Powered industrial trucks, commonly known as forklifts, are used in a wide range of industries. From manufacturing plants to warehouses to construction sites, forklifts are critical pieces of workplace equipment used to raise, lower, and move materials. Because they are so common, many employers want to understand exactly what OSHA requires and how to provide compliant, effective training for their operators.
Forklift operator training is not only essential for a safe working environment, it is required under OSHA's powered industrial truck standard, 29 CFR 1910.178(l). Forklifts are an exceptional tool for efficiency, but they can also be dangerous, damaging, or even deadly. According to the U.S. Bureau of Labor Statistics, 614 workers lost their lives in forklift-related incidents from 2011 to 2017, and more than 7,000 nonfatal forklift injuries each year required time away from work.
To build forklift training for your team, start by understanding the OSHA requirements and how to put them into practice.
The Current OSHA Training Rule for Forklift Operators
OSHA's operator training requirements were published as a final rule on December 1, 1998, and took effect on March 1, 1999. That rule, codified at 1910.178(l), remains the current federal training requirement for forklift operators. It was designed to reduce workplace injuries and fatalities through quality operator training.
The rule applies to general industry employers that use powered industrial trucks; construction employers are covered through 29 CFR 1926.602(d), which requires training consistent with 1910.178(l). Farm vehicles used in agricultural operations are not covered.
The core requirements are:
- Each operator must be trained and their performance evaluated before operating a powered industrial truck independently. Trainees may operate a truck only under direct supervision and where doing so does not endanger the trainee or other employees.
- The employer may designate any person who has the knowledge, training, and experience to train operators and evaluate their competence as the trainer or evaluator. OSHA does not require trainers to hold a special certification.
- OSHA does not certify, accredit, or approve trainers or training programs for powered industrial trucks. Responsibility for compliance rests with the employer.
In summary, employers covered by the standard must train their operators, evaluate each operator's performance before allowing independent operation, certify that the training and evaluation took place, and use a trainer or evaluator who is qualified for the task.
Forklift Trainer Requirements Under OSHA Regulations
Under OSHA's standard, ensuring that forklift operators are properly trained is ultimately the employer's responsibility. Employers can use outside trainers or pre-developed courses for the formal instruction portion, but the training provided must prepare employees for both general forklift operation and the specific conditions of your workplace.
Forklift Training Format
Training must combine formal instruction, which may include:
- Lecture
- Video
- Discussion
- Written materials, such as training booklets
- Interactive computer learning
Training must also include practical, hands-on elements, such as:
- Demonstrations performed by the trainer
- Practical exercises performed by the trainee under supervision
- Evaluation of the operator's performance in the workplace
Trainees may operate the vehicle only under direct supervision and only where it does not endanger them or other employees. During the practical portion of training, set aside a safe, designated area and keep other employees out of it.
Training Content
The training program must cover truck-related topics and workplace-related topics that apply to the trucks and conditions your operators will encounter. If operators will use different types of forklifts, they must be trained on each type they are authorized to operate.
Workplace-specific training
Your training must address the hazards specific to your place of business. If operators will use forklifts at multiple locations, they must be trained on the conditions unique to each location.
Workplace-related topics include:
- Surface conditions where the vehicle will be operated
- Composition of loads to be carried and load stability
- Load manipulation, stacking, and unstacking
- Pedestrian traffic in areas where the vehicle will be operated
- Narrow aisles and other restricted places where the vehicle will be operated
- Hazardous (classified) locations where the vehicle will be operated
- Ramps and other sloped surfaces that could affect the vehicle's stability
- Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust
- Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation
Truck-related topics
Training must go beyond basic operation and include information about the vehicle's controls, capacity, maintenance, and precautions.
Truck-related topics include:
- Operating instructions, warnings, and precautions for the types of trucks the operator will be authorized to operate
- Differences between the truck and an automobile
- Truck controls and instrumentation: where they are located, what they do, and how they work
- Engine or motor operation
- Steering and maneuvering
- Visibility (including restrictions due to loading)
- Fork and attachment adaptation, operation, and use limitations
- Vehicle capacity, including how to read the truck's data plate
- Vehicle stability
- Any vehicle inspection and maintenance that the operator will be required to perform
- Refueling and/or charging and recharging of batteries
- Operating limitations
- Any other operating instructions, warnings, or precautions listed in the operator's manual for the type of vehicle the employee is being trained to operate
Load stability is one of the most important of these topics. For a closer look at load center, center of gravity, and the stability triangle, see our guide to understanding forklift load balance and stability for safe operation.
Vehicle class-specific training
Operators do not need to be trained on every make and model your business owns, but they must receive training on each type of truck they will be expected to operate. An operator trained only on a sit-down counterbalance truck cannot operate a stand-up truck until they have been trained and evaluated on it.
The industry classifications for powered industrial trucks are:
Class I: Electric motor rider trucks
These general-use vehicles are most often found indoors, though versions with pneumatic tires are sometimes used outdoors in dry conditions. They run on batteries rather than gasoline, LP gas, or diesel fuel, which helps protect indoor air quality.
Class II: Electric motor narrow aisle trucks
These trucks are designed to operate efficiently in tight spaces, allowing shelving and aisles to be placed close together to maximize storage area.
Class III: Electric motor hand trucks or hand/rider trucks
These small battery-powered trucks are controlled by an operator walking in front of or riding on the truck, with steering and controls located in the tiller.
