CASE STUDIES OF ACCIDENTS INVOLVING FORKLIFT OPERATIONS

Teo Han Ping Investigations Branch Occupational Safety & Health Inspectorate (OSHI) Occupational Safety & Health Division (OSHD)

Overview:
Case studies of 4 fatal accidents involving forklift.
Synopsis of Accident Description of Accident Key Findings / Observations Learning Points Summary of Key Learning Points.

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CASE STUDY 1

Fatal Accident at Waste Paper Factory.

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Synopsis of Accident:
Workplace Premise: Factory repackaging waste paper Forklift: 3 ton (load capacity) Work Activity: Deceased was operating the forklift on a metal ramp to load up compressed bales (blocks) of waste-paper into a container Nature of Accident: Forklift overturned and crushed worker

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Description of Accident
The forklift was loading blocks of compressed recycled papers ("paper bales") into a 40 ft long container stationed at the end of the ramp. The ramp was propped up by paper blocks. Another forklift was used to move the paper blocks onto the ramp for loading.
Position of container Paper blocks

Steel Ramp

Paper blocks used to prop up the ramp

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Description of Accident
While the deceased was in the process of loading a paper block, the forklift suddenly reversed out from the side of the ramp and toppled off the ramp. The deceased was pinned onto the ground by the forklift and was killed.
Paper blocks (bales) Forklift Involved In Accident

Ramp used in accident Forklift was operating on top of the ramp prior to the accident

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Key Findings / Observations

Forklift involved in the accident.

Badly worn out tyres: evidence of poor maintenance

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Key Findings / Observations

1. The deceased had not undergone the mandatory Forklift Driver's Training Course prior to the accident. 2 Forklift involved in the accident was poorly maintained and there was no proper maintenance regime for the forklifts in the workplace. 3 Unsafe work method of operating forklift on ramp propped up by paper blocks. 4 There was no risk assessment conducted on the work activity. There was also no safe work procedure established.

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Learning Points
1. Importance of ensuring forklift operators are trained and competent. (Mandatory Forklift Driver's Training Course). 2 Importance of ensuring any machineries such as forklifts are safe and without risks for workers; proper maintenance regime for the forklifts in the workplace. 3 Importance of conducting risk assessment to identify and implement control measures which include proper safe work procedure for forklift operations.

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CASE STUDY 2

Fatal Accident at Warehouse Premise

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Synopsis of Accident:
Workplace Premise: Warehouse premise in a distribution park Forklift: 3 ton (load capacity) Work Activity: Deceased was taking stock of goods to be transported out of the warehouse. He squeezed through the gap between two racks and was crushed when a forklift pushed the racks closer to make space for more racks. Nature of Accident: Crushed between objects

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Description of Accident
The deceased worker was involved in tallying stock stored on metal racks within yellow boxes.

Yellow box

Warehouse Premise

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Description of Accident
The deceased worker was conducting checks in between two metal racks just prior to the accident. To free up space for more cargo, a forklift operator used his forklift to push the adjacent metal racks. The deceased worker was trapped in between the metal racks. Deceased worker was found dead an hour later.

Forklifts position prior to pushing the metal racks

Deceased was caught in between the metal racks

Labels on carton boxes

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Key Findings / Observations

1. Risk assessment on such work activity was not carried out; 2 It was a common practice for tally clerks and other workers to work in between cargoes and containers while forklifts were operating in close proximity; 3 Lack of entry prevention into yellow box and / or work procedures not established to prevent such work activity from being carried out concurrently; and 4 Inadequate safety trainings and briefings to effectively promote safety awareness among workers.

