5 Recommended Safety Features to Reduce Forklift Truck

As notoriously powerful machines operating in particularly busy environments, remaining safe whilst working with forklift trucks is key. One way to ensure safety in this hazardous space is by implementing specific safety features.

XRLL contains other products and information you need, so please check it out.

Having the right equipment on your truck can significantly reduce the risk of accidents in the workplace. However, there's such a wide range of safety equipment on the market that it can be difficult to know exactly what you need to reduce forklift truck accidents.

All TCM trucks come fully equipped with standard safety features, but some environments are more prone to forklift truck accidents than others. So it can certainly be worth going a step further to safeguard your vehicles and your drivers.

Here are the top five safety features we recommend adding to your forklifts for extra protection against workplace accidents.

1. Blue Spot LED Lamp

Blue spot LED lamps warn anyone nearby that a forklift truck is coming their way. Many forklifts are virtually noise-free, with operators using their horns to alert people of their presence. Having a blue spot LED lamp as an additional indicator will provide a visual signal to further alert your workers that a forklift truck is in their proximity.

Our new FB/FTB14-20(L)-E3, for example, is created with safety and comfort at the forefront of its design. As well as blue safety lamps with direction-dependent activation, the FB/FTB has standard lighting fitted on the mast, overhead guard and at the rear and reversing lights to illuminate the truck’s load and surroundings to give operators, and those around them enhanced awareness and a clear line of sight.

Related read: The True Cost of Forklift Accidents Revealed

2. Low Height LED Flashing Beacon

A low-height LED flashing beacon can be placed below the overhead guard to reduce potential impact damage to lower and industrial flexible doors. Used as a hazard warning, the LED flashing beacon these lights instruct workers to keep a healthy distance from the vehicle in motion. As well as improving workplace safety, having this additional safety feature can decrease downtime caused by collisions.

To some, low height LED flashing beacons aren’t the favoured choice of hazard light simply because they flash directly in the eyes of workers, obscuring their field of vision. Nevertheless, flashing beacons are an essential safety feature in low light conditions, particularly in darker warehouses or for those operating a forklift truck outside at night.  

Specifically designed with efficiency, comfort and safety in mind, read about our latest FHB25-35(L)-F2 is a 4-wheel 80V lift truck right here.

3. Horizontal Forks Levelling System

Reducing damage to your forklift is important from a safety point of view, as there is less likely to be an accident on a healthy truck. A horizontal fork levelling system can help in this regard, as your operators will be less likely to have incidents that cause damage to themselves, the materials they're moving, or their trucks when forks are positioned correctly.

A primary cause of product, rack and equipment damage is unlevel forks. When the vehicle’s forks are tilted at the wrong angle, drivers can splinter pallets, push over racking or spear and knock products. Ensuring the forks on your vehicle are at the correct level is key to the security of your products, warehouse and forklift trucks, and to the safety of your operators.

Related read: How Our Electric Counterbalance Range Ensures Operator Safety

4. Panoramic Rear View Mirror

For forklift operators, having a good view of people, objects and other vehicles in your vicinity is essential. With a 180° view, panoramic rear-view mirrors offer additional safety by reducing blind spots and improving operator visibility. 

A panoramic view ensures that a forklift operator can see everything that's going on around them easily and efficiently. This is particularly useful in a busy working environment or towards the end of a shift when tiredness can contribute to reduced concentration.

5. Full LED Light Package

Finally, a full LED light package is another important way to enhance forklift safety. By ensuring trucks are visible in your working environment at all times, you reduce the risk of danger for the materials you're working with and for other warehouse workers, for the truck itself. 

Poor visibility can contribute to warehouse injuries; when workers or pedestrians are manoeuvring between forklift trucks or bays, the risk of being crushed or struck increases greatly without correct lighting. LED lights are extremely bright and effective, yet relatively easy to install and cheap to maintain. This seemingly insignificant addition to your forklift fleet can really make a huge difference.

What forklift safety lights are required by OSHA? Just headlights and taillights? What about blue spotlights or red zone LED lights? Unfortunately, there isn't a simple answer. 

OSHA's powered industrial truck standard (§.178) only requires two types of forklift lights:

• Brake/tail lights (if your forklift came equipped with them) 
• Headlights, but only if the light in the work environment is less than 2 lumens per square foot.

The powered industrial truck standard doesn’t mention blue, red, or flashing lights; BUT, they may be required under OSHA’s General Duty Clause.

Keeping track of all the rules and regulations may seem like a hassle, but it pays to stay informed. As of January , the minimum OSHA fine is $975 per violation. Here’s what operations managers and business owners need to know:

If you want to learn more, please visit our website Forklift Arc Light Manufacturer.

Forklift Safety Lights and OSHA Compliance

Here's a round-up of the forklift lights OSHA requires:

Forklift Headlights: OSHA regulation .178(h)(2) states: when general lighting is less than 2 lumens per square foot, auxiliary light shall be provided on the truck.

