Forklifts might not be the primary backbone of the industrial world but they certainly play an invaluable role. They are essential for the lifting and moving of large and heavy loads. The fundamental forklift design concept hasn’t changed much over the years but the controls, safety and comfort features have evolved in recent decades. Forklift attachment designs however have continued to proliferate over the years and today you’ll find a wide variety of forklift attachments that can be adapted to fit many different forklifts and accomplish an infinite number of lifting and moving tasks. It is important to choose the correct forklift attachment for the forklift and the material handling job.
Consider for example the class of machines designated as rough terrain forklifts. This type of forklift is specially built and designed to handle off road terrain and is commonly used on construction sites, farms and landscaping projects. To successfully transverse the outdoor terrain, rough terrain forklifts are built with off road pneumatic tires, similar in many ways to the tires found on tractors or earth movers. These tires provide better cushioning and traction which is invaluable on uneven surfaces.
Rough terrain forklifts typically employ internal combustion engines unlike many indoor forklifts which utilize electric motors because internal combustion engines provide the power to carry heavier loads and achieve faster speeds without the need to plugged in for refueling.
Given the strength and power behind these machines, employers and operators of forklifts are expected to work within the regulations outlined by the Occupational Safety and Health Administration. These safety regulations are aimed at creating a safer work environment. They address crucial areas such as the certification of a fork lift operator and the standards for forklift attachments.
In the case of the latter, the OSHA does not permit any modification to a fork lift attachment that will change its stated lifting capacity. The equipment capacity is an important operational factor and affects the type of task that the unit can be used for. Attempting to move an item that exceeds the lifting capacity of a forklift can affect the balance of the forklift and exposes the operator and workers to potential risk. Forklifts and forklift attachments are typically accompanied with tags, instructions and labels to this effect.
It is important to note that the addition of a new forklift attachment can significantly alter the carrying capacity of a fork lift and also affects the overall stability of the unit. In line with OSHA forklift certifications, employers are therefore required to ensure that the maximum capacity load for the new attachments be clearly marked on the fork lift capacity data plate or nameplate.
Manufacturers are duty bound to provide information on the capacity rating of a fork lift. However, there are situations where this information might not be available. In such instance, a suitable alternative is to work with a professional engineering firm accustomed to performing fork lift capacity calculations. Some companies may provide a capacity calculator for use in estimating the capacity of a forklift with attachments. Forklift Capacity calculators are computing programs that allows users to accurately determine the fork capacity for their unit. Working with a fork lift capacity calculator provides employers with an effective method of assessing if they have sufficient fork capacity for an intended task but the employer must work with a professional engineering firm or the original manufacturer to obtain an OSHA compliant Forklift capacity plate.
An example of a reliable tool is the Lift Truck Capacity Calculator.
Built by Professional Forklift Engineering Services in Southern Carolina, the Lift Truck Capacity Calculator is an effective tool that allows users to quickly assess the capacity of their machine and obtain a rating plate firmly within the regulations of the OSHA. You can calculate your capacity ratings or get OHSA complaint ratings tags for your forklift attachment by visiting the website.
There is no questioning the value of forklifts. They're an invaluable asset to any business where large or heavy items are going to be lifted. Depending on the design and model, forklift attachments can be used indoors or outdoors.
Properly determining the capacity of forklifts is important. This is because that a failure to get it right can lead to a myriad of problems. Included among these are injuries to employees that can be serious. |
There are a multitude of factors that affect the lifting capacity of a forklift and these parameters, which are indicated on the capacity data plate, include:
- Make or Manufacturer
- Model
- Power Source
- Battery Weight (for electrics)
- Tire Type
- Tire Size
- Mast Lift Height
- Mast Carriage Type
- Attachment(s) Type
- Attachment(s) model
- Load Center of Gravity (CG or LC)
If any of these parameters are changed, particularly the attachments on the forklift carriage or the load center, the capacity plate should be checked for accuracy to ensure safe load handling.
Forklift attachments include anything that is attached to the front carriage of a forklift or is attached to an attachment on the forklift. A typical forklift attachment configuration might include a hang-on side shifter and two forks. In this case, if the forks are removed and longer forks are added, the capacity of the machine could be drastically reduced. Or if the forklift is used to pick up a fork mounted attachment, such as a drum handler or fork extensions, then a capacity data plate must be changed or added to reflect the new configuration. OSHA forklift safety regulations state that a forklift must have a legible capacity plate to reflect any attachment used on the lift.
