Instability

Tipping over is the biggest danger for an employee using a forklift? A forklift can tip over by rolling or overturning sideways; or by pitching forward, when the back wheels lift off the ground.

Forklifts can tip over if you:

 accelerate quickly in reverse 

 brake too quickly, especially on a loaded forklift 

 brake or accelerate while cornering 

 brake or accelerate down a slope 

 carry a load facing down a slope  carry an unevenly balanced load 

 collide with another vehicle 

 drive across inclines or uneven ground such as potholes (particularly with a height difference greater than 20mm across the front wheels) 

 drive with the tines raised too high (loaded or unloaded) 

 strike low doors or overhead structures 

 turn too fast 

 tow without using the designated tow point. 

Forklift stability: key practical issues

 To avoid a forklift tipping over, the most important specifications to consider are lift capacity, the maximum load supported, and vertical lift travel. 

 When stationary at the rated load and with the load down, forklifts have a stability safety margin of 30–50%. 

 For a fully elevated load with a vertical mast, the stability safety margin is reduced to 15–20%.  While stacking with off-centre loads at full height — on a surface with a 2% difference in gradient 

 (20mm in 1 metre) — stability can be significantly affected. 

 Loads suspended from a jib attachment on a forklift make it more likely to tip forward when braking.

 When making lifts over four metres, a dual wheel forklift should always be used to improve stability. 

What employers can do

 Do a risk assessment where you will be working, to determine a suitable forklift. 

 Get the manufacturer’s information about your forklift’s limitations including: – operation on uneven surfaces and inclines – the effect of different tyre types on stability – capacities at different lift height and positions – how the limiting capacity was determined 

 When commissioning a new forklift, adjustments can be made to mast lift cylinders to prevent overloading. 

 The maximum hydraulic pressure should be set at about 110 per cent of the rated load at full height with the mast vertical. 

 Forklifts are often supplied with a model number painted on the side, which can be mistaken for the forklift’s operating capacity. 

 Make sure operators use the load capacity data plate, and don’t assume the forklift’s capacity from these markings. 

 Ensure seatbelts are correctly fitted and worn (for example, by installing intelligent systems, the forklift can only be started if the seatbelt is fastened). Seatbelts may be retro-fitted. 

 Buy or hire forklifts with speed-limiting devices, load-weighing devices and other stability-enhancing features. 

 Be aware that productivity incentives may encourage your employees to drive and work too quickly which can increase the risk of incidents. 

 Implement traffic control measures that account for the risks in the workplace, to reduce the risk of instability. 

 Reduce the speed limit at your workplace. 

 Ensure all forklifts are appropriate for the workplace. 9 

 Buy or hire forklifts with a slightly greater load capacity than you actually need. 

What employees can do 

To ensure your own safety, and that of others, always operate forklifts safely. However, if tipping occurs you should: 

 stay in the cabin with the seatbelt on 

 brace yourself with your feet pressing down and your arms pushing you back into your seat 

 stay with the forklift and lean in the opposite direction of tipping. 

Jumping from an overturning forklift often results in death. While seatbelts might be considered a nuisance, they can also be a lifesaver.