerial Lift Safety online training program: http://www.liftupright.org/

CAN I OPERATE ANY TYPE OF AL/EWP,

FORKLIFT OR INDUSTRIAL LIFT EQUIPMENT

ONCE I’VE BEEN TRAINED AND LICENSED? No. Operators may only use the AL/EWP, forklift or industrial equipment type they have been trained and licensed to operate. Different types of equipment require a separate training and license to operate. AL/EWP, forklifts and industrial equipment may be operated by unlicensed operators only when under the direct supervision of persons who have the knowledge, training and experience to train operators and who can evaluate their competence “in the field”.

CAN I OPERATE AL/EWP, FORKLIFT OR

INDUSTRIAL LIFT EQUIPMENT I’VE BEEN

LICENSED ON IN DIFFERENT DEPARTMENTS

AT UC? The short answer is, “That depends upon your campus and the department who’s property you’re working on.” Some campus departments may require that users of equipment go through the host-department’s licensing process and/or are licensed-checked by a hands-on observation of operator skill in their department’s work area before allowing equipment users to operate equipment on their property. Other departments may allow users of equipment who have been licensed by one department to operate the equipment they’ve been licensed to operate on the hosting-department’s property. The bottom line is you must ask someone in authority in the hosting department what their rules are for allowing AL/EWP, forklift and industrial lift equipment use on their


property, and then follow those rules. The hosting department where the work is being done sets the rules of how the work gets done and what qualifies as being “licensed”.

WHAT’S INVOLVED IN TRAINING AND

LICENSING PERSONNEL TO USE AL/EWP,

FORKLIFT OR INDUSTRIAL LIFT EQUIPMENT? Training is “two-part” and consists of a combination of written, classroom and/or interactive computer learning, followed by hands-on “field” training and documented testing that’s specific to the AL/EWP, forklift or industrial lift equipment. Both sections of training are documented to record successful completion of that portion of the training. Written / classroom training includes familiarization with equipment types and components, hazard assessment and mitigation, equipment inspection requirements, and other requirements of this program. Upon successful completion of classroom training, the trainee then takes hands-on training in the field.

Classroom Training

Classroom training is verified through a written final exam that demonstrates the trainee understands basic AL/EWP, forklift and/or industrial lift truck operation and safety. Completion of this classroom training exam with a passing grade of 70% or more is required before the scheduling of the hands-on/field training. Records of completed exams are kept by the UC Learning Management System, and also optionally by the Department in the trainee’s personnel file.

Hands-On / Field Training / Testing

The “Hands-On” training and testing is conducted using a representative piece of AL/EWP, forklift and/or industrial lift truck equipment under the direct supervision of the EH&S Trainer and/or the host-Department’s Safety Program manager depending on the campus who has the knowledge, training and experience to train equipment operators and evaluate their competence. Field training using AL/EWP, forklift and/or industrial lift equipment includes demonstrations performed by the trainer, practical exercises performed by the trainee and observed by the trainer, as well as evaluation of the trainee's successful performance on a standard ‘skills assessment’ course that is documented for recordkeeping purposes on the LMS by EH&S.

Licensure for Operating Equipment

Once training is successfully completed, a license to operate the specific AL/EWP, forklift or industrial lift equipment is issued and must be carried by the operator when using the equipment. Licensure is good for 3-years or until work conditions, the equipment or other factors change warranting retraining. Operators must attend and successfully complete a ‘retraining’ when specific conditions or unsafe work behaviors are observed, or an accident occurs that can be determined to be operator error. In


addition, retraining must be completed within 90-days of expiration of an operator’s license to operate AL/EWP, forklift and/or industrial lift equipment. Refresher Training Cal-OSHA requires refresher training to ensure the Operator has the knowledge and skills needed to operate AL/EWP, forklift and industrial lift equipment safely when:

• Their 3-year license to operate expires within 90-days, or

• The operator has been observed to operate the equipment in an unsafe manner, or

• The operator has been involved in an accident or near-miss incident, or

• The operator has received an evaluation that reveals that the operator is not operating the equipment safely, or

• The operator is assigned to a different type of equipment that they haven’t been trained on previously, or

• A condition in the workplace changes in a manner that could affect safe operation of the AL/EWP, forklift of industrial lift equipment.

