[Hallb-engineering] Fwd: Lesson Learned "Forklift Load Transfer Considerations - URS | CH2M Oak Ridge LLC"

[Douglas Tilles]

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Sent: Wednesday, June 11, 2014 11:00:44 AM
Subject: Lesson Learned "Forklift Load Transfer Considerations - URS | CH2M Oak Ridge LLC"






	Forklift Load Transfer Considerations - URS | CH2M Oak Ridge LLC 	
Statement of Lessons Learned 
For a copy of the original report, see Attachments on Lessons Learned page. 

Damage can occur to a forklift when it is overloaded.  Overloading can result not only from actual stagnant weight, but also a change in the floor level can cause a load�s center of gravity to shift toward the end of the forklift tines.  Evidence of this is when the rear of the forklift floats off the floor. Discussion of Activities 
On April 23, 2014 a concrete monolith was being relocated into a facility for processing.  The original forklift selected to move the load was too wide to fit through a doorway.  An alternative method was devised, which included a manual steer rigger / roller skate and a smaller forklift.  The skate had a high enough capacity to handle the entire weight of the monolith while the forklift had more than sufficient capacity to carry half the load.  Cribbing was used to provide an approximate 2-foot gap to separate the tines of the forklift from the monolith edge (see Attachment - Figure 1).

The smaller forklift pushed the monolith up the ramp.  The skate was guided by a worker on the uphill side.   When the skate reached the top of the ramp the transition, from slope to level, caused the load to pivot in relation to the forklift tines (see Attachment - Figure 2). This resulted in a transfer of weight from the skate to the forklift and a shift in the center of gravity toward the end of the forklift tines causing the rear of the forklift to float a few inches off the ground. Analysis 
Forklift operators are trained to calculate loads to ensure they do not exceed capacity.  Loads, which are too heavy for one piece of equipment, may be spread to other devices to support a load, as long as it is within the capacity limitations of the machine(s).  In this instance the grade change was not taken into consideration and led to the transfer of most, if not all, of the load�s weight to a forklift whose capacity was not adequate. Recommended Actions 
Below are the consequences of the above event.  They are provided for information and discussion purposes only. 

Since the forklift lifted off the grade, it is considered to be an overload condition. 
�	The forklift was taken out of service and checked for damage by a qualified person. 
�	The operator received refresher training. 
�	This lessons learned was generated to communicate the need to consider grade changes when using more than one piece of equipment to move a load. 
Comments 
6/11/2014 10:49:10 AM by Bailey, Mary Jo 
submitted to those current in training:
�SAF502: FORKLIFT OPERATOR
�SAF502B: FORKLIFT ATTACHMENTS 	
Summary 	Lesson ID: 	827 
	Status: 	OK 
	Doc ID: 	2014-JLAB-827 
	Priority: 	Info 
	Safety Related: 	YES 
	Originator: 	Bailey, Mary Jo 
	Issued: 	6/11/2014 10:46:41 AM 
	Approved By: 	Bailey, Mary Jo 
	Approved On: 	6/11/2014 10:49:11 AM 
	Source: 	DOECRD 
	Location: 	ORNL 
	Cost Savings: 	
	Contact: 	Wayne Sproles, D&D Project Manager URS | CH2M Oak Ridge LLC, via Telena Moore, 865-241-5795 
	Queued Emails: 	0 
	Sent Emails: 	0 
	Viewings: 	1 times Attachments 

    * M:\wcd\LessonsLearned\DOEOEC\DOE Lessons Learned - Material Handling9.pdf 
    * M:\wcd\LessonsLearned\DOEOEC\DOE Lessons Learned - Material Handling9 pics.pdf 
Hazard Issues 

    * Material Handling Equipment 
    * Powered Industrial Trucks 
Skills 

    * SAF502: FORKLIFT OPERATOR 
    * SAF502B: FORKLIFT ATTACHMENTS 
Distribution/Notification 

    * *Division Safety Officers (DSOs) 
    * *Safety Wardens 
    * *DOE Notification 
    * *ESH&Q Liaisons