Key Strategies to Safer Forklift Operation at Lumber and Building Material Businesses

A fundamental component of daily operations for a lumber and building material dealer, forklifts are also a key contributor to costly accidents resulting in damage to inventory and property, as well as employee and bystander injuries and even fatalities. 

Forklift accidents led to nearly 25,000 days away from work for employees and were the source of 73 work related deaths in 2022, as reported by the National Safety Council. While this figure accounts for forklift accidents across all industries, lumber and building material dealers, which are largely dependent on these machines for transporting inventory, are particularly at risk. 

At Pennsylvania Lumbermens Mutual Insurance Company (PLM), we see claims related to forklift accidents all too often. In fact, these incidents rank among our most common claims for damage or injuries—some of which are accompanied by multi-million-dollar price tags. Unfortunately, oftentimes business owners do not have adequate insurance limits to cover astronomical costs like this and cannot afford to pay the losses out of pocket. As a result, operations cease and businesses close.

While accidents happen, a strong safety culture can greatly reduce forklift incidents, protecting your employees, others, and your inventory and property. A good safety culture starts with examining forklift training, operations, and safety equipment. Smart, applied risk mitigation strategies can reduce risk exposure and set up your business for optimal—and safe—operation.

Keys to Safer Forklift Usage

Comprehensive, Reinforced Training
At PLM, we cannot say it enough: good training, reinforced on a regular basis, is critical for safe operations, particularly the safe operation of forklifts. 

Business owners should create and implement a formal forklift training program, overseen by a designated team member, that combines both “classroom” and behind-the-wheel training. Additionally, all forklift drivers should be officially certified to operate the vehicle and keep in mind that certifications from previous employers are not valid. And, just as important as it is to ensure your drivers are certified, business owners should ensure those certifications stay up to date, recertifying drivers every three years. Different certifications may be required depending on the type of forklift the business uses. Counterbalanced and truck-mounted forklifts both require their own separate certifications as do propane-powered and gas-powered forklifts. 

Once a good training program is established, be sure to reiterate forklift safety tips at team meetings and in regular communications to ensure safety is top of mind. Be sure to update that training when new equipment is purchased.

Training is most effective when it’s reinforced in practice. Managers should model strong behavior consistently, following their own training and expectations. Improper conduct that is witnessed should be corrected in real-time and a written disciplinary guide should be enforced. 

Thorough Operating Protocols
While some operating protocols may seem obvious, others are not, and anyone can get lax with rules over time. As such, it can be invaluable to clearly post operating rules and remind drivers of the following when operating these 4,000-8,000 lb. vehicles:

• Never operate the vehicle with an extra rider on board. 
• Drive the vehicle as it was meant to be driven, avoiding tricks, stunts or other inappropriate activity. 
• Avoid distracted driving, including cell phone use and headphones. 
• Maintain a safe speed limit of less than 10 MPH and avoid sudden stops and turns that could tip the vehicle.
• Incorporate the use of a spotter when loading and unloading and ensure loads are secured.
• Ensure loads are balanced with forks spread wide and operate the vehicle with the load positioned against the back of the carriage.
• Maintain clear visibility by avoiding the use of hoodies etc. 
• Define designated forklifts areas.
• Always operate the vehicle with the forks low to the ground and park with the forks to the ground.

Additionally, managers and/or forklift operators should be sure to conduct daily inspects before operating forklifts. Problems should be reported immediately and maintenance records should be kept in an accessible location. Inspections should include checks of: brakes, tires, steering, hydraulics, horns, oil level and pressure, fuel, battery, water level and temperature, lever and controls, warning lights and more. 

Safety Add-ons
Additional features can be added to forklifts to improve safety, as well as the use of telematics. 

Physical features that can improve safety and should be incorporated into all forklift operations include an overhead guard, a mounted multi-purpose fire extinguisher, a sign on the back with a triangle to signify a slow-moving vehicle, and warning lights and back-up alarms. 

As telematics have made strides in improving driver safety across the commercial auto operations, we also recognize telematics can improve forklift safety. Telematics can assist lumber and building material owners and operators in monitoring driver behavior, in better controlling driver speed, and in identifying a forklift that may have been involved in an accident and in particular those unreported by staff. Additionally, telematics can help to enforce designated forklift areas to improve facility safety.

A Partner in Safety

Of course, one of the best ways to improve forklift safety within a lumber and building material operation is not to go at it alone. An insurance carrier with deep expertise in risk mitigation and risk assessment for lumber and building material dealers can be an invaluable asset in this endeavor. PLM is the oldest and largest mutual insurance company serving the lumber and building material industry and can serve as that trusted advisor.

We recommend business owners meet with insurance company representatives, in particular their loss control team, regularly, to ensure they not only have the insurance coverage they need should something go wrong, but that they understand the risks unique to their particular business and how to mitigate them. Insurers and/or brokers should conduct walk throughs of the business to carefully assess risks and make those risk mitigation recommendations. 

A good insurance partner, like PLM, will advise your business on forklift safety and more, assisting your business in avoiding accidents and costly losses.

At PLM, we have 129 years of experience in the wood niche and we understand the needs of our policyholders. We stand beside our policyholders at the ready to not only assist in a time of crisis and help them rebuild, but to help them reduce their risk exposure to help prevent a loss in the first place. 

For more information regarding our services, please visit www.plmins.com or contact us at CustServ@plmins.com or 1-800-752-1895.