Workplace safety, especially in environments using heavy machinery like forklifts (or lift trucks), is an absolute priority. These vehicles are essential tools for moving goods and materials in warehouses and construction sites, but they carry significant risks. To mitigate these dangers, legislation and international standards (such as ISO 6055 or EN 1551 specifications) mandate rigid structural resistance tests, particularly for the operator protective structure, known as the overhead guard.

THE VITAL FUNCTION OF THE OVERHEAD GUARD

The overhead guard is not merely protection against the elements, but a crucial safety component. Its primary function is to shield the operator from the risk of falling loads or materials from above during lifting and transport operations. Without this protection, even relatively light objects falling from great heights can cause severe or fatal injuries.

The design and materials used for this element must ensure that, in the event of an incident, the structure is capable of absorbing the impact energy without collapsing or deforming in a way that crushes the driver inside the cabin.

EXECUTION AND STANDARDS FOR RESISTENCE TESTS

Overhead guard resistance tests are conducted to simulate the most severe impact conditions. The objective is to verify the guard’s capacity to withstand a significant and concentrated load.

Structural Requirements: The structure must resist without fractures or significant breakages..

Load Simulation: The test simulates the impact of a load that might accidentally fall from the mast, from a high shelf, or from another truck operating at a higher level. The load is not simply set down; the regulation requires that it be dropped from a certain height or that an equivalent static force be applied that exceeds the maximum weight the truck is certified to lift.

Deformation Measurement: During the test, technicians closely monitor the permanent deformations of the structure. The standard sets precise limits for deformation; the structure must not yield in a way that encroaches on the operator’s maneuvering or safety space, ensuring the driver’s vital space remains intact.

MAINTENANCE AND COMPLIANCE

For a company, ensuring that forklifts are always compliant with tests and regulations is essential not only for safety but also to avoid legal sanctions and operational shutdowns.

• Initial Certification: Every new forklift model must pass these tests during the design phase to obtain CE certification (in Europe) and homologation.
• Regular Inspections: Forklifts in use must undergo periodic inspections by qualified personnel. Any visible damage to the overhead guard, even minor (such as cracks, dents, or damaged welds), compromises its effectiveness and requires immediate decommissioning and repair or replacement.
• Training: Operators must be adequately trained to always operate safely.

THE VALUE OF CERTIFICATION: A GUARANTEE OF SUITABILITY AND LEGAL PROTECTION

Relying on a Notified Body for the execution of the tests is the best guarantee of compliance. ECM, with specialized technical personnel and regularly calibrated instrumentation, performs the test in conformity with current regulations, issuing an official test report. Entrusting the process to ECM provides the employer with objective proof of having rigorously fulfilled prevention obligations, ensuring maximum operational safety and the full legal validity of the verification.

We provide high-quality testing services for products, machinery, and equipment to ensure the best possible safety in the workplace. Contact us for more information at info@entecerma.it.