The safety manager wanted to provide a demonstration for the employees while at the same time provide us hands on experience mitigating a forklift rescue. With many businesses closing, the number of forklifts in use is down considerably in our area. In larger populated districts your department may be running these emergencies quite often, but as we are aware in the fire service, each call is typically unique and forklift rescues can provide hazards and challenges that some of us don’t see daily.
OSHA estimates forklifts cause about 85 fatal accidents per year; 34,900 accidents result in serious injury; and 61,800 are classified as non-serious. The highest percent of fatalities occur in the manufacturing environment accounting for more than 40 percent of incidents. The majority of all fatalities are a result of the vehicle tipping over. Many factors contribute to these injuries and deaths each year with some of the leading causes being operator error, equipment malfunction, lack of training and improper use.
The day of our scheduled drill a final briefing took place to make sure all hazards were removed from the lift and to identify all areas designated as “training zones.” Our rescue mannequin was also given to the plant safety manager to include in the scenario. The plan called for a large forklift that had backed off a four foot high loading dock while unloading a container. This would prove to be a more challenging drill than anticipated and some of our concerns will be discussed as the operational tactics are highlighted. Since the forklift was not operational all rescue options were available to free the victim. The type of drill was not known to the majority of our members to ensure a real-life feel to the training. Visit your local businesses and check out the different types of lift trucks being used and review the operation and hazards associated with them. If you have a member on your department that is familiar with this equipment it is essential that he/she is involved in the rescue.
To accurately time stamp the training, the plant workers placed a mock emergency call to our 911 center. From there, our dispatchers notified us according to protocol. This provided an accurate documentation for the safety manager during his post-training report. Our dispatch center was notified prior to the drill so there would be no confusion during their daily operation.
One of our mutual aid departments also participated and responded with their large high pressure airbag and additional cribbing. Once all units arrived on scene, command was established and only the apparatus being used were positioned close to the dock area. If your rigs are equipped with hydraulic reels or pneumatic reels you will need to be in position to utilize them. Positioning the apparatus within close proximity to the rescue prevented our rescue personnel from being fatigued by carrying heavy equipment a great distance.
If the accident is inside the structure, or you are not able to position close, consider using additional forklifts, gators, golf carts or small trucks to transport your equipment and personnel to the incident. Upon arrival, we were met by the safety manager who gave the incident commander a brief description of what happened as a couple of members began the size up procedure.
An inner and outer circle survey was performed to recognize potential hazards, make contact with patients, and deploy quick stabilization where possible. A one and three-quarter inch hoseline was pulled to handle any fire condition that could have occurred. Once information was gathered an operations position was staffed and an action plan was developed.
We found the victim — rescue mannequin — completely trapped beneath the lower part of the forklift, driver’s roll cage and pinned against the loading dock. A crib team was tasked with completing stabilization while other personnel gathered the lifting equipment that would be needed. Initially the amount of cribbing used was minimal, but as the drill progressed a large amount and various sizes were used. The forklift’s propane cylinder was removed early on and no hydraulic or petroleum fluids were present. The weight of the forklift was 24,000 pounds and was the biggest at the plant.
The plan was to use airbags at the front and rear of the lift due to the patient being in the middle. This would also give us room to slide the victim out once the needed lift was achieved. With the forklift being directly on concrete there were not many void areas to the rear to get an airbag in position. Using a small bag and cribbing allowed us to work up to a larger bag.
Several sizes of high pressure airbags were used and supplied by our air reel from the rescue engine. Air hoses were stretched to a manifold allowing the operator to make visual contact with those working at both ends of the forklift. From there air hoses were connected to airbags to perform the lift.
In the front area a crib box was built to provide a base for an airbag to be positioned on the vertical lift track. Rescue and EMS personnel made access between the forklift and loading dock to facilitate patient care.
Additional hazards faced were several 100 pound aluminum billets that had to be removed to perform the rescue. The training was kept as real as possible and due to the position of the “victim,” several methods were tried to achieve the safest lift possible.
During the drill we continuously encountered problems with our airbags not lifting and stalling without reaching maximum lift. Near completion we experienced a blowout failure of our largest airbag which was positioned at the lift track and forks. Fortunately, our cribbing was in place and our mutual aid department utilized their bag to replace the one that failed.
Although the rescue drill took longer than expected, the victim was completely extricated in approximately 40 minutes keeping the “golden hour” intact.
Lessons Learned and Points to Consider
- Pre-plan your district to know what equipment is being used. Talk with maintenance personnel to find out the technical information you will need during a rescue.
- Seek out to build strong partnerships with local businesses to assist you in training.
- Provide rehab and replacements for personnel during incidents involving heavy work. Consider operational work periods in extreme temperatures.
- Use of Incident Command is crucial in developing an action plan. Complete a proper size-up to assist you with your plan.
- If the incident occurred inside the building, check for structural instability, machinery involved, or any unsecured product or materials that were being lifted or transported. Ensure Lockout/Tagout is in place.
- Can’t stress enough the importance of having a large supply of cribbing. At extrication incidents, one statement is always the same, “could have used more cribbing.” Educate your members on appropriate crib box construction, weight capacities of lumber and reinforcing lift an inch-crib an inch.
- Be sure to avoid overloading winches, griphoists, or cable pullers if used during stabilization or lifting. Make sure the chain used with the equipment is rated for the work being done. Use Grade 80 chain for overhead lifting.
- During rescue or training consider alternative methods of lifting the forklift. Always have a plan B, C, D — well you get the picture. Think outside the box if your airbag system fails. Will it be possible to use another forklift to assist you or could you call in a heavy duty wrecker. Think about situations where hydraulic tools could be used or will it be necessary to cut or disassemble the forklift.
- Perform routine checks on your airbags and components. Follow manufacturer guidelines with use, care and maintenance. Consider replacing your equipment if it is over 10 years old, just as our airbag manufacturer did.
- Keep the “Golden Hour” in mind while operating. Have medical personnel ready to begin patient care.
- Determine the fuel source — propane, other — and secure this immediately.
- Expect hydraulic fluid, oil or other hazards and mitigate them accordingly.
Overall the drill went great and provided a mental and physical challenge for all rescuers. A price tag cannot be placed on the valuable experience everyone gained by taking part in this training. Check with your local businesses, scrap yards, construction sites, etc. and see if there is equipment available for training. I challenge all fire/rescue personnel to get out in their districts and see what obstacles they could possibly face in the event the tones are dropped for a forklift emergency.