Lifting concrete barriers safely using just a forklift (without a Kenco Barrier Lift or similar attachment) is challenging and not always recommended due to the risks of instability, barrier damage, and operator injury. However, if a dedicated barrier lift is unavailable, it can be done with careful planning, proper equipment, and strict adherence to safety protocols. Below is a comprehensive guide on how to lift concrete barriers safely using only a forklift, focusing on methods that minimize risks.

Key Considerations

• Forklift Limitations: Forklifts are not designed to lift concrete barriers directly, as barriers (e.g., jersey walls, T-walls) are heavy (400–500 lbs per linear foot), long (10–40 ft), and lack consistent lifting points. This increases the risk of tipping, load imbalance, or damage.
• Safety First: Always prioritize operator and site safety, adhering to OSHA regulations and ASME B30.20 standards for lifting operations.
• Barrier Type: Ensure the barriers have forklift slots or are designed for direct fork lifting. If not, alternative rigging methods may be needed, but these are less safe without specialized attachments.

Methods to Lift Concrete Barriers with a Forklift

1. Using Forklift Tines in Barrier Slots (If Available)

• When to Use: This method is only suitable for barriers with pre-cast forklift slots or pockets designed for direct lifting (e.g., some precast jersey walls or modular barriers).
• Steps:
  1. Inspect the Barrier and Forklift:
     • Confirm the barrier has intact forklift slots and no cracks or damage that could weaken it.
     • Verify the forklift’s load capacity exceeds the barrier’s weight (e.g., a 20 ft jersey wall weighs ~8,000–10,000 lbs). Check the forklift’s load center rating, as long barriers extend far from the mast.
  2. Position the Forklift:
     • Align the forklift parallel to the barrier, centering the forks with the slots.
     • Adjust fork spacing to match the slot distance (typically 24–36” apart for standard barriers).
  3. Insert Forks Carefully:
     • Slowly insert the forks fully into the slots, ensuring they extend through the barrier to maximize stability.
     • Avoid forcing forks, as this can crack the barrier.
  4. Lift Slowly:
     • Raise the barrier 6–12” off the ground to test stability.
     • Check for tilting or shifting. If the load is unstable, lower it immediately and reposition.
  5. Transport and Place:
     • Move slowly, keeping the load low (a few inches off the ground) to maintain stability.
     • Avoid sharp turns or sudden stops to prevent the barrier from sliding or tipping.
     • Lower the barrier gently onto a flat, stable surface, ensuring it is aligned correctly.
• Safety Tips:

• • Use a spotter to guide the operator and monitor load stability.
  • Ensure the barrier’s center of gravity is within the forklift’s load center to prevent tipping.
  • The longer the barrier, especially longer than 10–12 ft, are more difficult to balance and prone to imbalance.

• Limitations:

• • Many barriers lack forklift slots, making this method inapplicable.
  • Risk of chipping or cracking the barrier if slots are worn or forks are misaligned.

• 1. Forcing a forklift tine into an undersized fork slot may cause it to become wedged and difficult to extract.

2. Rigging with Slings or Chains (Advanced, High Risk)

• When to Use: This method is a last resort for barriers without slots or when a pallet/frame is unavailable. It involves rigging the barrier to the forklift’s mast or forks using slings or chains.
• Steps:
  1. Select Appropriate Rigging:
     • Use load-rated slings or chains (e.g., nylon slings or Grade 80 chains) with a working load limit (WLL) exceeding the barrier’s weight.
     • Ensure slings/chains are free of cuts, abrasions, or corrosion.
  2. Attach Rigging to the Barrier:
     • Wrap slings around the barrier at balanced lifting points (e.g., near the ends but avoiding edges to prevent chipping).
     • Alternatively, use lifting loops or embedded anchors if the barrier has them.
  3. Connect to the Forklift:
     • Attach the slings/chains to the forklift’s mast or a designated lifting point (e.g., a carriage-mounted hook).
     • Avoid attaching to the forks alone, as they are not designed for suspended loads.
  4. Lift and Transport:
     • Lift the barrier slightly (6–12”) to test stability, ensuring it hangs level.
     • Use taglines to control swinging and keep the load low during transport.
     • Place the barrier gently, ensuring precise alignment.
  5. Remove Rigging:
     • Lower the barrier fully before detaching slings/chains to avoid sudden drops.
• Safety Tips:

• • Only trained and certified riggers should perform this method, as improper rigging can cause load failure.
  • Use a spotter and taglines to manage load swing and ensure clearance.
  • Inspect rigging before each lift, per ASME B30.9 standards.

• Limitations:

• • High risk of barrier damage (chipping or cracking) due to sling pressure.
  • Increased risk of load imbalance or forklift tipping, especially for long or heavy barriers.
  • Not recommended for repetitive lifts or large projects due to setup time and safety concerns.

Safety Protocols for Lifting Concrete Barriers

To ensure safe lifting with a forklift, follow these best practices:

1. Verify Forklift Capacity:
   • Check the forklift’s data plate to confirm it can handle the barrier’s weight at the required load center. For example, a 20 ft jersey wall (~8,000 lbs) may exceed the capacity of smaller forklifts when extended.
   • Account for the extended load center of long barriers (e.g., 10–20 ft from the mast), which reduces capacity.
2. Inspect Equipment:
   • Inspect the forklift for hydraulic leaks, tire condition, and mast stability before use.
   • Check barriers for cracks, spalls, or weak spots that could fail during lifting.
   • Inspect pallets, frames, or rigging for damage or wear.
3. Prepare the Site:
   • Ensure the ground is level and stable to prevent forklift tipping.
   • Clear the lifting and transport path of obstacles and personnel.
   • Use cones or barriers to create a safety zone around the lift area.
4. Train Operators:
   • Operators must be certified for forklift operation and trained in load handling.
   • For rigging methods, ensure personnel are trained in rigging techniques per OSHA 1926.251.
5. Use Spotters and Communication:
   • Assign a spotter to guide the operator and monitor load stability.
   • Use hand signals or radios for clear communication between the operator and spotter.
6. Lift Low and Slow:
   • Keep the load as low as possible (a few inches off the ground) to minimize tipping risk.
   • Move slowly and avoid sudden acceleration, braking, or turns.
7. Secure the Load:
   • For pallets or rigging, use straps or chains to prevent sliding or shifting.
   • Ensure the barrier is centered to avoid uneven weight distribution.
8. Avoid Overloading or Long Barriers:
   • Do not lift barriers exceeding the forklift’s capacity or longer than 10–12 ft without specialized equipment, as they are prone to imbalance.
   • Avoid lifting multiple barriers at once, as this increases instability.
9. Follow Regulations:
   • Comply with OSHA 1910.178 (forklift operations) and ASME B30.20 (below-the-hook lifting devices) for safe lifting.
   • Ensure rigging complies with ASME B30.9 (slings) if used.