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Forklift Safety: Load Management – Lifting, Carrying, and Stacking Safely

Proper load management is one of the most critical aspects of forklift operation. Mishandling materials can lead to serious injuries, product damage, and costly downtime. Ensuring that loads are lifted, carried, and stacked safely helps maintain a secure and productive facility.

Today, we’ll cover key techniques for managing loads the right way.

Here are a few tips to assist you with safe load handling:

• Center the Load Properly – Keep the load centered and stable on the forks to prevent tipping. If the load is uneven, place the heavier side closer to the forklift’s backrest to maintain balance. Adjust the fork width as needed to distribute weight evenly.
• Secure Awkward or Oversized Items – If a load is bulky or irregularly shaped, use straps, shrink wrap, or pallets to keep it stable. Never carry loose or unbalanced loads, as shifting weight can cause the forklift to become unstable.
• Follow Height Restrictions – Stack loads within recommended height limits to prevent tipping hazards. Never exceed the forklift’s rated capacity; ensure visibility remains clear while transporting materials. When stacking, align loads evenly and place heavier items at the bottom for stability.
• Keep Loads Low While Moving – Carry loads as close to the ground as possible, usually within 4 to 6 inches. This lowers the center of gravity and reduces the risk of tipping. Keep the load uphill to maintain control if traveling up or down an incline.
• Lower Loads Smoothly and Safely – When setting a load down, do so gradually to avoid sudden weight shifts. Ensure the area is clear and the load is securely placed on a stable surface. Never adjust a load while the forklift is in motion.

Effective load management improves efficiency and prevents dangerous situations. Operators should always inspect their loads before transport and know weight limits and stability concerns. Safe handling techniques protect workers, reduce damage, and keep operations running smoothly.

Thank you for being part of another episode of Warehouse Safety Tips.

Until we meet next time – have a great week, and STAY SAFE!

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