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Learning Points
1. Importance of conducting risk assessment to identify and implement control measures. for forklift operations. 2. Proper management of forklift and human traffic in workplace, e.g. Proper demarcated paths for human and forklift traffic. 3. Importance of safety training and briefings to increase safety awareness and manage workers behaviour

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CASE STUDY 3

Fatal Accident at Shipyard

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Synopsis of Accident:
Workplace Premise: Vehicle access road in shipyard. Forklift: 7 ton (load capacity) Activity: Deceased was sleeping near vehicle access road next to steel fabrication block. The road is part of a T-junction. At around 11.55 pm, a 7-ton forklift carrying a concrete block turned left at the T-junction into the road and ran over the deceased. Nature of Accident: Ran over by forklift

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Description of Accident
At near midnight, the deceased and 4 co-workers were sleeping at an open space near fabrication block after they had taken their supper. The 4 co-workers were sleeping near steel fabricated block. However, the deceased slept at an open path further away from the rest.

Position of 4 co-workers

Position of deceased

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Description of Accident
The 7 ton forklift carrying a concrete block (measuring 1.5m X 1m X 1.5m and weighing about 5.4 ton) turned into that area and ran over the deceased worker (who was lying on the path of the forklift). The deceased worker subsequently succumbed to his injuries in Alexandra hospital.

Deceased worker was found here.

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Key Findings / Observations

1. Not all workers were informed about the existence of the resting shed (just 100m away). No instruction was given to prohibit workers from resting near the steel fabricated blocks or other work area. 2. The operators vision was obstructed during operation by the concrete block, but he continued driving forward. 3. There was no lighting around the proximity and the operator did not switch on the 2 headlights. 4. The operator worked from 7.30am till mid-night and fatigue may have compromised his judgment and functionality.

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Learning Points
1. Proper management of forklift and human traffic in workplace, e.g. Enforcement of designated resting area for workers 2. Importance of safety training and briefings to increase safety awareness and manage workers behaviour. 3. Proper lighting for forklift operations at night. 4. Issue of fatigue -adequate hours of rest for workers

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CASE STUDY 4

Fatal Accident at Construction Site

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Synopsis of Accident:
Workplace Premise: Circular vehicle ramp of a light industrial building under construction. Forklift: 3 ton (load capacity) Work Activity: A worker (the deceased) was driving the forklift down a circular vehicle ramp from the 4th level towards the 3rd level. The forklift suddenly swerved and overturned at the 3rd level. The deceased was pinned by the forklift and he died on the spot. There was no load on the forklift. Nature of Accident: Forklift overturned and crushed worker Forklift operator had not undergone the mandatory Forklift Driver's Training Course

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Description of Accident
The forklift was moving down the circular vehicle ramp when it suddenly overturned and pinned down the deceased.

Position of deceased
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Worn rear wheels

Area where worker s head was pinned

Wires coming out of panel. Lowered fork

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Key Findings / Observations

1. The forklift involved in the accident, belonged to the main contractor and was poorly maintained, though there is an existing maintenance regime established. 2. The deceased was an employee of the plastering and brick-laying works sub-contractor. He had not undergone the mandatory Forklift Driver's Training Course. 3. There are insufficient trained forklift operators with respect to number of forklifts. 4. There was no risk assessment conducted on forklift operations.

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Learning Points
1. Control and management of sub-contractors: Ensuring forklift operators are trained and competent. (Mandatory Forklift Driver's Training Course). 2. Sufficient trained forklift operators to number of forklifts. 3. Importance of effective implementation of maintenance regime for the forklifts in the workplace.

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Summary of Key Learning Points

1. Risk assessments is important even for simple forklift operations; 2. Competency of forklift operators (mandatory Forklift Driver's Training Course) is critical to the safe operation of forklift; Procedures / system should be established to ensure operation of forklift by authorised, trained persons for own workers and subcontractors 3. Control measures to effectively manage forklift and human traffic within the workplace are critical for ensuring the safe movement of workers 4. Safety orientation, training and briefing are important in promoting safety awareness and vigilance among workers working in the vicinity of forklifts; 5. Proper maintenance regime should be established and effectively implemented for forklifts and other machines in workplace.
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CONCLUSIONS
All accidents are preventable. Be proactive: it is up to YOU to prevent it.

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THANK YOU

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