Forklifts, officially known as powered industrial trucks, are specialized machinery designed for moving, raising, and lowering heavy materials. Their function is strictly focused on material handling, making workplace safety regulations governing their operation extremely important. Compliance with these standards is necessary to prevent severe accidents.
The Fundamental Rule for Riding on a Forklift
The fundamental rule is that only one person is permitted to ride on a standard forklift: the trained and authorized operator. Standard forklifts are engineered as material movers, not personnel carriers, and lack seating or restraints for additional passengers. Federal safety standards, such as those established by OSHA (29 CFR 1910.178), prohibit operators from giving rides or using the forks to lift people. Deviating from this single-operator rule constitutes a serious misuse of the equipment.
Why Safety Regulations Prohibit Extra Riders
This strict rule is grounded in the physics of forklift operation and the inherent instability of the vehicle’s design. A forklift maintains balance by keeping the combined center of gravity of the machine and its load within the stability triangle. The addition of an unauthorized rider, whose weight is often positioned outside the operator compartment, drastically shifts this center of gravity. This movement significantly increases the risk of a tip-over.
The unauthorized rider also faces direct physical hazards due to their exposed position on the truck. They risk being struck by the mast or lifting mechanism, falling from the moving vehicle, or being crushed in the event of an overturn. Unlike the operator, who is protected by the overhead guard and often a seatbelt, an extra passenger has no specialized restraints or protective structure.
Exceptions to the Single Rider Rule
A limited set of circumstances allows for more than one person to be involved in a forklift operation, but these are highly regulated exceptions. Some specialized equipment, such as operator-up high lift trucks, is designed by the manufacturer to accommodate personnel for specific purposes like order picking or inventory. These trucks are engineered with controls and safety features rated for human elevation and movement.
The other primary exception involves the use of an approved, specialized work platform, often called a man basket, which is securely attached to the forks. This attachment transforms the forklift into a temporary aerial device for tasks like maintenance or inspection. These platforms are only permitted when they meet specific design and safety criteria and the forklift is explicitly rated for the combined weight of the platform, personnel, and equipment.
Proper Use of Approved Work Platforms
Using an approved work platform requires strict adherence to multiple safety protocols to ensure personnel safety at height. The platform must be securely fastened to the forks or the mast, often utilizing a positive securing mechanism and safety chains to prevent it from slipping or pivoting. The combined weight of the platform, all personnel, and their tools must not exceed one-half of the truck’s rated load capacity.
Workers on the elevated platform must be protected from falls. This mandates the use of guardrails, including mid-rails and toe boards, that are at least 42 inches high.
Safety Requirements for Elevated Platforms
- Personnel must wear personal fall protection equipment, such as a full-body harness and lanyard, attached to an approved anchor point on the platform.
- The operator must remain at the controls of the forklift at all times while the platform is occupied.
- The truck must not be moved horizontally while the workers are elevated.
- Personnel must only enter and exit the platform when it is lowered to floor level.
Consequences of Violating Rider Limits
Ignoring the limitations on forklift riders can lead to severe legal, financial, and disciplinary consequences for both the employer and the workers involved. Regulatory bodies like OSHA enforce safety standards and issue substantial fines for violations. For example, in a single recent year, OSHA issued over 1,800 citations related to the powered industrial truck standard, resulting in millions of dollars in proposed penalties.
An accident involving an unauthorized rider will also trigger intense scrutiny from insurance providers and can negatively impact worker’s compensation claims. Beyond the financial penalties, businesses face increased insurance premiums, potential lawsuits, and a damaged safety record. Individuals involved in safety breaches, including operators and supervising personnel, are often subject to internal disciplinary actions such as suspension or termination to enforce a culture of compliance.