WHAT ARE THE SAFE-WORK PROCEDURES

FOR USING AL/EWP, FORKLIFTS OR

INDUSTRIAL LIFT EQUIPMENT? Safe work procedures for the use of any type of AL/EWP equipment are detailed in the training content of the Shop Manager’s Safety Management Tool Kit, and include the following:

• Assessment of AL/EWP, forklift or industrial lift equipment selection including a documented “Site Hazard Evaluation” and safe-work practices required,

• Documented Pre-Operation Equipment Inspection with determination if fall protection PPE and other gear must be worn during work aloft,

• Implementing an “Equipment Tag Out” notification procedure for repair when deficiencies in the equipment are discovered,

• Following specific operating procedures, safe work rules, hazard identification and controls when operating AL/EWP, forklift or industrial lift equipment.

DOES A PRE-OPERATION INSPECTION NEED

TO BE DOCUMENTED FOR EACH WORK-SHIFT? Yes. It’s required by law and makes good sense as equipment and site conditions can change, and unrecognized hazards develop, without the operator’s knowledge unless a pre-operation inspection is completed. This inspection assures the operator that the equipment they are about to use is safe to take them aloft and/or move large heavy objects, and alerts them to hazards in the work area. The documentation associated with the inspection assures that a systematic approach to hazard recognition is taken, and that Departments are complying with legal requirements.


Prior to operation at the beginning of each work-shift, Operators must review and assess the following equipment/work area conditions:

• Review work area for hazards, and remove/control them prior to operation.

• Always conduct an environmental hazard assessment prior to selecting / using AL/EWP, forklift and/or industrial lift equipment.

• Only use equipment designed to safely work in the work-area conditions observed.

• Review operating instructions, warnings, and precautions for the types of equipment being operated.

• Prior to operation at the beginning of the work-shift, inspect and document the equipment’s proper function of controls and instrumentation. Do they operate correctly?

• Inspect engine or motor operation.

• Inspect steering and maneuvering.

• Familiarize yourself with visibility.

• Inspect basket or platform capacity and equipment stability.

• Check fuel and/or charging of batteries, and refuel/recharge as needed.

• Review and understand equipment operating limitations.

• Review other operating instructions, warnings, or precautions listed in the operator's manual for the equipment that you will operate.

WHAT ARE SOME BASIC SAFE-WORK RULES

FOR OPERATING AL/EWP, FORKLIFT AND

INDUSTRIAL LIFT EQUIPMENT? • Alert all persons in the work area of intended work activities and hazards.

• Always face the direction of travel.

• Don’t travel horizontally with the platform or forks elevated or extended.

• Don’t exceed the basket or platform capacity.

• Position equipment on a firm level surface and minimize blocks or ramps for leveling the equipment.

• Always set outriggers prior to use if the AL/EWP is equipped with them.

• Wear proper safety harnesses and only tie-off to the work platform’s fall protection tie-off point if fall protection is required.

• “Barrier off” the lift swing work-area below the AL/EWP equipment’s work zone, or in the forklift / industrial lift work zone.

• Don’t climb on guardrails, climb on ladders or stand on other items when working from inside an AL/EWP platform or forklift personnel lifting platform.

• Practices good housekeeping when working in and around the platform.

• Never drop or throw objects to or from an elevated work platform.

• Always look below the platform and confirm it’s safe to lower the equipment before lowering the equipment.

• Never lean the platform on or against structures.


• Never use the boom or forks to push against something, or try and pull the AL/EWP or forklift equipment along in a horizontal direction.

ARE THERE CHECKLISTS THAT CAN BE USED

TO DOCUMENT PRE-OPERATION

INSPECTIONS? Yes. The Shop Manager’s Safety Management Tool Kit has pre-operation checklists customized by equipment type for use by Operators when conducting their equipment inspections and site hazard evaluation.

