OSHA Forklift Regulations and Workplace Safety in Illinois

In Illinois and across the country, OSHA forklift regulations set clear standards to keep workers safe when using powered industrial trucks. From warehouses and construction sites to manufacturing plants and other non-agricultural operations, these rules exist to prevent workplace accidents caused by unsafe forklift operation or inadequate forklift training.

What Are Forklift Regulations Set by OSHA?

The Occupational Safety and Health Administration, a federal agency, enforces guidelines that protect both forklift operators and the public from hazards like falling objects, load stability issues, and hazardous conditions.

The standards for powered industrial trucks (1910.178) don’t just cover how to operate a forklift; they also require forklift certification, practical training, and formal instruction before someone can handle lift trucks or other industrial trucks. 

For Illinois employees, failing to follow these OSHA mandates can lead to serious violations, and injured workers may be entitled to legal compensation. Our firm helps protect workers by holding employers accountable when safety and health rules are ignored.

Forklift Operators and OSHA General Requirements

Under OSHA Standard 1910.178(a), forklift operators are responsible for handling a wide range of powered industrial trucks—including fork trucks, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines. These rules apply in general industry, warehouses, manufacturing facilities, and more, but exclude over-the-road hauling, farm vehicles, and earth-moving equipment.

OSHA requires that all new powered industrial trucks meet the American National Standard for Powered Industrial Trucks (ANSI B56.1-1969) design and construction standards. Only approved trucks bearing the mark of a nationally recognized testing laboratory can be used in the workplace. Nameplates and capacity markings must be legible, and any modifications that affect capacity or operational safety require prior manufacturer approval.

Forklift Training and Competency Requirements

OSHA’s 1910.178(l) lays out detailed forklift training standards to protect workers. Before an employee can operate a forklift, they must complete a combination of formal practical training and on-the-job evaluation.

Training may include lectures, written materials, videos, or interactive learning. Practical training involves hands-on demonstrations and supervised driving exercises. Training content must cover both truck-related topics (controls, capacity, stability, fueling, maintenance) and workplace-related topics (surface conditions, load composition, narrow aisles, ramps, and unique hazards).

Only trainers with the knowledge, training, and experience to train operators and evaluate their competence may provide instruction. Employers are also required to offer additional training if workplace conditions change, or if an operator is assigned to a different type of forklift.

Formal Instruction and Practical Skills

OSHA stresses that formal instruction alone is not enough—skills must be proven through supervised forklift training. Trainers must observe operators during normal tasks, including load stacking, traveling in narrow aisles, and working around pedestrians.

Instruction must also cover fueling and battery charging. Fuel tanks cannot be filled while the engine is running, and fuel handling must follow the National Fire Protection Association (NFPA) standards. In battery charging, operators must use proper lifting devices, such as an overhead hoist, and ensure ventilation is adequate to avoid hazardous gas buildup.

Industrial Trucks – Types and Designations

Per 1910.178(b), OSHA identifies eleven designations for industrial trucks—D, DS, DY, E, ES, EE, EX, G, GS, LP, and LPS—based on power source and safety safeguards. For example:

• D units are diesel-powered, while G units use gasoline.
• E, ES, and EE are electrically powered, with increasing levels of spark and heat protection.
• EX units are designed for hazardous atmospheres with flammable vapors or combustible dust.
• LP and LPS run on liquefied petroleum gas, with LPS having extra exhaust and fuel safeguards.

Employers must match the truck designation to the hazard classification of the location (Class I, II, or III), ensuring operational safety in areas like grain storage, chemical plants, and narrow aisles with limited ventilation.

Operating Powered Industrial Trucks Safely

Safe operating practices for powered industrial trucks are critical to avoid injuries. OSHA prohibits actions like stunt driving, horseplay, or allowing unauthorized personnel to ride on the truck. Operators must maintain a safe following distance—about three truck lengths—and yield to emergency vehicles.

When traveling, visibility is essential. If the load blocks the view ahead, the truck should be driven in reverse. Crossing railroad tracks diagonally, avoiding sudden turns, and traveling slowly on grades are part of OSHA’s safety expectations. Trucks must not be driven up to people standing in front of a fixed object, and arms or legs must be kept inside the running lines at all times.

