How to Avoid OSHA Forklift Violations

In most businesses, some type of material handling device is used. Most commonly, it is a forklift, but it can be a powered pallet jack as well. These devices can cause major accidents, if not maintained and operated properly. In addition, a company can accumulate large fines, if OSHA visits their location.

OSHA forklift violations frequently involve inadequate operator training, lack of daily inspections, and unsafe driving practices like speeding or driving with elevated loads. These violations often lead to accidents such as tip-overs, falls, and pedestrian injuries, resulting in heavy fines up to $16,131 per violation in 2024. Common infractions are violations of standard 29 CFR 1910.178.

In fact, forklift violations rank in the top 10 of all OSHA violations. That is why it is important to be proactive with any forklift safety. Not only will it reduce your potential for a violation, but make your workplace safer for not only the operators, but also for any pedestrians in the area.

Top OSHA Forklift Violations (29 CFR 1910.178)

• Lack of, or inadequate operator training (1910.178(l)(1))

  Serious violation with typical penalty of $8,000 - $16,550 per untrained operator

  This is the most common forklift citation. OSHA requires formal instruction, practical (hands-on) training, and performance evaluation before an operator can use a powered industrial truck.

• Missing or expired operator certification records (1910.178(l)(6))

  Serious violation with typical penalty of $4,000 - $16,550

  Every operator must have a written certification record with the operator's name, training and evaluation dates, and identity of the trainer/evaluator. Missing records are treated the same as no training.

• No pre-shift inspection program (1910.178(q)(7))

  Serious violation with typical penalty of $4,000 - $12,000

  Operators must inspect forklifts before each shift. OSHA requires both an inspection process and documented records; without documentation, the program is considered nonexistent.

• Operating with known defects (1910.178(q)(7))

  Serious violation with typical penalty of $8,000 - $16,550

  Failing to remove a forklift from service after identifying a safety defect during a pre-shift inspection results in a separate violation with high gravity.

• Pedestrian safety violations (1910.178(n))

  Serious violation with typical penalty of $4,000 - $16,550

  Ignoring forklift pedestrian safety protocols including missing traffic lanes, no pedestrian barriers, no warning devices, and inadequate clearance in shared traffic areas.

Key Requirements to Avoid Fines

• Train Operators: Require all operators to complete a certified training program with formal training and performance evaluation. Ensure program addresses each type of forklift to be used, including attachments, and site-specific hazards. Note: Operator performance must be evaluated at least once every three years.

• Keep Certification Records: Maintain training logs, performance evaluations, and certification records.

• Verify and Enforce Daily Inspections: Provide operators with daily forklift inspection checklists to ensure vehicles are safe to operate. While not mandatory, documenting inspections is strongly recommended to prove compliance during inspections and ensure safety.

• Address Equipment Malfunctions Promptly: Ensure forklifts with mechanical issues or damages are removed from service and clearly marked as out of order until they’re repaired or replaced.

• Proper Procedures: Enforce safety procedures including seatbelts used, forks kept low while traveling, proper load distribution, and three points of contact when mounting/dismounting.

• Pedestrian and Traffic Safety: Use floor markings for lanes, create separate walkways, and enforce the use of horns at blind corners. Implement one-way aisles if space permits.

As a reminder, if OSHA visits your facility give us a call, we will do everything we can to respond right away.  Check out our Helpful Hints for Finding Your Way Through an OSHA Inspection.  For questions about forklift safety or to schedule forklift operator training, contact ACS for assistance.