Forklift Carbon Monoxide Poisoning: Symptoms and Prevention

Yesterday’s Advisor initiated a discussion of the dangers posed by the exhaust gases of gasoline, propane, or LPG-powered forklifts. The key danger is carbon monoxide (CO), a colorless, tasteless, odorless gas that takes over the body’s oxygen supply, in effect, suffocating your body’s systems. Even at low levels, exposure can quickly be fatal.

All fuel-powered forklifts emit this gas, as do any similarly powered devices such as generators, compressors, and some power tools. There are, however, ways to minimize the danger.  These include:

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Don’t just tell forklift operators what to do. Show them with action footage on DVD in BLR’s Training Solutions Toolkit: Forklift Safety.  Read more.

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▪ Avoid operating in enclosed or partially enclosed spaces.
▪ If the devices must be operated in enclosed areas, provide adequate forced ventilation (just windows and doors open are not enough.)
▪ Keep the motors in tune. Well-maintained engines emit a fraction of the noxious gases that those out of adjustment do. They also use fuel more efficiently. One expert recommends a tune up every 250 hours of operation.
▪ Add aftermarket pollution control systems, such as catalytic converters. These are often a direct fit on popular brands of trucks.
▪ Replace older model forklifts with newer ones, which are far more efficient, even in stock condition.
▪ Use electric-powered material movers indoors.

Also recommended: Placing CO detectors with audible alarms anywhere fuel-burning devices are operated, especially indoors. Personal detectors, also with alarms, are available for workers not in a fixed location.

Train on the Symptoms

Equally important, say the experts, is training your workforce on the signs of CO poisoning, and on what to do should it occur.  Proper diagnosis and speedy treatment is essential, as damage to the body’s vital organs increases as the exposure is prolonged. Here, from public health authorities in Massachusetts and Washington State, is a list of what to watch out for:

▪ Headache
▪ Nausea
▪ Dizziness
▪ Visual Disturbances
▪ Rapid breathing
▪ Fatigue
▪ Tightness across the chest
▪ Shortness of breath
▪ Muscle weakness
▪ Loss of consciousness

One difficulty in diagnosing CO poisoning is that many of these symptoms are similar to common sicknesses, such as the flu (without the fever, of course). But if there are engine-powered devices around, CO should always be among the first suspects.

Treatment includes the following:

▪ Get the victim outdoors to fresh air in an open area immediately!
▪ Call 911 or your company’s designated emergency number and get medical aid as soon as possible.
▪ If the victim is unconscious, administer CPR.
▪ If you are a rescuer, you also are in danger in an exposure area. Get out as soon as possible.

Meeting OSHA’s Forklift Training Standard

Training in the dangers forklifts pose is, of course, just part of the complete forklift training program OSHA demands that you provide to anyone who operates the machines. Equally important are instruction in proper driving, loading and unloading, parking, and maintenance.

To this end, we’d like to recommend BLR’s Training Solutions Toolkit: Forklift Safety. It uses the best technique known to show how to properly operate a moving vehicle: broadcast quality video in the convenient DVD format.

In fact, Forklift Safety is really a 20-minute mini-motion picture, complete with professional actors and a realistic script. It trains on every key aspect of forklift operation and is specifically designed to meet OSHA’s forklift training standard. The kit also includes these supplementary materials:

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BLR’s Training Solutions Toolkit: Forklift Safety on DVD comes to you satisfaction assured! Click for details.

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▪ 15 copies of an employee workbook, and accompanying leader’s guide. Additional copies may be ordered at special low prices.
▪ 3 posters. Hang them around your facility as a constant reminder of the training.  (And note the pleased expression on any OSHA inspector who happens to see them.)
▪ Trainer’s log. Creates a permanent record of whom you trained and when—another must-have if your facility is inspected.
▪ Customizable completion certificate. Just add each trainee’s name and other company specifics and print out.
▪ A complete bonus PowerPoint® forklift training program. This 30-slide PowerPoint, with accompanying slide show notes and takeaway booklets, allows you an alternative way to train, and lets you customize your training with specific company policies and situations, and add your comments as you present the material.

Training Solutions Toolkit: Forklift Safety is available with satisfaction completely assured or you get a full refund. Click here for more information or to order.