Forklift Training, Certification, and Safety Program Requirements

Forklifts and other powered industrial trucks (PITs) are widely used in many industries, but common use does not equal low risk. These machines can weigh several tons and move at surprising speeds, making even a small mistake potentially life-threatening. That’s why OSHA requires comprehensive training, certification, and regular evaluation of all forklift operators. In addition to these requirements, employers should also maintain a comprehensive PIT safety program to help prevent injuries and keep workers safe.

What OSHA Requires

According to OSHA’s standard 29 CFR 1910.178, no employee is allowed to operate a forklift without first receiving proper training and certification. The training must include both formal instruction and hands-on practical training with the specific type of equipment the operator will use. After completing both parts, the operator’s performance must be evaluated in the actual workplace environment.

However, this training isn’t a one-size-fits-all approach. OSHA makes it clear that training must be tailored to the specific type of forklift being used and the conditions of the workplace itself. For example, driving a forklift on a smooth warehouse floor is very different from navigating uneven outdoor terrain or maneuvering in tight aisles around pedestrian traffic. Certification must be documented and include the operator’s name, the dates of their training and evaluation, and the names of the trainers and evaluators involved.

When to Retrain

Even well-trained operators can become complacent, or circumstances may change. That’s why OSHA requires retraining whenever an operator is observed using a forklift unsafely, if there’s an accident or near-miss, or when the operator is assigned to a different type of powered industrial truck. Retraining is also necessary when conditions in the workplace change in ways that could affect how a forklift is operated, such as new layouts, equipment, or work surfaces.

Even if none of these changes occur, every operator must be evaluated at least once every three years to ensure they still meet the required level of competency.

Creating a Safety Culture Around PITs

Forklift safety doesn’t stop after initial training. In fact, training should be treated as the foundation of a broader PIT safety system. OSHA’s powered industrial truck standard requires employers to establish and maintain a written program that includes not just training but also written policies and procedures outlining the safe operation of PITs in the workplace.

The written program should clearly define:

• Who is authorized to operate forklifts
• The types of equipment in use
• Inspection and maintenance procedures
• How hazards are identified and corrected
• How operators are trained and evaluated
• What steps are taken when unsafe conditions or behaviors are observed

New hires must receive forklift-related safety orientation specific to their environment, and that training should be documented. Supervisors should reinforce safe practices through regular oversight, coaching, and follow-up evaluations; not just at the three-year mark, but anytime unsafe behavior is observed or conditions change.

Visible signage, mirror placements, and floor markings are also important elements of a PIT safety program. These tools help separate forklift traffic from pedestrian walkways and reduce the likelihood of collisions. Operators should be encouraged to report unsafe conditions or equipment concerns without fear of retaliation. A strong safety culture supports proactive communication, where everyone plays a role in preventing accidents before they happen.

Safety Best Practices

Remember, OSHA requirements are the minimum. Employers are always encouraged to take safety a step further and implement proactive measures that go beyond basic compliance. Placing mirrors at blind intersections, setting speed limits in congested areas, and using floor markings are all proven ways to reduce risk.

Above all, forklifts must only be operated by employees who are properly trained and certified in accordance with OSHA standards.

Forklifts might be familiar tools, but that familiarity can quickly turn into complacency. A strong training program combined with daily oversight and a culture that values safety is the best way to ensure that these powerful machines are used responsibly.

If your facility needs help developing a forklift safety program, updating written procedures, conducting operator evaluations, or training personnel, contact Walden at 860-846-4069 for expert support from our EHS specialists. If you are interested in reading more about forklift safety, visit Walden’s recent blogs about attachment and extension requirements and inspections and maintenance.