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Learn how forklifts can safely lift oversized loads—or even another forklift. This guide covers lifting capacity, safety protocols, and attachments to boost efficiency in warehouses and construction.
When most people think of forklifts, they picture a machine lifting pallets, crates, or heavy loads. But in some unusual and highly specialized cases, you may actually see a forklift lifting another forklift. While it sounds extreme, these situations highlight just how adaptable forklifts can be. They also emphasize the importance of understanding safe lifting practices, capacity limits, and the right attachments for the job.
Forklifts are designed to move heavy objects efficiently, but their applications often go beyond palletized loads. With specialized training and equipment, forklifts can:
Safely lift oversized loads.
Handle stacked or irregular cargo.
In rare situations, lift another forklift for transport or maintenance.
These operations require precision, advanced knowledge, and strict adherence to safety protocols.
Efficiency is critical in warehouses, distribution centers, and construction sites. Every lift must balance three elements:
Speed: Maximizing throughput without cutting corners.
Accuracy: Ensuring loads are placed correctly to avoid damage.
Safety: Protecting operators, equipment, and bystanders.
Improper lifting practices not only compromise safety but can also cause costly downtime. Mastering forklift lifting techniques directly improves workflow and ROI.
A forklift’s rated capacity depends on several key factors:
Load center distance: How far the load’s center of gravity is from the mast.
Mast height and extension: Higher lifts reduce stability.
Attachments: Additional weight reduces net capacity.
Operators must always consult the load capacity plate and avoid guesswork.
Attachments that add bulk or weight.
Uneven or unstable terrain.
Forklift design—electric vs. internal combustion, cushion tires vs. pneumatic.
Lifting another forklift—or unusually heavy loads—requires extreme caution.
Key safety protocols include:
Never exceed rated load capacity.
Secure loads before lifting.
Always use a spotter during complex maneuvers.
Avoid sudden movements that could shift the center of gravity.
Just because a forklift can lift another forklift doesn’t mean it should. These lifts are generally reserved for controlled scenarios such as equipment relocation or maintenance.
Fork extensions: Add length for oversized loads.
Drum handlers: Secure cylindrical items.
Clamps: Grip paper rolls, appliances, or bales.
Booms and jibs: Turn a forklift into a mini-crane.
Man baskets: Safely lift personnel (with OSHA approval).
Heavy-duty lifting frames: Occasionally used for forklift-on-forklift lifts.
Pros: More flexibility, higher efficiency, fewer machines required.
Cons: Reduce lifting capacity, require additional operator training, and increase maintenance.
Only perform in supervised, controlled conditions.
Confirm ground stability and forklift readiness.
Maintain clear communication between operators and spotters.
Use heavy-duty attachments built for machinery transport.
Ensure both forklifts are on level, reinforced surfaces.
Use secondary securing devices such as straps or chains.
Warehouse Relocation: Heavy-duty forklifts used to load compact forklifts onto flatbed trucks.
Construction Sites: Telehandlers lifting smaller forklifts to higher floors for material handling.
These examples show that while uncommon, forklift-on-forklift lifts can be done safely with the right preparation.
Forklift lifting forklift operations are rare but possible with the correct safety measures.
Load capacity, balance, and the right attachments are non-negotiable.
Safety protocols should always take priority over efficiency.
Modern forklifts increasingly integrate load sensors, stability controls, and telematics to prevent unsafe lifts. These technologies improve both safety and efficiency in demanding environments.
As automation and robotics evolve, forklifts will likely operate alongside autonomous systems. This will reduce the need for risky forklift-on-forklift lifts and push efficiency across industries even further.
👉 Want to dive deeper into forklift safety and efficiency? Listen to Forklift Attachments and Safety Essentials: A Deep Dive Conversation to learn how the right attachments and best practices can maximize productivity while minimizing risks.
