Safe Use of Manual Forklifts
A safety talk focused on manual forklift hazards, including load stability, capacity, foot injuries, pinch points, ramps, visibility, hydraulic lifting, and safe travel paths.
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Key Hazards
- Loads tipping, sliding, or falling during movement
- Overloading beyond rated capacity
- Pinch or crush injuries around forks, wheels, mast, and lift mechanisms
- Foot injuries from wheels, forks, pallets, or dropped loads
- Loss of control on ramps, slopes, thresholds, or uneven floors
- Blocked visibility from tall or oversized loads
2–3 Minute Talk Script
Manual forklifts and stackers can lift and move loads without powered travel, but they still create serious hazards from load height, weight, and pinch points.
Workers should inspect the manual forklift before use. Forks, wheels, handle, mast, hydraulic system, brakes, chains, guards, and capacity markings should be checked.
The load must be within the equipment’s rated capacity. Workers should consider load weight, height, center of gravity, and how far the load extends from the forks.
Forks should be fully and evenly inserted under the load. Poor fork placement can make the load unstable or damage the pallet.
Hands and feet should stay clear of forks, wheels, mast sections, chains, and lift mechanisms while raising, lowering, or moving the load.
Loads should be kept low during travel when possible and raised only when positioning or stacking. Elevated loads increase tip and struck-by hazards.
Travel paths should be checked for ramps, thresholds, wet floors, debris, tight corners, and pedestrians before movement begins.
Safe manual forklift use depends on inspection, capacity control, stable loads, slow travel, clear visibility, and keeping workers out of pinch and crush zones.
Safety Reminders
- Inspect manual forklifts before use.
- Do not exceed rated capacity.
- Center and secure the load.
- Insert forks fully and evenly.
- Keep hands and feet clear of forks, wheels, and mast.
- Travel slowly with loads low when possible.
- Check the route before moving.
Ask the Crew
- Is the manual forklift in safe condition?
- Is the load within rated capacity?
- Are the forks positioned correctly under the load?
- Could the load tip, shift, or block visibility?
- Are workers clear of pinch and crush points?