OP 60.19: Forklift Safety Program

[Major revision–posted 3/17/26 (replaces 1/12/22 edition)]
[PDF Version]

Texas Tech University Double T

Operating Policy and Procedure

OP 60.19: Forklift Safety Program

DATE: March 17, 2026

PURPOSE: The purpose of the Forklift Safety Program is to ensure the safe operation, maintenance, training, and oversight of all forklifts and powered industrial trucks (PITs) used on campus, in accordance with OSHA 29 CFR 1910.178. Environmental Health & Safety (EHS) administers this program and maintains training and compliance documentation.

REVIEW: This Operating Policy/Procedure (OP) will be reviewed in September of every fourth year by the Assistant Vice President for Environmental Health & Safety with substantive revisions forwarded through the Associate Vice President for Research to the Vice President for Research & Innovation. This OP will be reviewed again in 2030.

POLICY/PROCEDURE

1. Scope

This OP applies to all TTU employees who operate, maintain, or supervise PITs on campus.

2. Definitions

a. Powered Industrial Truck (PIT) – Any forklift, lift truck, pallet truck, or similar vehicle as defined by OSHA 29 CFR 1910.178.

b. Operator – An employee trained and authorized to operate a PIT.

c. Refresher Training – Training required due to unsafe operation, incident/near miss, change in workplace or equipment, or at least every three (3) years as part of evaluation.

d. Pre-Operational Inspection – A documented inspection completed before operating a PIT each shift.

3. Responsibilities

a. Department heads, directors, and administrators will:

(1) Ensure that all provisions of the Forklift Safety Program are followed, as it pertains to each area;

(2) Provide funds to perform required maintenance and repairs on assigned PITs;

(3) Retain a copy of the employee’s forklift “Certificate of Completion of Training” in the employee’s personnel file;

(4) Ensure that all PITs are registered with EHS and that nameplates/markings remain legible; and

(5) Departments must notify EHS when acquiring, transferring, or decommissioning a PIT.

b. Supervisors will:

(1) Ensure that employees operate forklifts safely and in accordance with training;

(2) Ensure that employees are scheduled for initial, refresher, and remedial training as required; schedule and document operator evaluations at least once every three (3) years;

(3) Verify employees are competent to operate assigned PIT types based on evaluation and performance criteria;

(4) Report all near-misses and accidents to EHS within 24 hours and remove operators from service pending remedial training/evaluation as necessary;

(5) Ensure that employees operate only PITs on which they have been trained and authorized;

(6) Ensure employees receive refresher training as triggered by incidents, unsafe operation, and changes in workplace/equipment, and at least every three years as part of evaluation;

(7) Ensure new or reassigned employees complete PIT training and evaluation before operating equipment; and

(8) Verify completion, retention, and review of daily pre-operational inspection checklists; remove unsafe PITs from service and ensure proper tag-out.

c. Employees (Operators) will:

(1) Inspect PITs before each shift and do not operate if defects are found;

(2) Report any deficiencies found during daily inspections immediately to their supervisor;

(3) Not operate a PIT that is in need of repairs or a PIT/type for which they are not authorized; and

(4) Report any unsafe acts, near-misses, or incidents to their supervisor.

d. Environmental Health & Safety will:

(1) Train and/or approve trainers for all employees required to operate a PIT; ensure training includes formal instruction, practical training, and evaluation;

(2) Maintain a record of all employees trained and evaluated, including PIT type(s) authorized and certification details (operator name, training date, evaluation date, trainer/evaluator identity);

(3) Perform refresher training and operator evaluations on a three-year cycle or sooner if required;

(4) Determine the extent of refresher training based on performance, incident history, and workplace/equipment changes;

(5) Investigate all accidents/incidents and recommend corrective actions to prevent recurrence; and

(6) Maintain master documentation of PIT registrations, inspections, training certifications, and evaluations.

