Handling hazardous materials (Hazmat) with forklifts adds another layer of responsibility — and risk. While standard forklift operation already involves significant hazards, introducing flammable liquids, corrosive chemicals, pressurized containers, or combustible dust raises the stakes exponentially. The good news: when Hazmat handling and forklift operations are addressed together in a thoughtful program, workplaces stay safer and businesses stay compliant. At Charleston Forklift Training (CFT), we offer combined training to ensure your operators meet all requirements while working confidently in high-risk environments.
Forklift operation falls under the standard 29 CFR 1910.178 (“Powered Industrial Trucks – Forklifts”), which includes handling in hazardous atmospheres. For example, § 1910.178(c)(2)(ii) states that only trucks “designated as EX” may be used in atmospheres containing volatile flammable liquids or gases.
Hazmat and chemical handling falls under the 29 CFR 1910.1200 (“Hazard Communication”) standard, which requires classification, labeling, training, and written programs for hazardous chemicals in the workplace.
The intersection of Hazmat & forklifts: According to OSHA’s “Working with Hazardous Materials” section, forklift operators in Hazmat environments must understand special hazards such as flammable/combustible atmospheres, appropriate truck types for those zones, and spill/exposure protocols.
Together, these standards create a clear requirement: in warehouses or distribution centers where hazardous materials exist, forklift training must integrate both safe truck operation and Hazmat awareness.
Here are typical hazards you’ll find when forklifts and Hazmat intersect—and why they matter:
Flammable materials
Working near volatile liquids or vapors (gasoline, solvents, LPG) means any spark, friction, or equipment malfunction can cause ignition. Under 29 CFR 1910.178(c)(2)(iv), only specific truck classes (DY, EE, EX, etc.) may be used in such atmospheres.
Corrosive chemicals
Acids and bases may cause operator injury, equipment damage, or create explosive reaction hazards if not handled correctly. Maintenance and inspection of trucks in these zones require extra attention.
Pressurized containers or liquified gases
Forklifts moving pallets of compressed gas cylinders or liquified containers pose unique risks—including sudden release, ruptures, or leaks—and must be handled accordingly.
Dust‐filled or combustible atmospheres
Warehouses with fine metal dust (like aluminum, magnesium), grain handling, or flyings may be explosive zones. 29 CFR 1910.178(c)(2)(iii) defines prohibited conditions unless EX-approved trucks are used.
Refueling and battery hazards
Electric forklifts and IC engine trucks in chemical or Hazmat zones introduce spill, acid exposure, or vapor hazards during maintenance or refueling. OSHA highlights the broad hazard exposure in its vehicle maintenance tool.
To operate safely and meet compliance, integrate the following practices:
Ensure operators have appropriate Personal Protective Equipment (PPE)—chemical suits, gloves, goggles, respirators—based on the Hazmat profile. Additionally, trucks assigned to hazardous zones must meet classification requirements (EX, DS, ES, GS, LPS) under 1910.178.
If the area is classified for flammable vapors or combustible dust, only trucks rated for those zones should operate there. Using the wrong truck is an immediate violation and risk.
Reducing speed in a Hazmat zone helps prevent jostling, accidental spills, or load shift. Awareness of the surrounding environment, ventilation, and material stability is essential.
Establish written procedures and train operators on chemical spill response. Under Hazard Communication (1910.1200), your facility must maintain SDSs (Safety Data Sheets) and train staff accordingly.
Forklift training in ordinary conditions doesn’t always cover Hazmat-specific threats such as chemical exposure, gas leaks, dust explosions, or unapproved areas. Use curated training that addresses your environment.
If you introduce new chemicals, change storage practices, change truck classifications, or reconfigure an area, retrain your operators accordingly. OSHA’s forklift standard emphasizes evaluating operator competency and retraining when conditions change.
When you partner with CFT, you get:
On-site training using your equipment and environment — we integrate Hazmat module with your forklift operator certification for maximum relevance.
Combined curriculum — from standard PIT operation to chemical hazards and emergency response, all in one convenient session.
Certified instructors who understand the local market, equipment types, Hazmat zones, and real-world risks.
Certification and documentation — you’ll receive the necessary records and support for OSHA compliance.
Flexible scheduling — we come to you, minimizing downtime and keeping your operations smooth.
We treat the Hazmat-forklift intersection not as an add-on, but as fundamental. Because in the reality of warehousing and industrial logistics, the two go hand in hand.
Operating forklifts in environments that contain hazardous materials isn’t just about moving pallets—it’s about moving them safely, with full awareness of chemical, vapor, and dust hazards that could turn a routine shift into catastrophe.
By aligning forklift training with Hazmat awareness, you reduce risk, improve compliance, and build a safer workplace culture.
📅 Ready to train your team for both forklift operation and Hazmat readiness? Contact Charleston Forklift Training today to schedule your combined program and ensure your team is prepared for whatever your facility demands.
Contact Charleston Forklift Training today to reserve your session and keep your workplace OSHA-compliant year-round.