Forklift Mast Height and Transport Hazards

[MikePhua]

Why Mast Positioning Matters in Forklift Transport
Transporting forklifts with tall masts presents a unique challenge in logistics. While loading the machine onto a trailer may seem straightforward, failing to properly lower or remove the mast can result in serious consequences. Forklift masts, especially those designed for stacking in marine or warehouse environments, can exceed legal height limits when mounted on standard trailers. If not addressed, this can lead to bridge strikes, overhead wire damage, and even catastrophic accidents.
Improvised Solutions and Their Risks
In one documented case, a forklift was loaded with its mast fully upright and blocked with cribbing to clear the trailer deck. While creative, this method introduced multiple risks:

• Center of gravity instability: Blocking the mast elevated the load’s center of mass, increasing the chance of tipping or shifting during transit.
  
• Stacked dunnage movement: Using multiple pieces of cribbing without securing them created a floating platform prone to vibration and bounce.
  
• Tire-based support: Resting the mast on the tires rather than the frame compromised structural integrity and load distribution.
  

Operators noted that removing the mast entirely would have been safer and more efficient. Disconnecting hydraulic hoses and unpinning the mast allows for flat transport and avoids clearance issues. Ironically, the effort spent blocking the mast exceeded the time required to detach it properly.
Legal Height Limits and Clearance Surprises
In the United States, the federal legal height limit for vehicles is typically 13 feet 6 inches (13'6"), though this varies by state and local jurisdiction. However, real-world conditions often deviate:

• Summer sag: Overhead wires, especially phone and cable lines, can sag several inches in hot weather, reducing clearance.
  
• Unmarked resurfacing: County crews may add layers of asphalt without updating clearance signage, leading to unexpected height reductions.
  
• Intersection hazards: Traffic lights and signal arms may hang lower than posted limits, requiring evasive maneuvers or rerouting.
  

One operator recounted a bridge strike on I-90 caused by a forklift mast that exceeded clearance by mere inches. The impact destroyed the trailer tires and launched the driver onto the hood—yet the forklift itself remained intact.
Best Practices for Forklift Transport
To avoid such incidents, follow these guidelines:

• Measure total height after loading, not just the forklift’s specs
  
• Use a grade rod or laser height tool to verify clearance before entering underpasses
  
• Detach or fold the mast whenever possible, especially for long-distance hauls
  
• Consider drop-deck or lowboy trailers to reduce overall height
  
• Secure all cribbing and dunnage with straps or brackets to prevent movement
  

In some cases, obtaining an overheight permit may be necessary. However, permits do not guarantee safe passage under all conditions, especially on rural or secondary roads.
Creative Workarounds and Local Wisdom
Operators have explored unconventional solutions, such as:

• Driving the forklift off the trailer to bypass low obstacles, then reloading on the other side
  
• Weaving through intersections to avoid traffic lights
  
• Carrying a clearance pole to manually check overhead wires
  

While these methods may work in isolated cases, they are not substitutes for proper planning and equipment configuration.
Conclusion
Transporting forklifts with tall masts requires more than just loading skill—it demands awareness of clearance laws, structural dynamics, and real-world road conditions. Improvised blocking may seem clever, but it introduces risks that can be avoided with proper mast removal or trailer selection. As infrastructure evolves and clearance standards fluctuate, the safest path forward is one grounded in preparation, measurement, and mechanical discipline.