WHAT DO I DO IF I FIND AN EQUIPMENT

DEFICIENCY OR NEWLY RECOGNIZED

HAZARD? If a hazard in the work-site is identified (for example, soft ground due to a recent rain storm), then the operator must conduct an assessment of the hazard, implement control measures (for example, install steel support plates on the ground), determine if the AL/EWP, forklift or industrial lift equipment is appropriate to use at the work-site, or if a different type of equipment or other work-method is needed. If there is an equipment deficiency that can be corrected by the operator without causing them or the work site harm (for example, refueling the lift prior to use), then the operator corrects the deficiency and proceeds to use the equipment. If the deficiency cannot be repaired by the operator, then the operator follows an “Equipment Tag Out” procedure to alert others of the deficient condition, alerts their Supervisor of the deficient condition to arrange for repair, and does not use the equipment until the condition has been corrected.

“Lift Truck Tag Out” for Repair

No AL/EWP, forklift or industrial lift truck is used until any deficiency(s) discovered during a Pre-Operation Inspection are corrected. If a hazardous deficiency is discovered during a Pre-Operation Inspection, the Operator alerts their Supervisor of the condition, and “Tags Out” the truck from being used by controlling all ignition keys for the vehicle, and placing a “Warning Tag” on the vehicle steering wheel with the following information:

• Person’s name that has “Tagged Out” the vehicle and has the keys in their possession as well as their contact information.

• Date vehicle was “Tagged Out”.

• Reason(s) for “Tagging Out” the vehicle including all noted deficiencies. (A photocopy of the completed inspection form may be taped to the steering wheel for this purpose.)


• Name and contact information for the Department’s responsible person for implementation of this program.

No repairs are made on any AL/EWP, forklifts or industrial trucks until the vehicles and their components are blocked, tagged, locked out or otherwise made safe for repair work to commence according to application of Section 8 – Energy Isolation – Lock out Tag out of this Shop Safety Reference Manual.

WHAT KINDS OF RECORDS SHOULD MY

DEPARTMENT KEEP TO DEMONSTRATE

PROGRAM COMPLIANCE? Each department that owns / rents / leases this type of equipment must designate a responsible person to manage the records, and ensure appropriate training, concerning the equipment’s procurement, maintenance and use. Recordkeeping requirements include:

• An inventory of Department owned equipment,

• A list of currently-licensed AL/EWP, forklift and/or industrial lift Operators employed by the Department,

• inspection records,

• rental / lease / purchase agreements, etc….

WHAT REGULATIONS GOVERN THE

REQUIREMENTS OF THIS SECTION? Regulations that govern the need for and requirements of the AL/EWP Safety Program include Cal/OSHA, US-DOT and other regulations. A list of these regulations with links to their specific content is included in the Shop Manager’s Safety Management Tool Kit. Contact your campus’ EH&S Department for questions and help on implementing the requirements of this section in your Shop / Lab / Department.

AS A FORKLIFT OPERATOR, WHAT ARE THE

KEY PIECES OF EQUIPMENT AND

ASSESSORIES I SHOULD KNOW ABOUT?

Counter Weight –

The rear section or area of the forklift which is usually made of solid steel, and/or combination of steel and the weight of the battery on an electric lift, that counter balances the load that is placed on the forks.


Data Plate –

Manufacturer’s equipment specification and information data, which includes load rating/lift capacity, lift heights, load center measurements, vehicle weight, and vehicle attachments. This plate is required to be affixed to all Industrial Lift Equipment by regulatory code. This is the vehicle operator’s primary source of basic information about their vehicle for safe-work and use planning.

Dumpster Bin –

A fork-attachment used to transport a variety of materials. Always stand clear and keep hands away from all pinch points when releasing the lever to dump the bin.

Fall Protection –

An approved full body safety harness w/lanyard is to be worn at all times and attached to a secure anchor point when drivers or personnel are using an Order Picker/Stock Picker Industrial Lift Truck or “Personnel Lifting Platform” fork attachment.

Fork Extensions –

These attachments can be slipped over the existing forks to lift larger/longer loads with greater stability. Using Fork Extensions does not increase the forklift lift load capacity.

Load Backrest Extension –

A device (permanently affixed or removable) extending vertically from the fork carriage/load apron frame.

Load Apron –

The part of the fork carriage permanently affixed and extending vertically from the fork carriage upon which the forks are “hung”/attached.

(See diagram following

this table.)

