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Policy Area

ESH-Environment Safety & Health

Procedure Number

ESH100.2.IS.22

Procedure Title

Manage Hazards for Forklifts

Procedure Manager

FONG, DARRELL G.

Status

Active

Subject Matter Expert

  • Danny P. Donald
  • Jeff H. Kokos
  • Herman O. Armijo, Jr. (CA)

 

Applicability, Exceptions, and Consequences

This corporate procedure applies to all Members of the Workforce who operate or supervise those who operate forklifts.

Exceptions to, or deviations from, this procedure must be approved through the Executive Policy Sponsor or Policy Area Manager, if delegated. Click here to view Contacts for Corporate Policy System Policies, Processes, and Procedures. See CG100.1.7, Request an Exception to a Policy, Process, or Procedure, for directions on how to obtain an exception to this procedure.

Granting or permitting exceptions or violations of policy, process, or procedure without authority, regardless of position or title, may be cause for disciplinary action up to and including termination of employment. Violating a policy, process, or procedure may be cause for disciplinary action up to and including termination of employment.

IMPORTANT NOTICE: A printed copy of this document may not be the document currently in effect. The official version is located on the Sandia National Laboratories Sandia Restricted Network (SRN).

Procedure Overview

This procedure lists the minimum requirements that must be followed for forklift operations on SNL-controlled premises. Manufacturers' requirements must be followed if they are more stringent than requirements discussed in either DOE-STD-1090-2007 or this procedure. For questions regarding forklifts, consult the cranes, hoists, and rigging program contact or the SNL Material Handling ES&H Safety Engineering website. For terms and definitions related to forklifts, see DOE-STD-1090-2007, Chapter 1, "Terminology and Definitions."

Procedure Requirements

Training

Activity Responsible Individual Required Action
Ensure Required Training Is Completed Managers

Ensure that Members of the Workforce complete the required training identified in ESH100.2.IS.22 prior to performing the indicated work activity or fulfilling the indicated role.

Note: See Sandia corporate procedure HR100.2.1, Identify and Complete Sandia Required Training for all Members of the Workforce.

Qualifications

Activity Responsible Individual Required Action
Oversee Qualifications of Members of the Workforce Managers
  • Ensure that only qualified SNL operators use SNL-owned, rented, or leased forklift equipment.
  • Ensure that your organization’s operators/inspectors maintain their skills and qualifications by implementing the following:
    • Require forklift operators to possess a valid state driver's license
    • Ensure that operators receive familiarization training (on-the-job [OJT]) with the line-supplied forklift equipment.
    • Ensure that operators use forklift equipment frequently enough to acquire and maintain skills. Note: It is recommended to have operators use equipment at least 1 hour per month.
  • Approve and maintain operators/inspectors qualification forms. (see ESH100.2.IS.22 ).
Acquire and Maintain Qualifications Forklift operators
  • Fulfill operator qualification and DOE-STD-1090-2007, Chapter 6, "Personnel Qualifications and Training."
  • Maintain a valid state driver’s license.
Acquire and Maintain Qualifications Members of the Workforce who perform inspections and maintenance on forklifts
  • Fulfill DOE-STD-1090-2007, Chapter 6, "Personnel Qualifications and Training."
  • Complete applicable SNL-specific training (see ESH100.2.IS.22 ).
Complete On-the-Job Training Members of the Workforce who pass forklift training
  • Acquire familiarization training (on-the-job [OJT]) with the line-supplied forklift equipment.
  • Complete appropriate qualification forms (see ESH100.2.IS.22 ) provided in class and obtain approvals and signatures from the forklift trainer and management before operating/inspecting forklift equipment.

Inspections and Maintenance

Activity Responsible Individual Required Action
Oversee Inspection of Forklifts Managers Ensure that inspections of forklifts are performed, as shown in the inspection summaries on the Material Handling ES&H Safety Engineering website for Forklifts and Motorized Hand Trucks.

Procurement of Forklifts

Activity Responsible Individual Required Action
Procure Forklifts Managers and Members of the Workforce Follow the requirements in ESH100.2.IS.6, Procure Cranes, Hoists, Rigging Equipment, and Forklifts.

Replacement Parts

Activity Responsible Individual Required Action
Use Replacement Parts Forklift owners and operators
  • Use only replacement parts from the original equipment manufacturer or parts that are equal to the manufacturer's specifications for all forklift equipment.
  • Do not use any suspect/counterfeit items (SC/I) (see Currently Recognized Rigging Equipment Manufacturer Markings on the Material Handling ES&H Safety Engineering website). 

