What to Do if the Forklift Load is Too High

Published on 09-18-2024

If a forklift load is too high, it compromises stability and visibility, which can lead to accidents. The first step is to lower the load to a safe height if possible. If lowering the load isn't feasible, you may need to break down the load into smaller, more manageable pieces. Always ensure the load is within the forklift's weight capacity and evenly distributed on the forks. Keep the load as low as possible to the ground to maintain balance, and if visibility is obstructed, drive in reverse to see better or have a spotter guide you.

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When a forklift load is too high, it poses significant risks to both the operator and surrounding workers. High loads reduce visibility, increase the risk of tipping, and may even exceed the forklift's weight capacity. Here's how to handle situations when a forklift load is stacked too high for safe operation.

Key Actions to Take

Lower the Load

The most straightforward action is to lower the load to a safer height. Forklifts are designed to operate most safely when the load is carried at a low height, typically just a few inches off the ground. This keeps the center of gravity low and reduces the risk of tipping.

Disassemble the Load

If lowering the load is not possible because it's too large or tall, you may need to disassemble it. Break down the load into smaller, more manageable sections. Removing some items and carrying them in multiple trips is a much safer option than attempting to move an oversized load all at once.

Drive in Reverse if Visibility is Obstructed

When a high load obstructs the operator's view, it's recommended to drive the forklift in reverse. This allows the operator to see where they are going and avoid hazards. However, driving in reverse should be done with caution, and it's best to have a spotter assist in particularly tight areas.

Use a Spotter

If you must transport a load that blocks your vision and driving in reverse isn't an option, use a spotter. A trained spotter can guide you, helping to ensure you safely navigate obstacles and avoid accidents.

Check the Forklift's Weight Capacity

Always verify that the load does not exceed the forklift's rated capacity. Even if a load is physically too high, it may also be too heavy, which could lead to catastrophic equipment failure or tipping.

Why Height Matters in Forklift Operation

Operating with loads that are too high affects the forklift's stability and maneuverability. A high center of gravity can cause the forklift to tip, especially when making turns or stopping suddenly. Moreover, visibility is critical for avoiding obstacles and ensuring a safe operating environment. Keeping loads at a manageable height helps maintain balance and control, reducing the chance of an accident.