Create a Forklift-Pedestrian Safety Zone with Proper Signage

A traffic flow analysis will help identify high-traffic areas, intersections, and blind spots where visibility is limited. Photo courtesy of DuraLabel.

High-visibility signage and durable floor markings play a key role in preventing accidents, guiding employees and enhancing overall operations.

By: Henry Verdine, Contributor

Forklifts and pedestrians often share the same spaces in industrial facilities, creating significant safety risks. In 2023, forklifts were involved in 67 work-related deaths, as reported by the National Safety Council (NSC).¹ Preventing these incidents starts with clear traffic separation and visual communication.

Designating pedestrian and forklift zones with high-visibility signage and durable labels reduces collisions and improves traffic flow. Properly marked walkways and forklift paths also support regulatory compliance, keeping facilities safer and more organized. Here’s how to create effective forklift-pedestrian safety zones.

BEST PRACTICES FOR LABELING PEDESTRIAN WALKWAYS AND FORKLIFT PATHS

A facility assessment lays the foundation for an effective forklift-pedestrian safety system. Start by conducting a traffic flow analysis, tracking forklift and employee movement to identify high-traffic areas, intersections, and blind spots where visibility is limited.

Steps to Conduct a Facility Safety Audit:

1. Create a Traffic Flow Map: Map out pedestrian walkways, forklift paths, and common pinch points.
2. Identify Risk Zones: Focus on loading docks, warehouse intersections, and narrow aisles.
3. Collect Employee Insights: Workers often know the most hazardous areas firsthand—engage them in identifying risks and proposing safety improvements.
4. Determine Corrective Actions: Develop a plan to separate pedestrian and forklift traffic by incorporating safety signage and floor markings to enhance visibility and reduce accidents.

A facility safety audit helps ensure compliance with OSHA’s 29 CFR 1910.176, which requires employers to maintain clear, hazard-free aisles and pathways. Proactively addressing these risks reduces accidents and keeps employees safe.

SELECT DURABLE FLOOR MARKING SOLUTIONS

Floor markings are a critical component of safety zones and guide traffic flow. They must withstand heavy traffic, extreme temperatures, and harsh chemicals without fading or peeling. Choosing the right materials ensures the markings remain effective for years.

Types of Floor Marking Solutions:

• Vinyl Floor Tape: Quick to apply and highly durable for high-traffic areas. Ideal for warehouses and manufacturing facilities.
• Paint: Offers strong adhesion, but wears down faster in areas exposed to forklifts or cleaning chemicals.
• Reflective Markings: Great for low-light environments, such as cold storage or outdoor areas.
• Light Line and Sign Projectors: A durable solution for dark or high-wear areas where traditional markings fade or wear away.

A standardized color system improves workplace safety by helping workers quickly identify designated areas. Each color serves a specific purpose, ensuring clear communication and reducing risks.

Color-Coding for Safety Zones:

• Yellow: Indicates caution zones and forklift paths.
• White: Marks pedestrian walkways.
• Red: Designates emergency stops or hazardous areas.

Consistent color-coded markings eliminate confusion for workers and enhance safety.

THE ROLE OF HIGH-VISIBILITY SIGNAGE IN MAINTAINING SAFETY ZONES

Designating pedestrian and forklift zones with high-visibility signage reduces collisions and improves traffic flow. Photo courtesy of DuraLabel.

High-visibility signage keeps employees alert and aware of their surroundings. Bright, reflective signs ensure workers notice warnings, even from a distance.

For example, “Forklift Crossing” signs at busy intersections remind pedestrians to stop and look for oncoming traffic.

Different sign types can serve multiple purposes:

• Floor-Mounted Signs: Ideal for intersections and crosswalks to direct foot and vehicle traffic.
• Wall-Mounted Signs: Placed at entry points or along pathways to reinforce traffic patterns.
• Glow-in-the-Dark Signs: Enhance visibility in low-light or emergency situations.

Strategically placing these signs throughout a facility creates a clear visual system that keeps employees informed and reduces the risk of accidents.

For Maximum Effectiveness:

• Install signs at eye level near intersections, doorways, and shared spaces.
• Ensure signs are not blocked by equipment or shelving.
• Keep signs clean and legible at all times.

In low-light areas, reflective or illuminated signs improve visibility and enhance workplace safety.

BENEFITS OF AN EFFECTIVE SAFETY ZONE SYSTEM

A well-designed forklift-pedestrian safety zone reduces accident risks, improves traffic flow, and boosts worker confidence. Clear color-coded markings and high-visibility signs help employees navigate safely, minimize confusion, and prevent collisions. Defined pathways reduce congestion, creating a safer, more efficient workplace where employees feel engaged and supported.

Maintaining compliance with OSHA standards not only enhances safety but also helps avoid costly fines while reducing workplace injuries and associated expenses.

Maintenance and Regular Audits

Establishing safety zones is just the first step. Regular maintenance is essential to ensure these safety measures remain effective over time. Damaged labels and faded signs can create confusion and increase risks, making regular inspections a critical part of workplace safety

Key Maintenance Tasks:

• Inspect floor markings for wear, peeling, or fading.
• Check signs for damage, obstruction or reduced visibility.
• Ensure high-risk areas remain clearly labeled and easy to identify.
• Update safety zones after facility layout changes.

Encourage employees to report damaged or missing labels to help maintain a safe work environment. Scheduling regular audits helps identify potential issues early, preventing minor problems from turning into major hazards.

THE PATH TO IMPROVED WORKPLACE SAFETY

Forklift-pedestrian safety zones are essential for any facility where workers and vehicles share the same space. High-visibility signage and durable floor markings play a key role in preventing accidents, guiding employees, and enhancing overall operations.

Regularly assess your facility’s safety zones, identify areas for improvement, and implement necessary updates to create a safer, more efficient workplace for everyone. WMHS

Henry Verdine is a safety professional at Graphic Products, a global leader in safety solutions and the makers of DuraLabel industrial sign and label print systems. Learn more about visual communications and safety at www.duralabel.com/resources