Published: July 2025

What Industrial Supervisors Need to Know About OSHA’s 2025 Aerial Lift Standards Update

Forklifts are indispensable in warehouses, distribution centers, manufacturing plants, and construction sites. But with power and utility comes risk—especially if safety regulations aren’t followed closely. To help reduce incidents and ensure workplaces stay compliant, the Occupational Safety and Health Administration (OSHA) has updated its standards for powered industrial trucks in 2025. These updates affect operator training, equipment modifications, inspection protocols, and data reporting.

If you’re a supervisor, staying current with these changes is not optional; it’s essential to the safety of your team and the legal standing of your operation.

Overview of the 2025 OSHA Forklift Standard Revisions

While OSHA’s foundational forklift rules remain grounded in 29 CFR 1910.178, the 2025 updates bring several key changes:

1. Stronger Emphasis on Refresher Training
   Operators must now receive refresher training every three years or sooner if a safety incident, near-miss, or operational change occurs. Previously, the "or sooner" clause was considered a recommendation; it’s now enforceable.
2. Electronic Logging and Inspection Records
   Daily inspections of forklifts are still mandatory, but the updated regulation explicitly permits digital recordkeeping. Supervisors must ensure that logs are accurate, time-stamped, and retrievable for OSHA audits.
3. Attachment-Specific Training Requirements
   Any operator using attachments not originally included in training must receive supplemental instruction and evaluation. This includes rotators, clamps, side shifters, and push/pulls.
4. Clarity on Modified or Remanufactured Equipment
   Forklifts modified outside of manufacturer specs require not just written approval from the manufacturer, but also a new capacity rating plate. Remanufactured units must meet original ANSI/ITSDF B56.1 standards.
5. Supervisor Accountability for Operator Evaluation
   Supervisors are now explicitly responsible for overseeing and documenting operator evaluations every three years. The burden of proof in compliance cases falls more heavily on site leadership.

Why These Changes Matter

These updates reflect a broader industry trend: OSHA is focusing more on proactive compliance and digital accountability. Supervisors must adapt policies to reflect these expectations—especially when managing large teams or fast-paced shifts. Failure to comply could result in steep fines or liability following an incident.

Action Steps for Supervisors

To align with the 2025 OSHA updates, supervisors should:

• Review all forklift operator certifications and evaluation timelines
• Implement or upgrade to a digital inspection and maintenance log system
• Schedule refresher training and document attendance
• Verify that any forklift attachments are listed on updated data plates
• Audit compliance with pre-shift inspections and reinforce reporting habits

The 2025 forklift standard updates are about more than paperwork. They reflect OSHA's intent to foster safer, more accountable workplaces. As a supervisor, staying ahead of compliance isn’t just about avoiding citations—it’s about protecting your workforce and leading by example in an evolving safety landscape.

Helpful Links & Resources

• OSHA 2025 Forklift Safety Requirements
• Forklift Operator Training Requirements
• ANSI/ITSDF B56.1-2020 Standards for Powered Industrial Trucks
• NIOSH Workplace Safety Forklift Reports

FAQs

Q: Does every forklift operator need refresher training by a specific date in 2025?
A: No set date, but if it's been three years or more since their last evaluation, or if there's been a near-miss, refresher training must occur immediately.

Q: Can we use digital checklists and inspection apps now?
A: Yes. The 2025 update formally allows digital records, as long as they are accurate, timestamped, and accessible for audits.

Q: What if we added a clamp attachment years ago but never updated the data plate?
A: That’s now a compliance issue. You must get manufacturer approval and have the forklift re-rated with a new capacity plate.

Q: Who is responsible for operator evaluations?
A: Supervisors or designated evaluators are directly accountable. OSHA places responsibility on leadership to confirm evaluations are current and documented. Prosafe evaluators are at the top of their industry know-how. We only pass off operators-in-training under the utmost confidence that they will succeed.