In many industrial and warehouse environments, forklifts are indispensable for transporting heavy materials and managing inventory. However, because these machines handle heavy loads and operate in complex environments, they pose significant safety risks. To mitigate these dangers, regulatory bodies such as the Occupational Safety and Health Administration (OSHA) in the United States and the Health and Safety Executive (HSE) in the United Kingdom mandate that only certified individuals operate these vehicles.
Defining Who Needs Certification
The certification requirement applies to anyone tasked with operating a "powered industrial truck". This broad category includes a variety of machinery, ranging from standard sit-down counterbalanced forklifts to more specialized equipment. According to the sources, there are seven primary classes of powered industrial trucks that require specific operator training:
Electric motor, sit-down rider, counterbalanced trucks.
Electric motor narrow aisle trucks, such as reach trucks or order pickers.
Electric motor hand trucks or hand/rider trucks.
Internal combustion engine trucks with solid tires.
Internal combustion engine trucks with pneumatic tires.
Electric and internal combustion engine tractors.
Rough terrain forklifts.
Any professional responsible for transporting materials using this machinery, whether in a warehouse, construction site, or storage facility, must be certified. This includes not only full-time forklift drivers but also supervisors or maintenance staff whose duties involve operating the lift truck.
Eligibility and Legal Requirements
To pursue good forklift certification, an individual must meet several baseline criteria. In the United States, an operator must be at least 18 years of age and possess a high school diploma or its equivalent. Requirements can vary by jurisdiction; for instance, in Dubai, the Roads and Transport Authority (RTA) requires applicants to be over 20 years of age and pass an eye test before being eligible for a forklift licence.
While a valid driver’s licence for a car is not a federal requirement under OSHA laws to operate a forklift, the operator must show they can drive the machine safely. Employers often require medical fitness assessments to ensure operators have the physical and mental capacity for the role. These medical evaluations assess critical functions, including visual acuity, depth perception, hearing, and musculoskeletal mobility, to ensure the driver can safely enter the cab and operate the foot pedals.
The Two-Step Certification Process
Certification is not merely a matter of passing a written test; it is a comprehensive process that blends theory with practical application.
Formal Instruction: This initial phase involves classroom-style learning delivered in person or online. It covers OSHA rules, safety procedures, driving techniques, and maintenance. Operators must typically score at least 75% on a written exam to proceed.
Practical Training and Evaluation: OSHA Standard 29 CFR 1910.178 requires a hands-on evaluation. This must take place at the actual worksite using the specific forklift the employee will operate. A "competent person" must observe the operator performing tasks like pre-shift inspections, navigating tight spaces, and loading materials.
Employer Responsibilities and Compliance
The responsibility for ensuring certification rests primarily with the employer. It is the employer's responsibility to provide appropriate training and verify that every operator is competent before allowing them to work alone. If an employer allows an uncertified individual to operate a forklift, they may face substantial penalties. As of 2025, OSHA fines for such violations can range from $16,131 to $16,131 per violation, with even higher penalties for "willful or repeated" offences.
Beyond avoiding fines, certification benefits the workplace by reducing the risk of injury, minimizing equipment and property damage, and improving overall productivity. Trained operators are also trained to perform pre-shift inspections, which help identify mechanical issues early and extend the lifespan of the machinery.
When is Recertification Necessary?
Certification is not a one-time achievement. Generally, a forklift operator’s performance must be evaluated at least every three years to ensure they maintain safe habits. However, "refresher training" may be triggered much sooner if certain events occur, such as:
The operator is involved in an accident or a "near-miss" incident.
The operator is observed driving the equipment unsafely.
The operator is assigned to a different forklift type.
Changes in the workplace environment may affect safe operation.
Conclusion
In summary, any individual who operates a powered industrial truck in a professional capacity must be certified. This process ensures that the operator is not only legally compliant but also physically fit and technically proficient in handling heavy machinery in high-pressure environments. For employers, maintaining a rigorous certification and recertification programme is the best defence against workplace accidents, legal liability, and costly operational errors.