EH-92-3 Worker Safety Compromised
                        ENVIRONMENT, SAFETY & HEALTH
                                 BULLETIN

Assistant Secretary for                        U. S. Department of Energy
Environment, Safety & Health                   Washington, D.C.  20585

DOE/EH-0255                 Issue No. 92-3                     June 1992


                       WORKER SAFETY COMPROMISED
                  WHEN OPERATING FORKLIFTS IN REVERSE

Safety Issue

A pedestrian was killed in May 1991, and a forklift operator was
severely injured in March 1992 in accidents at DOE facilities.  The
accidents occurred when forklifts were driven in reverse.

Incident Descriptions

In May 1991, the operator of a rough-terrain forklift was carrying a
trash dumpster when the fatal accident occurred.  The mast of the
forklift was tilted back for travel, and the dumpster was secured by
its own weight and the angle of the forks.  In accordance with proper
procedures, the forklift was being operated in reverse because the
dumpster completely blocked the driver's forward vision (Figure 1).
The operator was driving with his left hand and looking backward
over his right shoulder.  The back-up alarm on the forklift was
functioning.  The pedestrian was walking on the right-hand side of an
asphalt road.  There were no sidewalks or walkways, and the
pedestrian was walking in the path of the forklift with traffic.  The
forklift approached the pedestrian at a speed of less than 10 mph,
and one or two of the tires struck and ran over him, causing fatal
injuries.  Figure 2 is a diagram of the accident scene.

In March 1992, the operator of an electric stand-up counterbalance
forklift was injured when he backed off the edge of a loading dock.
He had been asked to take a forklift from one building to another.
He conferred with a supervisor about the type of work to be done and
the specific forklift to use.  The path in front of the forklift was
blocked by materials; and the operator decided to back toward the
dock opening, pull forward, and proceed out of the area in another
direction.  He did not stop the forklift at the dock opening; and the
forklift fell backward off the dock, pinning him under the vehicle.
He received a severe cut on the back of his head, and his right foot
was crushed, requiring partial amputation.  Figure 3 is a photograph
of the accident scene.

Causal Factors

Several factors probably contributed to the incidents.  In
particular, an operator's vision when driving in reverse is blocked
by part of the forklift.  Also, there were no established procedures
for forklift operation in the dock area, and safety features there
were inadequate to prevent the accident.  Additional causes included
a lack of sidewalks or designated pedestrian walkways in an area of
construction traffic; the pedestrian walked on the wrong side of the
road, with traffic instead of against it; and operator inexperience.

Related Incidents

Several other incidents involving forklifts occurred at DOE
facilities in the last two years.  Descriptions of some of the
incidents follow.

Most incidents were the result of operator error, including several
that involved improper use of equipment or use of inadequate
equipment.  In these incidents, employees did not exercise caution or
follow procedures.  Operators sometimes used forklifts to transport
material that should have been moved with other equipment. This
resulted in the loads falling because they were not properly
secured.  In another case, an operator placed a load on inadequate
cribbing, and the load fell when the forklift was backed clear of
the cribbing.  Employees replacing a heating/air conditioning unit at
another site worked unsecured from a platform supported by a
forklift.  Although no accident occurred, procedures were violated
and a report was filed.

Several collisions occurred.  In one incident, a vendor backed a
forklift over an electrical junction box, tripping a breaker.  In a
second collision, an operator was unaware that the forks of the lift
extended through the pallet he was transporting. He struck a
battery on another pallet and punctured it, causing battery acid to
leak.  Another collision caused an electrical outage when the
operator struck a power pole.  There were no barriers around the
pole, but the operator admitted his inattention contributed to the
accident.

In one incident, a forklift overturned because the operator was
traveling too fast when he attempted to make a turn.  He was thrown
clear of the forklift and was not injured.

Safety Implications

All of these incidents demonstrate how easily worker safety can be
compromised when proper precautions are not taken during forklift
operation.  Operators should be certain their path is clear before
moving a forklift.  Also, employees should not bypass established
policies on proper use of equipment in an effort to perform a job
more quickly.

Recommendations

Managers and supervisors should follow these procedures and
practices in areas where forklifts are used:

1.    Ensure that the forklift's rated capacity is adequate for the type of
      work being performed and that all forklift operators are trained and
      certified.  Training should include the general equipment category, as
      well as instruction in how equipment will be used at the facility and
      how specific pieces of equipment should be operated.

2.    Study vehicle and pedestrian traffic.  Explore ways to separate the
      two in time and distance, and review compliance with existing traffic
      rules.  Determine whether employee training programs on vehicle
      and pedestrian safety are adequate.  Implement changes as necessary.



3.    Make operators aware of the severely limited visibility in some
      models of forklifts, and instruct them to use extreme caution when
      driving in reverse.  Consider the use of ground guides, rear-view
      mirrors, spotters, or other aids to increase visibility.

4.    Determine whether an area should have physical barriers such as
      ramps, raised concrete staging areas,and/or heavy-gauge safety
      chains in front of dock openings.  Add a "warning track" of yellow
      paint on the floor near dock openings.

5.    Ensure electrical equipment is protected from physical damage by
      location or substantial guards.

Operators of forklifts and other heavy industrial equipment should
follow these procedures and practices in areas where forklifts are used:

1.    Consider the noise level in the surrounding environment. Do not
      assume pedestrians or bystanders are able to hear the back-up alarm.
      In addition, never assume pedestrians or bystanders are aware of the
      presence of heavy equipment and/or the intended direction of travel.

2.    Select and use proper equipment for material handling and elevating
      personnel.  Verify material is secured properly.  OSHA regulation
      1910.178, "Powered Industrial Trucks," and American National Standards
      Institute (ANSI) standard B56.6, "Safety Standard for Rough Terrain
      Forklift Trucks," should be followed.

3.    Use ground guides when visibility is limited.

4.    Assure the path is clear prior to traveling. Note and take
      precautions near hazardous areas.


This Bulletin is one in a series of publications issued by EH to share
occupational safety information throughout the DOE complex.  To be added
to the Distribution List or to obtain copies of the publication, call
(615) 576-3482.  For additional information regarding the publications,
call Eleanor Crampton, Safety Performance Indicator Division, Office of
Environment, Safety and Health, U.S. Department of Energy, Washington,
DC 20585, (301) 903-3732.
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