Critical Lifts

Activity Responsible Individual Required Action
Comply with Requirements for Critical Lifts using forklifts Members of the Workforce
  • Follow the requirements in DOE-STD-1090-2007, Chapter 2, "Critical Lifts," and Critical Lift Plan on the Material Handling ES&H Safety Engineering website.
  • Complete an SF 2001-CLF, Critical Lift Data Sheet - Forklift (Word file/Acrobat file) for the planned critical lift.
  • Ensure that a rigging sketch, a detailed sketch of the planned lift, is documented on the Critical Lift Data Sheet or equivalent engineering document to ensure that all factors and associated hazards are mitigated before the lift occurs.
Oversee Critical Lifts Managers

In addition to the DOE-STD-1090-2007 requirements, ensure that:

  • Rigging devices used in critical lifts must have been proof tested or have evidence of proof testing, such as the manufacturer’s proof-testing certificate.
  • A critical lift plan is prepared in accordance with the Critical Lift Plan on the Material Handling ES&H Safety Engineering website. Note: Some chapters in the DOE-STD-1090-2007 have chapter-specific critical lift requirements. Check each chapter for special critical lift requirements.
  • An appointed person classifies each lift into one of the DOE categories (ordinary, critical, or pre-engineered production) prior to planning the lift.

Note: Further site-specific criteria may be developed to supplement those cited above and may include loads that require exceptional care in handling because of size, weight, close-tolerance installation, lifting personnel, suspended load hazards, or high susceptibility to damage, as well as lifts using multiple pieces of lifting equipment (for more information, see Examples of Suspended Load Hazards on the Material Handling ES&H Safety Engineering website).

Lifting Personnel

Activity Responsible Individual Required Action
Use Forklifts to Lift Personnel Members of the Workforce

Follow the requirements in DOE-STD-1090-2007, Chapter 4, "Lifting Personnel."

Note: The act of lifting personnel with a crane, hoist, or forklift  is always considered a critical lift (see Critical Lifts).

Hostile Environments

Activity Responsible Individual Required Action
Perform Activities in Hostile Environments Members of the Workforce Follow the requirements in DOE-STD-1090-2007, Chapter 5, “Hostile Environments.”

Forklift Trucks

Activity Responsible Individual Required Action
Use Forklift Trucks Forklift operators

When using forklifts, including pallet trucks and non-powered forklift trucks, follow the requirements in DOE-STD-1090-2007, Chapter 10, “Forklift Trucks.”

Note: For information on using forklifts and motorized hand trucks to conduct critical lifts, see Critical Lifts.

Use Forklift Attachments Forklift operators
  • Follow DOE-STD-1090-2007 requirements.
  • Ensure that attachments are inspected, at least annually, by a qualified inspector or QREI.
  • Understand the effects of attachments on forklift capacity and stability.
  • Do not attach or operate any attachment on a forklift truck that has not been approved for use by a forklift truck manufacturer or a qualified engineer in the absence of manufacturer approval.
  • Wear seat belts if they are provided on forklifts. See the topic General Traffic Rules in ESH100.2.IS.7, Implement Traffic Safety.

Note: Performing “free-rigging”/suspended load activities (using the forklift — other than rough terrain forklifts which are designed for this activity — like a crane with the load suspended below the tines), requires special care and may be considered a critical lift (see Critical Lifts). See ANSI/ITSDF B56-1 (5.4.5) for additional information.

Use Forklifts During High Winds Forklift operators

In addition to the DOE-STD-1090-2007 requirements, when moving high-profile loads in high winds (at or above 40 mph):

  • Avoid high-profile lifts from loading docks or trucks higher than four feet.
  • Do not conduct a lift (regardless of the start/stop position of the load) if uncertain about the safety of a high-profile load.

Note: Consult the wind advisory contact. Wind speeds may be reported in knots, which can be multiplied by 1.15 to obtain mph equivalent.

Implementing Tools

Forms

  • SF 2001-CLF, Critical Lift Data Sheet - Forklift (Word file/Acrobat file).
  • SF 2001-CMH, Inspection Checklist for Motorized Hand Trucks (Word file/Acrobat file).
  • SF 2001-FQO, Forklift/Motorized Hand-Truck Operator Qualification Form (Word file/Acrobat file).
  • SF 2001-SCF, Inspection Checklist for Forklifts (Word file/Acrobat file).

Websites

  • Material Handling – Cranes, Hoists, and Forklifts.

 

Required Records and Retention Schedule

Managers must ensure that the records specified below are managed in accordance with the Sandia Records Retention and Disposition Schedule. Required records (forms) are listed below the Record Series number for each group of forms.  

The following forms must be managed in accordance with Record Series LO-103-203-000:

  • SF 2001-CLF, Critical Lift Data Sheet - Forklift (Word file/Acrobat file).
  • SF 2001-CMH, Inspection Checklist for Motorized Hand Trucks (Word file/Acrobat file).
  • SF 2001-SCF, Inspection Checklist for Forklifts (Word file/Acrobat file).

