When to Replace Forklift Forks (and How to Inspect Them)

Thinking About Forklift Forks as Critical Wear Parts

At a glance, forklift forks appear to be solid masses of steel that might just last forever. In this case, looks are certainly deceiving, as forklift forks are some of the most directly worn parts on the entire lift truck. With every load pick and placement, a lift’s forks are subjected to stresses and friction that impact the forks in small but accumulative ways. Operator habits (like scraping the forks on the floor) and application conditions (like exposure to weather) further compound the wear that forklift forks receive, making it critical that fleet managers and operators alike consider forks just like any other wear part that must be inspected, maintained, and eventually replaced.

Going Straight to the Source on Forklift Safety

Figuring out how to properly manage forklift fork wear can be difficult, as there are many sources of information available (which often present conflicting recommendations). For the sake of operator safety, let’s go right to the source of forklift fork maintenance requirements:

• OSHA – the United States’ Occupational Safety and Health Administration (OSHA) is the federal government agency responsible for workplace safety. OSHA standard 1910.178 is the highest order legal code body that governs Powered Industrial Trucks. Section 1910.178(q) requires that every forklift is inspected and ensured to be in safe operating condition before use, and any lift found deficient must be removed from service until repaired. OSHA does not prescribe specific inspection procedures though, which is where ANSI comes in.

• ANSI – the American National Standards Institute (ANSI) is a private non-profit organization that develops and publishes voluntary consensus standards used across countless industries in the United States. The ANSI/ITSDF B56.1 Safety Standard for Low Lift and High Lift Trucks is the premier technical safety guidance document covering forklift design, operation, and maintenance, and is recognized by OSHA as containing suitable procedures that forklift owners can follow to comply with OSHA’s above requirements.

• ITSDF – the Industrial Truck Standards and Development Foundation (ITSDF) is the ANSI-accredited standards development organization formed to administrate the ANSI B56.1 standard (and others). The ITSDF is directly responsible for the standard’s technical accuracy, test methods, and test procedures, specifically from a safety perspective. Forklift owners can visit the agency’s website to get more information about the B56.1 standard, as well as historical records of review errata and technical interpretations.

In short, OSHA requires forklift inspections, and ANSI provides standard procedures for such inspections. Following B56.1, forklift owners can determine if their forklift forks are safe to use or due for replacement. Beyond these standards, forklift owners should also consult their forklift manufacturer’s (OEM) Owner’s / Maintenance Manual for additional requirements.

Knowing When to Replace Forklift Forks

How will you know when it’s time to replace your forklift’s forks? Let’s refer to OSHA’s Powered Industrial Trucks eTool to learn about the potential hazards recognized by OSHA (and a few of our own additions) as symptoms that require a lift to be removed from service until the forks are repaired or replaced:

• Surface Cracks
• Blade or Shank are not Straight
• Fork Angle from Blade to Shank is Not Straight
• Difference in Height of Fork Tips
• Positioning Lock Not in Working Order
• Fork Blade or Shank Wear
• Fork Hooks Wear
• Fork Marking Not Legible
• Loose Forks (that rattle or slide unexpectedly on the carrier)
• Unapproved Modifications or Repairs

Forklift Fork Inspection Tips to Ensure Safe, Secure Picks

Now that you know what to look for regarding forklift wear and damage, you might ask if there are specific methods or procedures on how to identify such issues. There sure are, which brings us back to the ANSI/ITSDF B56.1 Safety Standard for Low Lift and High Lift Trucks. Below we’ll summarize the main guidance from this document on forklift fork evaluation (noting each section number from the B56.1 code, for easy reference), accompanied by a few of our own comments:

• 6.2.8 Inspection and Repair of Forks in Service on Fork Lift Trucks – B56.1 states that all forks in use shall be inspected at least once per year (for single shift operations), or immediately upon notice of any of the above deformations. In addition, we suggest immediate inspection in the event of any accident or near-miss, and as needed for special, extreme, or high-wear applications.   

• 6.2.8.1 Inspection – the code requires that inspections be performed by trained and authorized personnel, and that lifts are pulled and repaired once any issue is detected or suspected.

• 6.2.8.1(a) Surface Cracks – all surfaces of the forks must be inspected visually for cracks and fractures, especially in the heel and any weld areas. Alternatively, non-destructive test methods such as X-ray scanning can be used.

• 6.2.8.1(b) Straightness of Blade and Shank – straightness of the top surface of the blade and front surface of the shank must be inspected and cannot exceed 0.5% of the blade length or shank height.

• 6.2.8.1(c) Fork Angle (Upper Face of Blade to Load Face of the Shank) – fork angles must be inspected and cannot exceed 3 degrees from OEM specifications.

• 6.2.8.1(d) Difference in Height of Fork Tips – fork tip heights must be inspected by measuring to a common flat, level surface, and cannot exceed 3% of the blade length.

• 6.2.8.1(e) Positioning Lock (When Originally Provided) – the fork positioning lock pin, tab, or lever must be inspected for being in good working order, free of binding and freezing in place, and cannot be so loose that it unexpectedly pops in and out of the locked position.

• 6.2.8.1(f)(1) Wear, Fork Blade and Shank – the fork blade and shank must be inspected for wear, looking at the heel in particular, and thickness wear cannot exceed 90% of OEM specifications.  (A common rule of thumb is that 10% fork erosion results in a 20% loss of fork capacity, but this is not a hard-and-fast rule – never use this to determine safe lift capacities, and always replace worn forks according to code.)

• 6.2.8.1(f)(2) Wear, Fork Hooks (When Originally Provided) – the fork’s hooks are the metal tabs that clip onto the lift’s carrier and retain the forks on the lift, and these hooks must be inspected for excess wear that would cause the forks to slide around or jump off of the carrier.

• 6.2.8.1(g) Legibility of Marking (When Originally Provided) – each fork must be checked to confirm that its capacity stamp, plate, or marking is present and legible, and matches the forklift’s capacity as well. 

All in all, remember that forklift fork inspections are just one part of a robust forklift maintenance program, which you can learn more about by downloading our Complete Preventative Maintenance Checklist here. 

We hope that this discussion has been helpful for your commercial material handling and operational needs. Fairchild Equipment is the Upper Midwest’s premier Material Handling Equipment and Service resource, with headquarters in Green Bay, Wisconsin, and numerous locations ready 24/7 to serve your needs throughout Wisconsin, Minnesota, North Dakota, Michigan’s Upper Peninsula and Northern Illinois. For more information or to discuss which equipment solution might be best for you, please call us at (844) 432-4724 or send us a message.