Forklift

A forklift is a motorized and steerable industrial machine equipped with a forked lifting mechanism, designed for lifting, transporting, and stacking heavy loads. It is commonly used in logistics, warehousing, manufacturing, and construction industries and plays a critical role in ensuring workflow continuity. Unlike conventional transport equipment, forklifts offer load-handling capabilities in both horizontal and vertical planes.

Structural Components and Working Principle

A forklift operates through a combination of mechanical and hydraulic systems. Its main components include:

• Chassis (Frame): The base structure onto which all systems are mounted.
• Mast: A vertical assembly that lifts loads vertically; it can be single-stage, two-stage, or telescopic.
• Forks: Steel arms that slide under loads for lifting.
• Counterweight: A fixed weight placed at the rear to balance the machine.
• Operator Cabin: Includes steering wheel, control levers, pedals, and instrument panels.
• Power Unit: Powered by electric motors, diesel, LPG, or gasoline engines.
• Hydraulic System: Controls the lifting and tilting of the forks.

These systems enable forklifts to transport palletized or bulky loads safely and efficiently over short distances.

Types of Forklifts

Forklifts can be classified based on power source, wheel type, and functional application:

By Power Source

• Electric Forklifts
• Diesel Forklifts
• LPG or Gasoline Forklifts

By Wheel Type

• Pneumatic Tire Forklifts (for outdoor use)
• Solid Tire Forklifts (for indoor use)

By Function

• Reach Trucks (for high-rack systems)
• Stackers (for light-duty lifting)
• Driverless (autonomous) Forklifts

Areas of Use and Function

The primary function of a forklift is to transport heavy loads in environments where human strength is insufficient. This capability is vital for maintaining efficiency in industrial workflows. Forklifts are widely used in:

• Warehousing and distribution centers
• Ports and airports
• Production lines
• Construction sites
• Food, automotive, metal, chemical, and textile industries

Role in Occupational Health and Safety

Forklifts are classified as mechanical work equipment and are central to lifting, moving, and stacking processes in industrial operations. However, due to improper use, inadequate maintenance, or insufficient training, they are considered high-risk machinery. According to occupational accident statistics, forklift-related incidents—such as collisions, tip-overs, falls, crush injuries, and load shifts—often result in serious and even fatal consequences.

In Turkey, under the Occupational Health and Safety Law No. 6331, forklifts may only be operated by qualified personnel. Risk assessments, training, supervision, and preventive engineering measures must be addressed comprehensively.

Managerial and Legal Responsibilities

Under occupational safety regulations, employers are obligated to:

• Conduct risk assessments before forklift operations.
• Ensure that operators possess a Class G machine operator license.
• Archive and update training records.
• Schedule regular maintenance and inspections.
• Define safe zones using signage, striping, and warning labels.

Occupational physicians and safety specialists should take active roles in planning, implementing, and auditing these processes.

Training and Supervision for Forklift Operators

Occupational safety training for forklift operators should include:

• Equipment introduction and technical specifications
• Principles of the center of gravity and stability
• Techniques for avoiding tip-overs and collisions
• Emergency procedures
• Use of personal protective equipment (PPE)

After training, written and practical exams are conducted, and successful operators are certified. Additionally, periodic observations, behavioral audits, and performance evaluations should be conducted by safety professionals.

Forklifts and Behavioral Safety

In addition to technical measures, behavioral safety is crucial in forklift operations. Operators should internalize rules such as:

• Being in the right psychological condition for work
• Avoiding mobile phone use while driving
• Not carrying loads that obstruct their field of vision
• Avoiding sudden movements

A true safety culture is maintained not by punishment alone, but through education and model behavior.

The Cost and Preventability of Forklift Accidents

Most workplace accidents are preventable with the right precautions. Forklift incidents not only pose a risk of injury or death but also result in:

• Production interruptions
• Equipment or product damage
• Increases in insurance premiums
• Legal expenses and compensation claims
• Reputational damage

Thus, investment in accident prevention and safety training leads to long-term cost benefits.