TL;DR
This forklift safety toolbox talk focuses on the people on foot, not just the driver: use marked walkways, get eye contact before crossing, and never walk under a raised load. Drivers slow down and sound the horn at blind spots, and everyone reports near misses.
Use this forklift safety toolbox talk with everyone who works where lift trucks run: pickers, packers, maintenance staff, visiting drivers and office staff who cut through the warehouse. Drivers should be there too, because the talk works best when both sides hear the same rules. By the end, the crew should know where to walk, how to cross safely and what to do after a close call.
Why does forklift and pedestrian safety matter?
A forklift is heavy, quiet and often reversing, and the driver's view is blocked by the mast and the load. OSHA lists being struck by a lift truck as one of the main ways workers get hurt, and notes that retail sites face extra challenges with pedestrian safety.
In the UK, HSE says lift trucks are involved in about a quarter of all workplace transport accidents, often due to poor supervision and a lack of training.
The US rule for powered industrial trucks, OSHA 1910.178, sets several pedestrian protections. No one may stand or pass under a raised load. Drivers must slow down and sound the horn at cross aisles and other blind spots, and travel with the load trailing if it blocks their forward view. Check the rules where you work.
Talking points for your forklift safety toolbox talk
- Stay in the marked walkway. Walkways and crossing points exist because drivers expect people there. Cutting between racks or across a loading area puts you where nobody is looking.
- Make eye contact before you cross. A driver who hasn't seen you can't stop for you. Wait for a nod or a hand signal, and if you can't see the driver's eyes, assume they can't see you.
- Never walk under a raised load. Loads can slip and forks can drop. Walk around, even if it takes longer.
- Drivers: horn and slow down at blind spots. Aisle ends, doorways and racking corners are where most surprises happen. Sound the horn every time, not just when you think someone is there.
- Watch for reversing trucks. Many loads are carried trailing, so the truck may come towards you backwards. Listen for alarms and look for warning lights, but don't rely on them alone.
- Keep earbuds out and phones away in traffic areas. You need your eyes and ears to judge where trucks are going.
- Report every near miss. A close call is free information. CCOHS recommends traffic management plans that are reviewed regularly, and near-miss reports are how those reviews find the weak spots.
Example to share with the crew
Picture this: a picker is walking back from break, reading a message on their phone, and steps out from the end of an aisle. A forklift is reversing towards the same junction with a tall load. The driver brakes hard and the load shifts, but nobody is hurt.
Both people walk away and neither says anything. Next week the same junction catches someone else. Ask the crew: what would have changed if one of them had reported it?
Forklift and pedestrian safety checklist
- Pedestrian walkways and crossing points clearly marked and unobstructed
- Barriers or bollards in place where walkways run next to truck routes
- Mirrors or warning lights at blind corners and doorways working
- Drivers trained and authorized for the truck they are using
- Drivers sounding the horn and slowing at intersections
- No one standing or walking under raised forks or loads
- Visitors briefed on site traffic rules and walkways
- Near misses between trucks and people being reported and reviewed
Questions to ask the crew
- Where on site do people and forklifts come closest?
- Is there a shortcut people use that isn't a marked walkway? Why?
- When did you last see a near miss, and was it reported?
How to close the talk
Close this forklift safety toolbox talk with one message: if you can't see the driver's eyes, don't cross. Report every near miss to your supervisor or through the site reporting system, even if nobody was hurt. For the operator side, run the pre-use vehicle checks talk next, or browse more safety topics for toolbox talks. The warehouse ergonomics guide covers the other big warehouse risk: manual handling.
Toolbox talk sign-in sheet
Print this page to get the talk and a blank attendance sheet on paper.
- Date
- Location / crew
- Presenter
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Frequently asked questions
What should a forklift safety toolbox talk cover for pedestrians?
Marked walkways and crossing points, making eye contact with the driver, staying clear of raised forks and loads, blind spots at aisle ends and doorways, and how to report a near miss.
Do forklifts have right of way over pedestrians?
It depends on your site's traffic rules, so check them. CCOHS recommends setting clear right-of-way rules at intersections and training both drivers and pedestrians on them.
Is it ever OK to walk under raised forks?
No. OSHA 1910.178 says no person may stand or pass under the elevated portion of any truck, whether it is loaded or empty.
Who is allowed to drive a forklift?
Only trained and authorized operators. In the US, OSHA says it is a violation of federal law for anyone under 18 to operate a forklift.
Sources
This toolbox talk is general safety information. Adapt it to your site's procedures and follow the regulations that apply where you work.