Mast –

Part of the lifting mechanism that the hydraulic lift cylinders are attached which allows the load to be lifted up and down.

(See diagram

following this table.)

Overhead Guard –

An overhead protection or shield which covers the machine operator in a manner that will minimize the possibility of injury

(See diagram



from falling objects. Usually built into an ROPS.

Personnel Lifting Platform –

A fork-attachment work platform designed for personnel to safely perform work in an elevated location. Fall protection is required during use of this attachment. Refer to the operating instructions for this fork-attachment and assume “Fall Protection” must be worn when using this attachment unless lift conditions prove otherwise.

ROPS –

An acronym for “Roll-over Protective Structure” that includes protective frames, overhead guards and driver enclosures to isolate the driver from injury in a “safe zone” in the event of rollover or falling objects.

(See diagram


Seat Belt –

The seat belt limits body movement and mechanically “connects” the operator to the equipment keeping the forklift operator inside the safety zone of the ROPS during a rollover.

(See diagram



Side Shifter –

An equipment attachment that allows the forks and load apron carriage to be shifted side to side, allowing easier fork-load alignment.

(See diagram


HOW DO I CONDUCT A SITE HAZARD

EVALUATION? Department Management is responsible for purchasing / owning or selecting / leasing the AL/EWP, forklift and industrial lift equipment based upon a work-hazard / site-hazard evaluation. There is a “Site Evaluation Checklist” as a sample in the last two pages of this section, and for specific operations / locations in the Shop Manager’s Safety Management Tool Kit for evaluating and documenting this assessment.

HOW DO I INVENTORY DEPARTMENT AL/EWP,

FORKLIFT EQUIPMENT? The owner Department conducts and maintains an inventory list of AL/EWP, forklift and industrial lift equipment owned/used by the Department. This list is used to identify training needs, equipment maintenance requirements, and to identify and limit equipment to safe use for department business activities. This list is updated


periodically as the Department procures or retires equipment, and is referenced to determine what equipment requires Operator’s Licensure for use. An inventory checklist template is available for use in the Shop Manager’s Safety Management Tool Kit.

WHAT REFERENCES / RESOURCES ARE

AVAILABLE FOR MORE INFORMATION?

AL/EWP Codes and Resources:

§1670. Personal Fall Arrest/Restraint Systems http://www.dir.ca.gov/Title8/1670.html

§3637. Definitions http://www.dir.ca.gov/Title8/3637.html

§3638. Equipment Instructions and Marking http://www.dir.ca.gov/Title8/3638.html

§3639. Factors of Safety in Design of Work Platform Assembly

http://www.dir.ca.gov/Title8/3639.html

§3640. Maintenance and Repairs http://www.dir.ca.gov/Title8/3640.html

§3642. Platform Equipment http://www.dir.ca.gov/Title8/3642.html

§3645. Stability on Inclined Surfaces http://www.dir.ca.gov/Title8/3645.html

§3646. Operating Instructions (Elevating Work Platforms)


§3647. Pin-On Platforms http://www.dir.ca.gov/Title8/3647.html

§3648. Operating Instructions (Aerial Devices) http://www.dir.ca.gov/Title8/3648.html

Fall Protection Equipment fact sheet http://ehs.berkeley.edu/pubs/factsheets/65fallprotequip.pdf

A free non-profit aerial lift training program with downloadable / printable signage and training videos geared for Universities and Colleges at: www.Liftupright.org http://www.liftupright.org/links-and-resources http://www.liftupright.org/downloadable-materials 28 MPH Wind Limit – If wind is gusting or steady beyond 28 MPH, no one goes aloft and anyone aloft must come down immediately.