In loading, only stable or safely arranged loads should be handled. Forklift operators must avoid exceeding rated capacity and must use a load backrest extension if there is a risk of the load falling backward.

Operating a Forklift in Hazardous Locations

Special requirements in 1910.178(c) apply when operating powered industrial trucks in hazardous areas. For example, only EX-designated trucks may be used where flammable vapors are present. In locations with combustible dust—like grain elevators or aluminum powder processing—special electrical enclosures and ventilation are required.

The classification of a location (hazardous vs. nonhazardous) determines what industrial trucks are allowed. OSHA also addresses overhead hoist use in battery charging areas, requiring proper handling equipment and precautions against sparks, open flames, and poor ventilation.

OSHA Requirements for Safe Operation

The OSHA requirements in 1910.178(m)-(n) detail safe operation procedures, including maintaining a clear square foot of space for fire aisles, keeping fire equipment unobstructed, and ensuring adequate headroom under overhead installations.

The rules also mandate that trucks be kept under control at all times, with speeds adjusted for wet or slippery conditions. Operators must avoid loose objects on travel surfaces and reduce speed before turning. In all cases, the goal is to protect workers from tip-overs, collisions, and falling materials.

Forklift Certification and Documentation

Employers must provide forklift certification that documents each operator’s name, the date of training, the date of evaluation, and the identity of the person conducting the training. OSHA requires evaluations at least once every three years, and refresher training if an operator is observed driving unsafely, is involved in an accident, or workplace conditions change.

A certified forklift operator is considered properly trained when they can demonstrate competence in both handling the truck and responding to workplace hazards. Certification isn’t just a formality, but part of OSHA’s enforcement under the Occupational Safety and Health Administration to protect workers and promote occupational safety.

Maintenance and Inspection of Industrial and Lift Trucks

Routine inspection and maintenance of lift trucks is essential for compliance with 1910.178(q). Trucks must be examined before each shift, with defects reported and corrected before use. Fuel leaks, worn brakes, faulty steering, and excessive smoke from the exhaust are all red flags.

Cleaning must be done with noncombustible agents, avoiding low-flash-point solvents. Trucks should be free of lint, grease, and excess oil, and mufflers must be unclogged. Compressed air must not be used for cleaning in a way that creates hazardous flying debris.

Why Choose Us to Handle Your OSHA Forklift Violation Case

At our Chicago forklift accident law firm, we know the OSHA standard for operating powered industrial trucks is more than a rulebook; it’s a critical safeguard meant to protect workers in busy warehouses, retail spaces, and distribution hubs across Illinois. 

Our record of success includes cases where truck collisions, equipment defects, and unsafe manner practices, such as stunt driving, ignoring blind spots, or failing to maintain a safe distance, caused life-changing forklift injuries.

Take Marcus, for example. He was a temporary worker at a large West Side shipping facility when a forklift backed into him, pinning him against a loading dock. Despite multiple OSHA forklift regulations violations, his employer had never provided proper forklift training. We fought to prove negligence and secured an $11 million settlement that will help Marcus and his family rebuild their lives.

Then there was David, a skilled powered industrial truck operator at a South Side manufacturing plant, who was severely injured when a lift truck tipped over due to poor load stability and a lack of safety guards. His pelvic and leg fractures left him unable to work for over a year. Through evidence of OSHA mandates breaches and unsafe workplace conditions, we obtained $4.4 million in compensation for his medical care, lost wages, and long-term rehab needs.

Finally, Anthony, a Chicago resident, suffered spinal injuries after being struck by a forklift in the parking lot of a home improvement store. The incident occurred because an employee, never given complete training, was allowed to operate a powered industrial truck in a congested customer area. We negotiated a $1.25 million settlement to cover his recovery and ensure changes in the store’s safety and health procedures.

No matter where your injury occurred and the type of machinery it involved, our Chicago work injury attorneys know how to investigate every factor, from the type of forklift used to fuel handling, fuel tanks, and even excess oil hazards. Our deep familiarity with workplace laws, safety standards, and Chicago’s industrial landscape means we can build a strong case to get you the justice you deserve. Book a free consultation today!