4. Operator Training and Evaluation (OSHA 1910.178(l))

a. Training will include (1) formal instruction (lecture, discussion, e-learning), (2) practical training (demonstrations and exercises), and (3) evaluation of the operator’s performance in the workplace.

b. Each operator shall be evaluated at least once every three (3) years.

c. Refresher training triggers are unsafe operation, accident or near-miss, evaluation indicating unsafe operation, assignment to a different type of truck, or a change in workplace conditions that could affect safe operation.

d. Truck-related topics are operating instructions, warnings and precautions; differences from automobiles; controls and instrumentation; steering and maneuvering; visibility (including restricted visibility); fork and attachment adaptation, operation and use limitations; vehicle capacity and stability; vehicle inspection and maintenance; refueling/charging and recharging batteries; operating limitations; and any other operating instructions, warnings, or precautions listed in the operator’s manual for the equipment.

e. Workplace-related topics are surface conditions; composition and stability of loads; load manipulation, stacking, unstacking; pedestrian traffic; narrow aisles and other restricted places; hazardous (classified) locations; ramps and other sloped surfaces; closed environments or other areas where insufficient ventilation or poor lighting may be present; and other unique or potentially hazardous environmental conditions in the workplace.

f. EHS shall certify that each operator has been trained and evaluated. The certification shall include the operator’s name, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation.

5. Equipment Modifications, Attachments, and Nameplates (OSHA 1910.178(a)(4)-(6))

a. No modification or addition that affects capacity, stability, or safe operation may be made without the manufacturer’s prior written approval. Capacity, operation, and maintenance plates, tags, or decals shall be changed accordingly.

b. Front-end attachments other than factory-installed must be identified on the truck; the combined weight of the truck and attachment at maximum elevation with load laterally centered shall be shown.

c. All nameplates and markings shall be in place and legible at all times.

6. Safe Operating Rules (OSHA 1910.178(m), (n), (o))

a. Only trained and authorized personnel may operate PITs; no riders are permitted unless the PIT is designed for passengers.

b. Operate at a safe speed; slow down and sound the horn at cross aisles and other locations where vision is obstructed.

c. Maintain safe clearances from pedestrians and fixed objects; pedestrians have the right of way.

d. Keep forks low (generally 4–6 inches) while traveling; tilt the mast back to stabilize the load.

e. Travel with the load upgrade when operating on ramps/grades; do not turn on a grade.

f. Ensure adequate overhead clearance; use overhead guards and load backrests as required.

g. Do not allow anyone to stand or pass under elevated forks, whether loaded or empty.

h. When visibility is restricted, drive in reverse or use a spotter as appropriate.

i. Do not elevate personnel on forks or pallets; use approved personnel lifting platforms with required fall protection only when permitted.

j. When leaving a PIT unattended, fully lower the forks, neutralize controls, set the brake, and turn off power; block wheels if on an incline.

k. No cell phone use while operating a PIT.

7. Fueling and Battery Charging (OSHA 1910.178(g))

a. No smoking or open flames are permitted in charging or fueling areas; post signage.

b. Provide adequate ventilation to disperse fumes from charging and fueling; keep ignition sources away.

c. Provide facilities for flushing and neutralizing spilled electrolyte, fire protection, and personal protective equipment (PPE) in battery-charging areas.

d. Turn off the truck and set brakes during fueling/charging; keep tools and metallic objects away from battery tops; replace battery caps and secure before operation.

8. Truck Designations and Hazardous (Classified) Locations (OSHA 1910.178(b), (c), (e), (f))

a. Use only trucks approved and labeled by a nationally recognized testing laboratory for the intended environment.

b. Select truck designations (e.g., D, DS, DY, E, ES, EE, EX, G, GS, LP, LPS) appropriate for potentially explosive or flammable atmospheres.

c. Prohibit the use of internal combustion engine trucks in areas with hazardous concentrations of flammable vapors unless properly designated.

9. Inspections and Maintenance (OSHA 1910.178(q))

a. Examine PITs before being placed in service each shift; do not operate until deficiencies are corrected.

b. Remove unsafe trucks from service immediately and tagout until repaired and deemed safe.

c. Maintain inspection and maintenance records per departmental/EHS requirements.

10. Incident and Near-Miss Reporting

Supervisors shall report incidents and near-misses to EHS within 24 hours and implement corrective actions, including retraining or reevaluation as required.

11. Recordkeeping

a. Departments shall retain operator training certifications and evaluation records; EHS will maintain the institutional master record.

b. Training certification must include operator name, training date, evaluation date, and identity of trainer/evaluator.

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Texas Tech Downtown Center Room 218
Email
officialpublications@ttu.edu

OP 60.19: Forklift Safety Program

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