Site Control: Impact on Forklift Operation Safety and Control Requirements
Site control serves as a critical external constraint and fundamental guarantee for the safe operation of forklifts. It directly defines the risk boundaries of the working environment, with its impacts spanning the entire process of static layout and dynamic operations, and ultimately contributing to the control of vehicle stability, personnel protection, and the probability of accidents such as collisions and falls. Below is a structured and quantifiable impact analysis along with corresponding control requirements.
I. Core Impact Dimensions and Risk Consequences
(1) Ground Conditions: Directly Affect Forklift Stability and Braking Performance
Ground Parameters | Compliance Standards | Impacts of Substandard Conditions | Typical Accidents |
| Flatness | No potholes, no protrusions, and smooth joints | Uneven wheel load distribution leading to center-of-gravity shift; driving jolts causing goods to shake or fall; steering jamming | Rollover, goods falling, steering loss of control |
| Slope | ≤ 5% for operating areas; anti-slip treatment required for ramps | Slopes exceeding 5% increase risks of vehicle slipping and sideslip during steering; heavy-load downhill travel imposes excessive braking load, resulting in overheating and failure | Vehicle slipping, rollover, brake failure |
Surface Condition | No oil stains, water accumulation, or ice/snow; dry and clean | Reduced friction coefficient leading to longer braking distances; doubled risk of sideslip during steering | Sideslip, collision, personnel crushing |
Ground Strength | Concrete grade ≥ C30 for heavy-load areas; no cracks | Ground collapse or settlement causing forklift tilting; uneven tire wear leading to decreased stability | Rollover, vehicle trapping |
(2) Aisle and Space Planning: Controlling Collision and Steering Risks in Dynamic Operations
Aisle Width
- Compliance Requirement: Aisle width = minimum turning radius of forklift + 0.5–1m safety margin (for narrow-aisle models, follow the manufacturer’s recommended values).
- Impact: Excessively narrow aisles force forklifts to make sharp turns and reverse frequently, increasing the risk of rollover and collision with shelves/pedestrians; overly wide aisles tend to cause speeding and reduce operational efficiency.
Pedestrian-Vehicle Separation
- Compliance Requirement: Prioritize physical isolation (guardrails, marking lines), and set up dedicated pedestrian aisles, as well as speed bumps/warning lights at intersections.
- Impact: Lack of isolation easily leads to mixed pedestrian-vehicle traffic; the risk of blind-spot collisions at intersections is extremely high, which is the primary cause of forklift-related injuries to personnel.
Turning and Intersection Areas
- Compliance Requirement: Turning radius must meet the model specifications; install convex mirrors, speed reduction signs, and audible-visual alarms at intersections.
- Impact: Insufficient turning radius causes over-steering of forklifts and increases rollover risk; lack of warnings at intersections easily leads to collisions.
(3) Signage and Lighting: Eliminating Visual Blind Spots and Standardizing Operational Behaviors
Signage and Marking Lines
- Mandatory Signs: Speed limit signs (generally 5km/h, ≤ 3km/h for turning/ramps), turning warning signs, ramp signs, no-parking zone signs, load limit signs, and pedestrian priority signs.
- Impact: Absence of signs easily results in speeding, illegal parking, and improper ramp operation, increasing accident probability; unclear marking lines lead to aisle confusion and pedestrian-vehicle conflicts.
Lighting Conditions
- Compliance Requirement: Illuminance ≥ 100 lux in operating areas; illuminance ≥ 150 lux in key areas such as shelf zones, intersections, and ramps.
- Impact: Insufficient lighting leads to misjudgment of goods weight/position, blind-spot collisions, and improper ramp operation, significantly increasing risks during nighttime operations.
(4) Environment and Obstacle Control: Reducing Sudden Risks
Weather Impact
- Rain/Snow, High Temperature, Low Temperature: During outdoor operations, rain and snow cause slippery ground; low temperatures affect hydraulic system and tire performance; high temperatures easily lead to battery overheating.
- Impact of Inadequate Control: Increased risks of sideslip, equipment failure, and battery fire.
Obstacle Management
- Compliance Requirement: No debris in aisles; shelves and equipment must be firmly fixed; no temporary stacked items allowed.
- Impact: Obstacles force forklifts to detour and brake suddenly, increasing collision and rollover risks; unstable shelves may collapse, triggering chain accidents.
II. Interactive Impacts of Site Control on the Safety System
- Implementation Effect of Operational SpecificationsSound site control (e.g., clear marking lines, adequate aisle space, stable ground) can reduce the probability of operators violating safety regulations. Conversely, unreasonable site design (e.g., narrow aisles, steep slopes) will force operators to cross the boundaries of safe operation.
- Equipment Maintenance Cost and Service LifeFlat and clean ground can reduce wear on tires, suspension, and steering systems, lowering maintenance frequency. On the contrary, harsh ground conditions will accelerate equipment aging, increase failure risks, and indirectly affect operational safety.
- Personnel Safety AwarenessClear signage, physical isolation, and sufficient lighting can strengthen operators’ safety awareness and foster a safety-first working atmosphere. Conversely, a chaotic site environment will cause operators to lower their vigilance and increase accident probability.
III. Implementable Site Control Optimization Measures
Control Dimension | Optimization Measures | Implementation Standards |
| Ground | Harden the ground of heavy-load areas (C30+); regularly repair potholes; promptly clean up oil stains, water accumulation, ice, and snow | Slope ≤ 5%; no obvious protrusions or depressions |
| Aisles | Design aisle width based on the turning radius of forklift models; implement physical pedestrian-vehicle isolation; install convex mirrors at intersections | Aisle width = turning radius + 0.5m; isolation guardrail height ≥ 1.2m |
Signage & Lighting | Install speed limit, turning, ramp, and no-parking signs; ensure illuminance ≥ 100 lux in operating areas and ≥ 150 lux in key areas | Clear signage; no lighting blind spots |
Environment & Obstacles | Promptly clear ground during rainy/snowy days; strictly prohibit stacking debris in aisles; regularly inspect the fixing status of shelves | No water accumulation or ice/ snow on the ground; no debris in aisles |
