FORKLIFT SAFETY

Hazards, Operator Obligations, and Ontario Requirements

Forklifts are among the most dangerous pieces of equipment in any workplace — heavy, fast-turning, carrying unstable loads, sharing space with pedestrians. Ontario requires documented training before any worker operates a powered industrial truck. This resource covers the key hazards, legal requirements, and safe operating practices.

Bullivant Health + Safety | bullivant.ca | 905-664-4943 | 158 S Service Road, Stoney Creek, ON
This resource is for general informational purposes only and does not constitute legal advice.

1. Key Hazards

• 135kg: Average counterbalance weight — heavier than the load it carries
• 85%: Of serious forklift incidents involve a pedestrian or result from tip-over
• 1 in 10: Forklifts will be involved in a serious incident at some point in its operational life

 

TIP-OVER The most common fatal forklift event. Occurs when the load is too heavy, raised too high, or the truck turns too fast. Operators must never jump from a tipping truck. LOAD FALLS Improperly secured or overloaded loads can fall onto operators, pedestrians, or other workers — even at low travel heights. FALLS FROM FORKS Workers riding on forks or load backrests — strictly prohibited. Falls from any height on the forks are likely to be fatal.

STRUCK-BY INCIDENTS Pedestrians struck by forklifts or loads. Forklifts have significant blind spots, especially when carrying loads. PINCH & CRUSH POINTS Workers caught between the forklift and a fixed object. Often occurs during spotting or when pedestrians enter travel lanes. CARBON MONOXIDE Propane, gasoline, or diesel forklifts produce CO. Operating in enclosed or poorly ventilated areas risks CO poisoning.

 

2. Operator Certification & Training

O. REG. 851, SECTION 51(1)

No employer shall permit a worker to operate a powered industrial truck unless the worker has been trained in the safe operation of the type of powered industrial truck to be operated and the training has been documented. (Ontario Regulation 851 — Industrial Establishments)

Training must be specific to the class of truck. A certification for a sit-down counterbalance truck does not qualify an operator for a reach truck or order picker.

• Pre-operational training: controls, stability principles, load capacity, fuel systems, and operating rules
• Practical evaluation: observed operating on the specific truck class in actual workplace conditions
• Documentation: worker name, date, truck type, and evaluator name must be retained
• Site-specific orientation: required even for experienced certified operators at each new workplace
• Refresher training: required following unsafe operation, incidents, or new truck class assignment

3. Pre-Trip Inspection

1. Check fluid levels — engine oil, hydraulic fluid, coolant, fuel (or battery charge and cables for electric trucks).
2. Inspect tyres — pressure, wear, damage, and secure attachment.
3. Test controls — forward/reverse, lift/tilt/side-shift, steering, and parking brake.
4. Test horn and warning devices. Test lights if operating in low-light areas.
5. Inspect forks — blade wear, cracks, bend, heel wear, and carriage integrity.
6. Check mast — chain tension and lubrication, hose condition, and free-lift operation.
7. Record inspection on the pre-trip form. Defective trucks must be tagged out of service until repaired.

 

4. Safe Operating Rules & Pedestrian Safety

SAFE OPERATING RULES

PEDESTRIAN SAFETY

Travel with forks 15–30 cm above ground — never travel with raised load Tilt mast back during travel to stabilize load Never exceed rated capacity shown on the data plate Slow down at intersections — sound horn at every crossing Never make sharp turns at speed — reduce speed before all turns On slopes — travel with load on the uphill side. Never turn on a slope No passengers on forks, load, counterweight, or any part of the truck Lower forks, neutralize controls, apply brake, remove key when parking

Physically separate forklift travel lanes from pedestrian walkways where possible Establish marked pedestrian crossing points with mirrors and warning signs All pedestrians in forklift areas must wear high-visibility clothing Install convex safety mirrors at blind intersections and corners Establish procedures preventing pedestrian access during loading operations Train pedestrian workers on forklift blind spots and how to make themselves visible

 

IF THE TRUCK TIPS — STAY INSIDE

The most dangerous instinct in a tip-over is to jump out. A worker who jumps is likely to be crushed by the overhead guard or truck body. Hold on, brace your feet, and lean away from the direction of fall. The overhead guard is designed to protect an operator who stays in the seat.

GENERAL INFORMATION NOTICE

This resource is for general informational purposes only. Consult O. Reg. 851 and the Ministry of Labour for requirements specific to your workplace.