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.