Forklift Operator Safety Program
Montana State University
Forklift Operator Safety Program
MSU Safety and Risk Management Office
Effective Date: 2023
Program Owner: Director, Safety and Risk Management
1. MSU SRM Forklift Operator Safety Program
Forklifts are vital for moving and handling materials and supplies in a variety of university settings, including facilities maintenance, grounds operations, and warehouse functions. Improper use or poor maintenance of forklifts poses a significant safety risk to operators, pedestrians, and bystanders. This document establishes the university’s official procedures and expectations for the safe operation, inspection, maintenance, and management of forklifts used on campus.
It is the policy of Montana State University that:
•Forklift operations must comply with OSHA regulation 29 CFR 1910.178.
•Only properly trained, certified, and authorized personnel may operate forklifts.
•Supervisors and departments are accountable for enforcing forklift safety rules.
•Any exceptions to this policy must be formally reviewed and approved by MSU Safety
and Risk Management.
2. Program Scope
This program applies to all university employees who:
•Operate forklifts in any capacity.
•Work near forklift operations (e.g., loading docks, shops, yards).
•Supervise, train, or evaluate forklift operators.
This policy covers all university-owned, leased, or otherwise managed facilities, including research centers, vehicle shops, construction zones, and satellite campuses.
3. Regulatory Compliance
This program ensures compliance with:
•OSHA 29 CFR 1910.178 – Powered Industrial Trucks
•ANSI/ITSDF B56.1 – Safety Standard for Low Lift and High Lift Trucks
•[MT Department of Labor MSCA]
•University motorized equipment and vehicle policies
4. Roles and Responsibilities
4.1 Safety and Risk Management Office
•Maintain the Forklift Safety Program document and associated procedures.
•Authorize forklift trainers and approve training curricula.
•Maintain central records of operator certification, inspections, and incidents.
•Provide guidance on compliance, enforcement, and incident response.
4.2 Supervisors and Department Heads
•Ensure only trained and certified staff operate forklifts.
•Assign forklift tasks responsibly and monitor compliance.
•Ensure daily inspections are conducted and documented.
•Coordinate with Safety and Risk Management for corrective actions.
4.3 Forklift Operators
•Complete training and certification prior to operating any forklift.
•Conduct pre-use safety inspections at the beginning of each shift.
•Report defects or unsafe conditions immediately.
•Operate forklifts safely and according to policy at all times.
5. Equipment Covered
This policy applies to the following types of forklifts:
•Sit-down counterbalance forklifts (gas, diesel, or electric)
•Stand-up electric forklifts
•Tractors, Skid-Steer, or multi-purpose loaders fitted with forks.
•Manual or powered pallet jacks used in material handling
•Rough-terrain forklifts used in construction or landscaping
If a department intends to use equipment that may fall under this category but is not listed, Safety and Risk Management must review it for inclusion.
6. Operator Training and Certification
6.1 Training Requirements
Training consists of:
•Formal instruction (e.g., classroom, video, or online modules)
•Hands-on practical instruction provided by a qualified trainer
•Performance evaluation under supervised conditions
Topics include:
•Forklift controls and instrumentation
•Operating limitations and stability
•Load handling and stacking
•Surface conditions and hazards
•Refueling/recharging procedures
•Workplace-specific hazards (pedestrian traffic, ramps, etc.)
6.2 Certification
Upon satisfactory completion of training and evaluation, the operator receives a forklift operator certificate valid for three years. The certificate includes:
•Operator’s name
•Type(s) of forklifts authorized
•Training and evaluation dates
•Evaluator's name
6.3 Refresher Training
Required under the following conditions:
•Involvement in an accident or near miss
•Unsafe operating behavior observed
•New type of forklift introduced
•Significant changes to the work environment
•Expiration of three-year certification
7. Daily Safety Inspections
Forklift operators must complete a Daily Pre-Use Inspection Checklist (Appendix A) before each shift. Inspections must verify:
•Brakes, horn, steering, and lights
•Fork condition and mast function
•Hydraulic systems
•Tire condition
•Battery levels or fuel system integrity
•Safety devices (seat belts, alarms, fire extinguisher)
Any defect must be reported immediately. Faulty forklifts must be removed from service
until repaired.
8. General Operating Procedures
Operators must follow these safety practices:
•Always wear required PPE and a seat belt.
•Drive at safe speeds and reduce speed at corners and intersections.
•Lower forks during travel and tilt slightly back when carrying loads.
•Yield the right of way to pedestrians at all times.
•Use the horn at intersections and blind spots.
•Do not exceed rated load capacity.
•Never carry passengers unless forklift is specifically designed for it.
9. Refueling and Charging Procedures
9.1 Electric Forklifts
•Batteries must be charged in designated, well-ventilated areas.
•Operators must wear chemical-resistant gloves and face protection.
•Acid spill cleanup materials must be immediately accessible.
9.2 Internal Combustion Forklifts
•Refueling or cylinder replacement must be done in outdoor or approved ventilated
areas.
•Shut off engine during refueling.
•Keep open flames, smoking, and ignition sources away.
•Ensure fire extinguishers are available at refueling stations.
10. Parking and Securing Forklifts
When not in use, forklifts must be:
•Parked on level ground, clear of exits and fire equipment
•Forks fully lowered to the ground
•Controls in neutral
•Parking brake applied
•Ignition key removed
Do not leave a forklift unattended unless it is properly secured and shut down.
11. Forklift Maintenance and Repairs
•Forklifts must be maintained according to manufacturer guidelines.
•Only qualified personnel may perform maintenance.
•Maintenance logs must be kept for each unit.
•Alterations or modifications must be approved by the manufacturer.
•Forklifts with unresolved safety issues must be tagged and locked out of use.
12. Pedestrian Safety and Traffic Controls
In areas where forklifts operate near pedestrians:
•Mark pedestrian walkways clearly
•Use mirrors at corners and intersections
•Ensure forklifts have functioning audible warning devices
•Use spotters when backing or operating in congested areas
Departments are responsible for maintaining safe traffic flow and signage in shared-use areas.
13. Incident Reporting and Response
All forklift-related incidents, including injuries, property damage, or near misses, must be reported to:
•The department supervisor immediately
•Safety and Risk Management within 24 hours
An investigation will be initiated to determine cause and corrective actions. Follow-up may include retraining, process changes, or equipment inspection.
14. Recordkeeping Requirements
The following records must be retained:
•Operator training and certification: 5 years (Safety and Risk Management)
•Daily inspection checklists: 30 days minimum (Department)
•Maintenance and repair logs: duration of equipment use (Department)
•Incident reports and investigations: 5 years (Safety and Risk Management)
Departments must make inspection and maintenance records available for internal review or regulatory audit.
15. Program Review and Revisions
This program will be reviewed and, if necessary, revised at least every two years by Safety and Risk Management, or sooner in response to:
•Changes in OSHA or ANSI standards
•Significant incident or audit findings
•Major operational changes affecting forklift use
Suggested revisions are reviewed by the Safety Oversight Committee prior to implementation.
16. Appendices
•Appendix A: Forklift Daily Inspection Checklist
•Appendix B: Forklift Operator Evaluation Form
•Appendix C: Operator Training Certification Record
•Appendix D: Forklift Incident Report Form
•Appendix E: Department Supervisor's PIT Oversight Log