Training equipment operators to understand forklift load capacity is vital for workplace safety. Every product is different in shape and size, so operators have to make in-the-moment decisions about how to load, lift and move products safely.
By understanding the basic principles of load capacity, operators can handle each situation safely. Training can reduce accidents and protect equipment from damage. Here’s an overview of everything you need to know about forklift load capacity.
How Much Weight Can a Forklift Lift?
High-capacity forklifts can manage loads weighing upwards of 100,000 pounds. For standard forklifts, it all depends on the forklift’s design, weight and what it was built to do. Every forklift comes marked with a weight range it can safely lift and carry.
However, the maximum weight you can move with a forklift also depends on other factors, like the size and shape of what is being moved, how it’s stacked on the forklift and what the terrain is like.
What Is Forklift Weight Capacity?
Forklift load capacity refers to how much weight a forklift can safely carry. Every forklift has a different weight capacity, so it’s essential that operators know how to find this information for safe equipment operation. A forklift’s rated capacity will be listed on its data plate.
However, this is only a recommended number and a forklift’s actual weight capacity can change based on several different factors. To ensure operator safety, it’s good practice to use a forklift with a slightly higher weight capacity than what you need.
What Affects Weight Capacity
In contrast to the listed rated capacity, net capacity describes how much weight a forklift can safely carry in any real situation. This number depends on factors like:
- Forklift dimensions
- Mast height
- Attachment weight
- Age of machinery
- Length of load
In any real-world situation, there are many physical forces exerting pressure in different directions. When these variables change, the rules for operating a forklift safely can change too.
For example, consider a scenario where a forklift is carrying a square box across a warehouse floor. If the forklift carries the box close to the ground, the equipment’s balance will be different than if the operator moved with the box lifted at a height of five feet.
Unless you add a heavy attachment, a forklift’s weight, height and length won’t change. Those variables will be constant and can be counted on to react the same way each time the machine is used. However, the size, shape and weight of products being moved can vary considerably.
With each change, operators must ensure their forklift is equipped to properly balance its new weight load. There is a lot of math that goes into calculating net weight capacity for each situation. However, some general principles can help operators move varying loads safely.
Parts of a Forklift
The best way to understand weight capacity is to discuss how forklifts are designed to balance weight. There are three parts of a forklift that work together to maintain balance:
- Counterweight: A heavy weight is built into the rear side of a forklift, to help balance the heavy products that operators pick up with this machinery.
- Fulcrum: If you think about a seesaw, a fulcrum is the point in the middle that balances both sides. The front axle of a forklift is where the majority of this pressure goes.
- Fork: At the front end of a forklift, the fork or other attachment is used to load and lift heavy products.
Because each load is a different weight, a forklift’s center of gravity shifts with every load. To stay within a safe range, forklift operators should learn about the stability triangle. This triangle is actually a pyramid, and it gives a visual for how operators can stay within a safe range of lifted weight.
The stability triangle has a point at each front wheel, since that’s where a forklift balances its weight. The third point of the triangle points back to the middle of a forklift’s back axle, right between the back wheels. If a forklift’s center of gravity stays within this triangle, the forklift can maintain balance and won’t tip over during use.
You can turn this triangle into a pyramid to understand how lifting products can impact weight and balance. Wherever the forklift’s center of gravity is, take that point up to make the top tip of the pyramid. If the top overextends beyond the triangle’s base, the forklift won’t be able to stay balanced and may tip over.
What Are the Risks of Capacity Issues?
Think about the last time you picked up a heavy box. You likely stacked the heaviest part close to your chest, leaning backwards to better balance the weight. If the box was long, you probably stacked it up high so the weight wouldn’t tip you forward.
A forklift works in a very similar way. It’s important to put weight near its center of gravity so that it stays balanced. When forklift weight capacity isn’t observed, a number of issues can occur, such as:
- Tip overs
- Equipment damage
- Operator injuries
To avoid these risks, it’s essential to train your operators to follow all safety guidelines for forklift operation. Staying within the equipment’s net weight capacity and working within the stability triangle can save lives.
OSHA Safety Requirements for Forklifts
OSHA requires all operators to be trained and certified in forklift use before operating this equipment to prevent accidents. If a business doesn’t follow OSHA safety guidelines for heavy machinery, it can be fined a significant amount.
In a study from 2018, OSHA estimated that around 97,000 injuries occur from forklift use each year. While not all of these accidents cause serious injuries, the numbers are much too high. Training can help prevent injury, protect your workers and improve your business’s reputation.
Find Forklifts at Burns Industrial Equipment
Burns Industrial Equipment has been supporting customers with top-quality equipment for over 50 years. We operate throughout Pennsylvania, Ohio and West Virginia, helping businesses to connect with the machinery and parts they need.
We also offer forklift repair, fleet management, operator training and warehouse solutions. If you’re looking for a forklift that’s durable, energy efficient and equipped with built-in safety features, look no further than Burns Industrial Equipment.
Our talented team can help you find the best forklift or other equipment solution for your needs. Reach out to us today or explore our inventory online to learn more!
