A forklift (also called a powered industrial truck or PIT) is the primary equipment for pallet handling.
Detailed Definition
Forklift types include the counterbalance truck (most common), the reach truck for narrow aisles, the order picker, which lifts the operator with the load, and the side-loader for long items. OSHA 29 CFR 1910.178 requires employers to train and evaluate each operator on the trucks they use and to certify that this was done. Performance must be evaluated at least once every three years, and refresher training is required after events such as an accident, a near miss or observed unsafe operation.
Power sources and where each fits
Forklifts run on electric batteries, LP gas, diesel or gasoline, and some use hydrogen fuel cells. Electric trucks produce no exhaust at the point of use, which suits indoor warehouses and food plants. Internal combustion trucks are common outdoors, in yards and on rough ground. The choice affects ventilation, charging or refueling space and maintenance, so it should match the building and the hours the trucks run.
Forklift capacity and the pallet
Every forklift has a data plate showing its rated capacity at a stated load center, often 24 inches for standard trucks. Long or off-center loads, attachments and high lift heights reduce what the truck can safely carry. Pallets matter too: broken boards, damaged fork openings or overhanging loads can shift the load center or let product fall. Inspect pallets before lifting and match pallet design to the trucks in use.
Daily checks before using a forklift
OSHA requires powered industrial trucks to be examined before being placed in service, at least daily, and trucks with defects that affect safety must be taken out of service until repaired. Typical checks cover forks, chains, mast, tires, brakes, steering, horn, lights, fluid leaks and the battery or fuel system. Many sites use a written checklist so problems are recorded and followed up.
Authoritative Sources
- Occupational Safety and Health Administration (OSHA): the US federal agency whose 29 CFR 1910 standards govern warehouse pallet handling and storage.
- Material Handling Institute (MHI): the largest US trade association for material handling, logistics, and supply chain technologies.
Related Glossary Terms
Frequently Asked Questions
How often do forklift operators need to be recertified?
OSHA requires an evaluation of each operator's performance at least once every three years. Refresher training is required sooner when an operator is seen driving unsafely, has an accident or near miss, receives a poor evaluation, is assigned a different type of truck, or when workplace conditions change in a way that affects safe operation. The employer, not an outside agency, certifies that the training and evaluation were completed.
Can an operator trained on one forklift drive any forklift?
Not automatically. OSHA training must cover the truck-related topics for the types of trucks the operator will use, along with workplace-related topics. A sit-down counterbalanced forklift, a stand-up reach truck and an order picker handle very differently. If an operator moves to a new type of truck, the employer needs to provide training on that truck and evaluate the operator before they use it on their own in normal work.