The following form must be managed in accordance with Record Series HR-104-201-000: 

  • SF 2001-FQO, Forklift/Motorized Hand-Truck Operator Qualification Form (Word file/Acrobat file).

 

Additional Drivers

  • 10 CFR 851, Worker Safety and Health Program.
  • DOE-STD-1090-2007, Hoisting and Rigging Standard.

 

Training Requirements

Responsible Individual Required Recommended
Members of the Workforce who supervise forklift operators. N/A

FKL111

FKL153S

RGH100

RGH134

RGH137

RGH201

Members of the Workforce who operate forklifts.

Note: Completion of proper forklift training is required before an operator's completion card will be issued or reissued.

FKL153 (includes the content of FKL110)

Note: Upon successful completion of FKL153, course credit will be given for both FKL153 and FKL110. The course content for FKL110 is included in FKL153.

FKL153R (does not include the content of FKL110) (retraining interval is 36 months)

FKL110 (in addition to FKL153R for operators of forklifts and motorized hand trucks, retraining interval is 36 months)

FKL111 (rough terrain forklifts, Class 7-Telehandlers)

RGH201
Members of the Workforce who operate pallet trucks, small (non-powered) forklifts.

Manufacturer’s instructions and recommendations: (No specific course) for pallet trucks, small non- powered forklifts.

Note: Training, operating, maintenance, inspection, and testing requirements for non-powered equipment must be based on the manufacturer’s instructions and recommendations.

 
Members of the Workforce who operate motorized hand trucks.

FKL110 (retraining interval is 36 months after the first completion of FKL153 or FKL110.  FKL153R is not applicable.)

Note: As with any compliance course, if FKL110 is needed, it must be entered in the individual's To Do List in TEDS, even if originally taken as part of FKL153 training.

RGH201
Members of the Workforce who perform inspections and maintenance on forklifts

See DOE-STD-1090-2007, Chapter 6 for guidance.

Note: Specialized training from outside resources may be required. The providers of outside training resources are responsible for the training content and compliance with DOE-STD-1090-2007, Chapter 6, and applicable OSHA regulations and ANSI standards.

RGH201

Related Processes and Procedures

Processes

  • ESH100.2, Analyze and Control Hazards.
  • ESH100.4, Feedback and Improve.
  • IM100.2, Manage and Protect Information.
  • SCM100.2, Acquire Property, Material, and Services.

Procedures

  • ESH100.2.IS.6, Procure Cranes, Hoists, Rigging Equipment, and Forklifts.
  • ESH100.2.IS.7, Implement Traffic Safety.
  • ESH100.4.RPT.5, Report Vehicle Accidents and Property Damage.
  • IM100.2.2, Control of Records.
  • SCM100.2.16, Acquire Special Approval Items or Services.

 

Required Reviews

Review Completion Dates
In Process

Change Summary

Date Summary
01/19/2012

Administrative

Added

Jeff Kokos was added as a subject matter expert.

10/19/2011

Administrative

Modified

Updated link to 10 CFR 851 in Additional Drivers.

10/18/2011

Administrative

Modified

  • Revised SAPLE links for subject matter experts to direct e-mail links for improved system usability.
  • Updated the following links:
    • Cranes, hoists, and rigging program contact (Overview).
    • Operator qualification (Requirements).
    • Critical lifts (several links in Requirements).
    • Training course FKL153S (Training Requirements).
    • 10 CFR 851 (Additional drivers).
    • Records Retention and Disposition (same field)
    • Record series number (Records Retention & Disposition Schedule).

Added

  • Added links to Related Corporate Processes and Procedures (ESH100.4, IM100.2, SCM100.2, ESH100.2.6, ESH100.2.IS.7).
  • Added "suspended load" to "free rigging" in "Use Forklift Attachments."
  • Added " "requires special care and may be..." in the same sentence as described above.
  • Added a hyperlink to ANSI/ITSDF B56-1 in same paragraph.

 

07/13/2011

Administrative

Modified

Revised links to DOE-STD-1090-2007 throughout this document.
02/07/2011

Administrative

Modified

  • Updated SAPLE links to subject matter experts for system consistency.
  • Un-merged cells in Requirements & Instructions for display purposes.
  • Updated all dictionary terms to contain term identification numbers for system consistency.
07/15/2010

Administrative

Modified

  • At Qualifications, Acquire and Maintain Qualifications, Forklift Operators, corrected the link for operator qualification.
6/25/2010

Administrative

Modified

  • Replaced "SNL Material Handling ES&H Safety Engineering" website, with "Material Handling – Cranes, Hoists, and Forklifts" under Implementing Tools.