Basically, any operation that uses forklifts outdoors or at night should have headlights, and indoor operations with heavy pedestrian or vehicle traffic should strongly consider adding them. Here's why:

• Headlights illuminate work areas and help forklift operators be more productive - operators who are 60+ need 3x as much light to see the same thing as a 20-year-old
• Forklift lights enhance safety by making the truck more noticeable to pedestrians - one in five (20 percent) of forklift incidents involve pedestrians.

Forklift Tail/Brake Lights: Most forklifts come with brake/tail lights. If you have a forklift that came from the factory without brake/tail lights, OSHA does not require you to pay for a retrofit. However, if the forklift operates in an area with a lot of pedestrian or vehicle traffic, you'll want to ensure your forklift has all the bells and whistles...and lights.

OSHA's standard states: where appropriate to the worksite, equip trucks with additional sound-producing or visual (such as lights or blinkers) devices.

Does OSHA Require Blue, Red or Flashing Forklift Safety Lights?

As mentioned above, blue spotlights, red side lights and flashing strobe lights are not required by OSHA’s powered industrial truck standard (§.178); however, OSHA’s website states: 

While §.178 standard does not specifically require flashing lights or back-up beepers, employers have a duty under the OSH Act, 29 U.S.C. § 654 (a)(1), also known as the General Duty Clause, to furnish employment and a place of employment free from recognized hazards that are causing or a likely to cause death or serious physical harm to employees, where employees are exposed to hazards, including but not limited to, struck by, caught-in-between and crushing by the forklift. B56.1- shows that industry recognizes this hazard and that equipping trucks with sound-producing and visual devices are feasible means to abate this hazard. An employer whose workplace presents this hazard and has not taken feasible steps to mitigate this hazard may be in violation of the General Duty Clause.

As of , the minimum OSHA fine is $975 per violation. Safety lights not only make your workplace safer, they are also cheap “insurance” against expensive fines. 

Forklift Safety Lights Demonstrate a Commitment to Safety

How often do you see someone walking through your workplace looking at their smartphone or wearing earbuds — oblivious to what’s going on around them? Probably way too often. 

You’ve sent emails and put up safety signs, but pedestrians fail to maintain a safe distance. That’s why safety and cost-conscious managers use red and blue LED safety lights to prevent collisions between pedestrians and forklifts.

A Red Zone Forklift Safety Light Establishes a No-Go Zone

Red zone safety lights project a red “no-go” area around the forklift. The illuminated area clearly shows the danger zone for pedestrians, whether the forklift is stopped or in motion. You don’t have to worry about pedestrians underestimating how much space they need to put between themselves and the lift truck. All they have to remember is: stay out of the red zone.

An LED Blue Spotlight Alerts Pedestrians to Oncoming Traffic

In a noisy environment or workplace with blind corners, a bright blue spotlight is one of the easiest and most effective ways to prevent forklift-pedestrian collisions. A blue LED spotlight (typically mounted on the overhead guard) projects a bright blue light 10-20 feet in front of the forklift. The light precedes the forklift into intersections, warning pedestrians of an oncoming lift truck.

Installing safety lights on your forklift costs a whole lot less than an OSHA violation, so it really pays to add both blue and red lights to your forklift. 

Forklift Strobe Lights - Appropriate for Certain Applications

Strobe lights are an excellent attention-getter; however, they should not be used in applications where employees wear auto-darkening welding helmets (or similar equipment). Strobe light placement is also important. You never want strobe lights placed at eye-level because bright, flashing LED lights can severely impair someone’s vision.

Don’t Forget: Add Forklift Lights to Operators’ Pre-Inspection Checklist
When safety lights are installed on a forklift, operators must confirm the lights are working properly at the start of each shift. Don't forget to add “inspect safety lights” to your forklift pre-shift inspection checklist and train operators how to inspect and use the lights.

Commit to a Safer, More Profitable Fleet

If your operation is located in Georgia or Florida, we can help you find the best OSHA-compliant forklift safety lights for your business needs. We sell:

• Blue LED spotlights in different sizes and lumens 
• LED “bullet” lights - a good alternative if you don’t have room for a conventional light
• Lights with plastic lenses (for food-processing environments) 
• Forklift strobe lights in different sizes and colors

We can design a custom solution for your needs and budget. For example, some operations want their forklift lights wired up so the lights only operate when the forklift is in motion. No problem, one of our expert forklift technicians can wire it up for you. 

Our goal is to help local businesses be as productive and safe as possible. That’s why we offer free facility audits. Ensure your operation is OSHA-compliant and as safe as possible. Contact a forklift safety expert online, by at (800) 226-, or in person at one of our nine locations.

FLORIDA
Jacksonville
Ocala
Orlando
Tampa
Winter Park

GEORGIA
Albany
Macon
Midland
Valdosta

For more LED Off-Road Light Manufacturerinformation, please contact us. We will provide professional answers.