Class IV: Internal combustion engine trucks with solid (cushion) tires
These forklifts often move pallets from the loading dock to indoor storage. Their low-profile tires give them low ground clearance, so they are best suited to smooth, dry surfaces.
Class V: Internal combustion engine trucks with pneumatic tires
These trucks run on gasoline, diesel, LP gas, or compressed natural gas. They are versatile and used both indoors and outdoors in warehouses and yards of every size.
Class VI: Electric and internal combustion engine tractors
These tractors are known for their towing power and are commonly seen hauling luggage carts on airport ramps.
Class VII: Rough terrain forklift trucks
Common in construction, these large forklifts are built for heavy outdoor use, lifting and moving lumber and building materials on uneven ground.
Vehicle Inspection Training
OSHA requires that forklifts be examined before being placed in service, at least daily, and after each shift where trucks are used around the clock (1910.178(q)(7)). Any condition that adversely affects safety must be corrected before the truck is used. Operators who perform these checks must be trained on what to inspect and how to recognize defects.
Many employers structure the pre-use examination as two parts:
Walkaround inspection
The walkaround inspection checks major areas of the vehicle, such as the tires, hoses and belts, fluid levels, forks, mast, engine, and data plate, for safe, good condition.
Seated inspection
The seated inspection is performed from the operator's seat and confirms that the controls, horn, brakes, steering, seatbelt, lights, and gauges are in safe operating condition.
Training the Trainers
OSHA's regulation at 29 CFR 1910.178(l), Operator Training, spells out what employers must do to train employees to use forklifts correctly.
OSHA does not require a special certification for forklift trainers or evaluators, but they must have the knowledge, training, and experience to train powered industrial truck operators and evaluate their competence.
Some employers choose to bring in an outside trainer, but OSHA does not require it. A qualified supervisor or experienced employee can conduct the training and evaluation, provided that person meets the knowledge, training, and experience requirement.
Timing of Forklift Training
New operators
Operators who have not been trained and evaluated must complete the training program before operating a forklift independently. Until then, they may operate the vehicle only under direct supervision as part of their training.
New employees
Experienced operators who are new to your company are not necessarily required to repeat every topic. Under 1910.178(l)(5), if an operator has previously been trained in a topic, that training is appropriate to the truck and working conditions, and the operator has been evaluated and found competent, you do not need to repeat that topic. You must still evaluate the operator, train them on any workplace-specific trucks and hazards, and complete your own certification.
Refresher training
Refresher training, including an evaluation, is required when:
- The operator has been observed operating the vehicle in an unsafe manner
- The operator has been involved in an accident or near-miss incident
- The operator has received an evaluation that reveals they are not operating the truck safely
- The operator is assigned to drive a different type of truck
- A condition in the workplace changes in a manner that could affect safe operation of the truck
When an incident triggers refresher training, it is also good practice to review the training program itself, to confirm the problem was not caused by a gap in what operators were taught.
Experienced operators
OSHA requires an evaluation of each forklift operator's performance at least once every three years. If the operator continues to perform safely, no additional classroom training is required at that time. OSHA does not require annual refresher training, though some employers choose to provide it.
Temporary employees
Temporary and contract workers must also be trained and evaluated before operating a forklift. OSHA treats the staffing agency and the host employer as joint employers, so the two should agree in advance on who will provide each part of the training. In most cases the host employer is best positioned to provide training on its own trucks and workplace-specific hazards.
Minors
Under the Fair Labor Standards Act's Hazardous Occupations Order No. 7, workers under 18 may not operate forklifts in nonagricultural employment. All operators in those settings must be at least 18 before beginning training.
Certification document requirements
OSHA requires the employer to certify that each operator has been trained and evaluated. Many people misunderstand this and think the training itself must be "OSHA-certified." OSHA does not certify training. Certification simply means the employer documents that training and evaluation were provided and met the requirements of 1910.178(l). The certification must include:
- The name of the operator
- The date of the training
- The date of the evaluation
- The identity of the person(s) performing the training or evaluation
For a closer look at what the employer certification involves and how often it must be renewed, see what OSHA requires for forklift certification.
For more on the certification and evaluation side of the standard, see our guide to complete forklift safety training requirements and compliance for 2026.
Employer training records
OSHA does not set a specific retention period for forklift certifications. In practice, keep each operator's current certification on file, along with the records of their most recent evaluation, so it is available during an inspection.
Forklift training under OSHA's standard is one step toward a safer workplace for every employee. With a clear understanding of the requirements, thoughtful classroom planning, and qualified trainers, the process is straightforward. By the end of training, you should be confident that your operators understand what they were taught, can operate their trucks safely, and have complete certification records on file.
To compare program options for your warehouse team, see our top 5 forklift operator training programs every warehouse manager needs.
Forklift Training Programs from National Safety Compliance
National Safety Compliance offers forklift training programs in English and Spanish that cover the formal instruction portion of 1910.178(l). Each program is available as streaming (30 days or 1 year), DVD, USB, or an MP4 license, and the training program kits include streaming access plus a PowerPoint presentation, a quiz, and an attendance log. The employer provides the hands-on training, the workplace evaluation, and the certification.
- Forklift Safety Training | Video & Program
- Forklift: Construction Safety Training | Video & Program
- Forklift Load Stability Training | Video & Program
- Forklift Safety Employee Training Booklets (pkg of 10)
- Forklift Safety: Construction Employee Training Booklets (pkg of 10)
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