Lift height or maximum fork height (MFH) has a significant effect on a forklift’s load carrying capacity, and forklifts with high masts will have a greater carrying capacity at lower lift heights than at the maximum lift height. For this reason forklifts with very high masts may have a dual capacity rating on the data plate; a maximum capacity up to a mid level lift height, and a lower capacity rating at the maximum lift height. This allows the forklift operator to work with heavier loads at low heights, i.e. loading and unloading trucks, cross-docking, etc., while using the same forklift to put away lighter loads to high storage locations.
Because a forklift is using leverage to lift a load, any condition that adds weight to the front of the forklift and causes the load center (LC or CG) of the load to be moved further away from the forklift will contribute to a reduction in the residual carrying capacity of the machine. Forklift attachments can cause these reductions, as well as the dimensions of the load and the load handling conditions. Load center typically refers to the horizontal distance to the load CG and is typically half the length of the load for symmetrical objects. To illustrate how attachments and load CG’s can affect residual carrying capacity, consider for example that a particular forklift with only forks on the carriage is rated at 5,000 lb capacity @ 24” load center on the data plate. This forklift will only be rated at 1,270 lb when equipped with a particular 8 foot long fork mounted jib boom because the boom adds weight and moves the load center out to 96 inches. In this case the forklift may employ a dual load center capacity rating on the capacity plate indicating a greater lifting capacity (2,750 lb) at a 4 foot load center and a lower capacity (1,270 lb) at the 8 foot load center.
Small changes in load center can also greatly affect the carrying capacity. Consider the capacity of the same 5,000 lb forklift with 48” forks and rated at a 24” load center, drops to 3,660 lbs when 72” fork extensions are employed to lift a 6 foot long load.
The main thing to consider is that every forklift has a legible capacity plate that accurately reflects the attachment configuration being used at the correct load center for the load being lifted and contact Professional Forklift Engineering Services at www.LiftTruckCapacityCalculator.com to check your lift capacity and get a professional engineering (PE) certified capacity rating plate on your forklift today.
"Employers who are cited for repeat violations demonstrate a lack of commitment to workplace safety and health standards. Deficient forklifts and improperly handled chemicals can lead to serious injuries or death,"said Diane Turek, director of OSHA's Chicago North office in Des Plaines. "All employers must take the necessary steps to eliminate hazards from the workplace."
Four repeat violations with proposed penalties of $132,000 have been cited,including exposing workers to hazards by allowing them to operate forklifts that remained in service even after deficiencies were noted; exposing workers' eyes, faces and hands to corrosive chemicals without providing suitable eyewash facilities; and failing to develop an emergency response plan and conduct fire extinguisher training. A repeat violation exists when an employer previously has been cited for the same or a similar violation of a standard, regulation, rule or order at any other facility in federal enforcement states within the last five years. The company was cited for the same violations at numerous facilities between 2006 and 2011.
Central Transport also has been cited for eight serious violations with proposed penalties of $30,800, including failing to train and evaluate forklift drivers, maintain forklift name plates in legible condition, label hazardous material containers, maintain the mechanic shop maintenance area in a dry condition, provide workers with training on hazardous chemicals and provide material data safety sheets for workers' reference. A serious violation occurs when there is substantial probability that death or serious physical harm could result from a hazard about which the employer knew or should have known.
Finally, the company has been cited for five other-than-serious violations with $2,000 in proposed penalties for failing to maintain the OSHA 300 injury and illness log, maintain fire extinguishers, illuminate exit signs and unlock a fire exit door. An other-than-serious violation is one that has a direct relationship to job safety and health, but probably would not cause death or serious physical harm.
The citations can be viewed at http://www.osha.gov/ooc/citations/CentralTransport_77120_1205_11.pdf*.
Central Transport, a national freight company based in Warren, Mich., has 15 business days from receipt of the citations to comply, request an informal conference with OSHA's Chicago North area director in Des Plaines or contest the findings before the independent Occupational Safety and Health Review Commission.
To ask questions, obtain compliance assistance, file a complaint, or report workplace hospitalizations, fatalities or situations posing imminent danger to workers, the public should call OSHA's toll-free hotline at 800-321-OSHA (6742) or the agency's Chicago North office at 847-803-4800.
Under the Occupational Safety and Health Act of 1970, employers are responsible for providing safe and healthful workplaces for their employees. OSHA's role is to ensure these conditions for America's working men and women by setting and enforcing standards, and providing training, education and assistance. For more information, visit http://www.osha.gov.