Forklift and Industrial Lift Codes and Resources

Cal/OSHA Online Training Link and Exam (NOTE: See Attachment 11 for UCB specific instructions on how to access and get credit for taking this online training.)

http://www.free-training.com/osha/forklift/forkmenu.htm

§1670. Personal Fall Arrest/Restraint Systems


§3338. Pallets http://www.dir.ca.gov/Title8/3338.html

§3384. Hand Protection http://www.dir.ca.gov/Title8/3384.html

§3385. Foot Protection http://www.dir.ca.gov/Title8/3385.html


§3649. Definitions http://www.dir.ca.gov/Title8/3649.html

§3650. Industrial Trucks. General http://www.dir.ca.gov/Title8/3650.html

§3651. Agricultural and Industrial Tractors http://www.dir.ca.gov/Title8/3651.html

§3653. Seat Belts http://www.dir.ca.gov/Title8/3653.html

§3655. Overhead Guards http://www.dir.ca.gov/Title8/3655.html

§3656. Order Pickers and Stock Pickers http://www.dir.ca.gov/Title8/3656.html

§3657. Elevating Employees with Lift Trucks http://www.dir.ca.gov/Title8/3657.html

§3659. Back Guards http://www.dir.ca.gov/Title8/3659.html

§3660. Rated Capacity http://www.dir.ca.gov/Title8/3660.html

§3661. Brakes and Warning Devices http://www.dir.ca.gov/Title8/3661.html

§3662. Internal Combustion Engines http://www.dir.ca.gov/Title8/3662.html

§3663. Maintenance of Industrial Trucks http://www.dir.ca.gov/Title8/3663.html

§3664. Operating Rules http://www.dir.ca.gov/Title8/3664.html

§3668. Powered Industrial Truck Training http://www.dir.ca.gov/Title8/3668.html

Fall Protection Equipment See Section 14 of this Shop Safety Manual


SITE HAZARD ASSESSMENT – AL/EWP, FORKLIFT AND/OR INDUSTRIAL LIFT Location(s): ______________________________________________________________________ Instructions: An Operator uses this form to conduct a Site Hazard Assessment for use of Aerial Lifts and/or Industrial Lift Equipment owned/operated by each department, identify all hazards in the area of intended work, and to select appropriate equipment for the work-task. Update this Hazard Assessment as equipment is purchased or retired from service, Department work activities or hazards change, and when new Operators are added to the Department’s “Licensed Operator” roster for using Aerial Lifts / Industrial Lift Equipment.

Site Evaluation Y N NA Is the floor/work surface structurally strong enough to handle the weight/load(s)? Are surface conditions where the vehicle will be operated clean, dry and have good traction?

Is there pedestrian traffic in areas where the vehicle will be operated? Are there narrow aisles and other restricted places where the vehicle will be operated?

Will the loads to be carried be stable and of uniform composition? Are there ramps and other sloped surfaces that could affect the vehicle's stability? Will there be significant load manipulation, stacking and un-stacking of materials? Are there “Classified Hazardous” locations where the vehicle will be operated? Is there an enclosed environment(s) or other areas where insufficient ventilation or poor vehicle maintenance could cause a build-up of carbon monoxide or diesel exhaust buildup for combustion motors, or hydrogen gas buildup at electric vehicle recharging stations?

Are winds in excess of 25mph a concern for working aloft? Are there rain / wet conditions possible? Process / Use of Lift Truck / Aerial Lift Equipment Y N NA

Should an Aerial Lift / Lift Truck(s) be used in the type of work being conducted? Does the Aerial Lift / Lift Truck(s) have the proper lift height, clearance and capacity for the job?

Are the proper attachments being used in the type of work in this process? Are cables and/or chains being used to lift objects with the Lift Truck? Are there designated parking areas for Lift Truck(s)? (Clear of exits, fire extinguishers, hydrants, pedestrian-aisles, doorways, footpaths, or electrical panels.)

Is the fueling and/or charging area well ventilated? Is there proper lighting in the areas the Aerial Lift / Lift Truck is being used? In loading dock areas, are there proper dock plates available for use? Are Propane bottles being kept in a secure area, and are they tagged “Full” or “Empty”?

List below other potentially hazardous process-conditions that could affect safe operation:

(Continued other side)


Safety Devices/Signs/Postings/Equipment Repair YES NO N/A

Signs warning pedestrians of Aerial Lifts / Lift Trucks operating in the area? Are there proper warning signs at blind corners, exits, and high traffic areas? Are wheel chocks available if needed during loading or unloading of trucks or trailers, or when going aloft in an aerial lift?

Are there proper warning signs in refueling or battery charging areas? Are all low overhead obstructions, electrical wires, etc… tagged, painted or marked for visibility to operators?

