Powered industrial truck training

Every employee who operates a powered industrial truck must be trained and evaluated before being allowed to operate one unsupervised. See 1915.120 (shipyard rule identical to 1910.178(l)).

• Employers must ensure operators are competent through training and evaluation before independent operation. 1910.178(l).

PIT operator training must cover both general and truck-specific topics such as controls, safe operating practices, load capacities, stability, refueling/battery charging, inspection procedures, and workplace hazards. This includes classroom instruction, practical training, and evaluation of performance. See 1910.178(l).

• Training must include vehicle-related topics (e.g., controls, instruments, capacity) and workplace-related topics (e.g., surface conditions, pedestrian traffic, hazardous locations).
• Practical demonstration of skills on the actual truck type(s) used is required per 1910.178(l).

Yes — hands-on (practical) training on the specific truck type and attachment is required along with formal instruction and evaluation. See 1910.178(l).

• Practical training should allow the trainee to demonstrate safe operation under typical workplace conditions before evaluation.

An employer may use a qualified person from inside or outside the company to provide training and conduct evaluations, but that person must be competent to train and evaluate operators. See 1910.178(l).

• The standard does not require a specific certification for trainers, but trainers/evaluators must demonstrate they are capable of teaching and assessing PIT skills and knowledge.

Refresher training and/or re-evaluation must be provided whenever an operator is observed operating unsafely, is involved in an accident or near-miss, when there are changes in the workplace that affect safe operation, or when the operator is assigned a different type of truck. Additionally, operators must be evaluated at least once every three years. See 1910.178(l).

• These triggers are mandatory to ensure ongoing competence and safety.

Employers must evaluate each PIT operator at least once every three years. See 1910.178(l).

• More frequent evaluations are required if unsafe operation, accidents, or workplace changes occur.

The employer must certify that each operator has been trained and evaluated; records should identify the operator, the dates of training and evaluation, and the identity of the person(s) who conducted the training/evaluation. See 1910.178(l).

• Maintain documentation that shows compliance with training and evaluation requirements.

Yes — training must be specific to the make and model of the truck and any attachments the operator will use, because operating characteristics and hazards can differ. See 1910.178(l).

• If an operator moves to a different truck type or uses a new attachment, additional training and evaluation are required.

Yes — employers must not permit an employee to operate a powered industrial truck unless that employee has been trained and evaluated and found competent to operate it safely. See 1910.178(l).

• Employers are responsible for ensuring only authorized and trained operators use PITs.

Yes — employer-provided training must include workplace-related topics such as surface conditions, ramps, load stability, traffic patterns, and pedestrian interactions to ensure safe operation in the actual work environment. See 1910.178(l).

• Training must prepare operators to recognize and respond to workplace-specific hazards.

Yes — instruction on refueling, battery charging, handling of fuels, and the hazards related to these activities is required as part of PIT operator training. See 1910.178(l).

• Practical procedures for safe refueling and battery maintenance should be taught and demonstrated.

While the standard focuses on operator training, employers must ensure overall workplace safety, which includes informing affected employees about PIT hazards in their work areas and procedures to avoid them. See 1910.178(l) and general employer duty under 1910.

• Practical steps include marking travel aisles, posting signs, and training non-operators to stay clear of operating PITs.

Employers must re-evaluate and provide retraining to the operator after an accident or near-miss before allowing unsupervised operation again. See 1910.178(l).

• Investigate the incident to identify training or procedural gaps and document any additional training provided.

Yes — retraining and possible re-evaluation are required when workplace changes affect safe operation, such as modifications to traffic patterns, floor surfaces, or storage configurations. See 1910.178(l).

• Employers should assess whether the change creates new hazards that warrant additional training.

No — classroom or simulated instruction alone is not sufficient; practical, hands-on training on the actual truck type(s) and workplace conditions is required in addition to formal instruction. See 1910.178(l).

• A combination of formal classroom, practical training, and an evaluation is the OSHA-required approach.

No — employers must not permit unsupervised operation until training and evaluation are complete; however, supervised hands-on training may occur under direct supervision of a qualified trainer as part of the training program. See 1910.178(l).

• Supervised practice is part of training, but independent operation requires successful evaluation and certification.

Employers should keep certification records that identify the operator, the dates of training and evaluation, and the identity of the trainer/evaluator; these records demonstrate compliance. See 1910.178(l).

• Records should be retained in accordance with the employer's recordkeeping practices and be available for inspection if needed.

Yes — training must teach operators how to determine load capacities, the effect of load center and attachments on stability, and safe loading/unloading practices. See 1910.178(l).

• Practical exercises should include handling loads near rated capacity and recognizing unstable conditions.

Employers must provide initial training, conduct regular evaluations (at least every three years), retrain after incidents or workplace changes, and maintain training records to ensure ongoing operator competence. See 1910.178(l).

• Employers should monitor operator performance and provide refresher training whenever needed to maintain safe operation.