Published: June 2025

Cal/OSHA vs. Federal OSHA: Forklift Certification Requirements

Understanding the differences between Federal OSHA and Cal/OSHA is essential for employers and safety professionals working with powered industrial trucks (PITs) such as  sit-down forklifts, stand-up and reach forklifts, order pickers, electric pallet jacks,turret lifts and many others. 

While both agencies aim to improve workplace safety, Cal/OSHA imposes stricter and more detailed regulations that go beyond the federal baseline. If your organization operates in California, failing to comply can lead to significant fines and enforcement actions.

What Is Federal OSHA and How Does Cal/OSHA Differ?

The Occupational Safety and Health Administration (OSHA) is the federal agency responsible for setting and enforcing safety standards in workplaces across the United States. OSHA provides training, outreach, education, and assistance to help employers ensure a safe working environment.

Cal/OSHA, or the California Division of Occupational Safety and Health, is one of 22 states that operate an OSHA-approved state plan. These plans must be at least as effective as federal standards—but California often goes further, requiring more stringent safety practices and documentation.

Tip: If your business operates in California, you must comply with both Federal OSHA and Cal/OSHA requirements, with Cal/OSHA taking precedence where it is stricter.

Regulatory Scope: Who Regulates What?

• Federal OSHA applies nationwide and sets the minimum legal safety standards.
• State Plans (like Cal/OSHA) can impose additional, stricter rules.
• California’s plan specifically regulates most private and public sector workplaces within the state.

You can find more about these regulations at OSHA.gov and dir.ca.gov.

Certification and Safety Requirements

Federal OSHA (29 CFR 1910.178)

• Training & Evaluation: Required every 3 years
• Refresher Training Triggers:
  
  • Unsafe operation
  • Accidents or near-misses
  • Unsafe evaluation results
  • Change in vehicle type or workplace conditions
• Training Topics (1910.178(l)(3))

Cal/OSHA (GISO §3668 + others)

• Includes all federal requirements plus:
  
  • Training & Evaluation: Required at least once every 3 years
  • Detailed training records:
    
    • Name of operator
    • Training & evaluation dates
    • Identity of trainer/evaluator
  • Specific safety device regulations:
    
    • Seat Belts (§3653)
    • Deflector Guards (§3654)
    • Overhead Guards (§3655)

Forklift Certification Rules: Federal OSHA vs. Cal/OSHA

Evaluation Frequency

• Federal OSHA: Every 3 years
• Cal/OSHA: Every 3 years (GISO §3668)

Refresher Training Triggers

• Federal OSHA: Unsafe operation, accidents, change in truck/workplace
• Cal/OSHA: Same as Federal, with stricter tracking requirements

Seat Belt Use

• Federal OSHA: Implied under General Duty Clause
• Cal/OSHA: Explicitly required under §3653

Training Documentation

• Federal OSHA: Basic records required
• Cal/OSHA: Must include name, date, and trainer identity

Penalties and Enforcement Actions

Cal/OSHA is known for thorough inspections and stricter enforcement. Its penalties for noncompliance are often higher and more precise than Federal OSHA’s.

Cal/OSHA Penalties (as of Jan 2025):

• General violations: Up to $16,285
• Serious violations: Up to $25,000
• Willful violations: Up to $162,851

Federal OSHA Penalties (as of Jan 2025):

• General/posting violations: Up to $16,550
• Willful/repeat violations: Up to $165,514
• Failure to abate: $16,550/day

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Real Case Study: Cal/OSHA Incident Investigation 

Company: Red Dipper, Inc. (San Francisco, CA)
Incident: November 20, 2020; Worker operating a forklift jumped out of the cab to avoid being crushed by the tip over. This resulted in 4 broken ribs and hospitalization.

Applicable Rule: Cal/OSHA §3328(A(2))

"[All machinery and equipment] shall not be used or operated under conditions of speeds, stresses, loads, or environmental conditions that are contrary to the manufacturer's recommendations or, where such recommendations are not available, the engineered design."

Violation Classification: Serious
Penalty: $10,800
Additional Penalties:

• Other(1509(A)): $350
• Other(3668(F)): $260

Total Penalties: $11,410

Inspection: 1503729.015

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What Employers Should Do

• Know the Differences: Familiarize yourself with both OSHA and Cal/OSHA requirements, especially if you operate in California.
• Keep Thorough Records: Document who was trained, when, and by whom—especially for forklift operators.
• Follow ANSI Guidance: Though voluntary, ANSI standards like ANSI/ASSP Z359.2 are widely endorsed and can improve your fall protection plans.

Bottom Line: Proactive safety training, clear documentation, and routine evaluations are the best defense against injuries—and penalties.

Takeaways

• Cal/OSHA requirements exceed Federal OSHA in areas like evaluation frequency, recordkeeping, and fall protection.
• Employers must stay informed and adopt stronger safety practices where state rules apply.
• Fines can range from $160 to over $160,000 for noncompliance—prevention pays.

For further details, refer to:

• Cal/OSHA official site
• Cal/OSHA Operating Rules for Industrial Trucks
• Federal OSHA
• ANSI/ASSP Z359.2