Are there walking lanes marked with yellow paint for pedestrians to use? Are there warning lights or buzzers to warn pedestrians on sidewalks of Lift Truck cross traffic?

Is an eye wash station with a unobstructed path within 10 seconds walking-distance of the battery charging area?

Are there a sufficient amount of fire extinguishers on site that have been inspected regularly?

Is the CAL/OSHA poster (Operating Rules) posted and available to all employees who operate Lift Trucks?

Are service repair orders for Aerial Lifts / Lift Trucks and/or attachments(s) being kept for record keeping purposes?

Are Daily Inspections being done, and are records being kept for program documentation?

Are all other personnel in the area aware that Aerial Lifts / Lift Trucks are operating in the area?

Are all safety devices on the Aerial Lift / Lift Truck in proper work condition (lights, horn, flashing lights, guards, seat belt, back-up alarm, etc.)?

Are the Aerial Lifts / Lift Trucks being kept in good working condition (maintenance, fuel, battery, oil, hoses, etc.)?

List below other equipment device(s)/operation(s) that could improve safe operation:

LIST SUGGESTED TRAINING and SITE/EQUIPMENT/PROGRAM IMPROVEMENTS: __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Operator/Evaluator: ___________________________________ Date evaluated: ___/___/____ Supervisor review: ___________________________________ Date reviewed: ___/___/_____


QUIZ – AERIAL LIFTS AND FORKLIFT SAFETY

1. Which of the following are hazards to be looked for as part of an equipment pre-use safety inspection? A. Quality and dryness of the surface the equipment is to be operated on. B. A check of all controls and their operation. C. Oil levels in the hydraulics D. The charge on the batteries, or fuel level in the tank. E. Signs of oil-leakage, battery leakage or electrical arching. F. All of the above

2. True or False? If you have been licensed to operate a 3 ton forklift used on a loading dock and warehousing operation, this also qualifies you to operate a 1-ton aerial lift on a football field.

3. When using an aerial lift outdoors, which of the following information is critical to know to plan for, and ensure, safe-use of the equipment? A. How firm the ground is that the equipment will be used on, and the weight of the

equipment. B. The weather forecast for the day and specifically for the microclimate in which the

equipment will be used. C. The wind speed aloft at the height the equipment will be used at. D. The number of people planned to go aloft, their body-weight and the reason each needs

to go aloft. E. A, B and C F. All of the above.

4. True or False? Students (juniors, seniors, graduate, and higher levels) can learn and be licensed to operate aerial lifts, forklifts and industrial lift trucks that are owned / leased / rented by the University as long as it’s part of their work activities, they possess a valid C-class driver’s license, and have passed both the “classroom” and “hands-on” training for licensure as required by your campus EH&S Department.

5. True or False? By reading through this section, and successfully completing this quiz, you have passed the written portion of your licensing procedure for operating AL/EWP, forklifts and/or industrial lift trucks.

6. It’s important to wear a seat belt when operating a forklift because:

A. Forklifts can topple-over and you could get thrown from them if not belted in. B. Loads can shift causing the forklift to become unstable and throw you from the seat. C. Forklifts generally have low clearance and can hit low unseen obstructions causing rapid

stopping of the lift / load and you to fall. D. Seatbelts assure you’re inside the ‘safety cage’ of the ROPS. E. All of the above.

7. True or False?

When using a personnel cage attached to forks on a forklift, the person in the cage does not need to wear fall protection devices.


* Quiz Answers: 1. F 2. False – You must be licensed for each type of AL/EWP, forklift and industrial lift truck you will operate, and for

the specific locations the equipment will be operated in. 3. F 4. True 5. False – This section is just a primmer to help guide your understanding of what’s required to become licensed

and safely use this type of equipment. You must go through classroom and hands-on training on each type of AL/EWP, forklift and/or industrial lift truck piece of equipment that you intend to operate.

6. E 7. False – Persons aloft in a personnel cage attached to forklift forks must always wear fall protection. The

attachment between the cage and the forks is not always stable, and the cage can shift causing instability of the person aloft. Always wear fall protection in such a situation.

section 16: aerial lifts, elevating work platforms, forklifts and...

Documents