Executive Summary

Forklifts powered by hydrogen fuel cells are already in use in North America, and the market for these forklifts is expected to grow within the next decade. This research was aimed at gaining a better understanding of the needs, gaps, and opportunities for standardization of forklifts operating with a hydrogen power source. It synthesizes the findings of a literature review, an environmental scan of regulations and voluntary standards, key informant interviews, and a review of CSA B335, Safety standard for lift trucks, to identify where gaps exist and where there might be opportunities for improvement.

Key findings include:

• The principal hazards of hydrogen include asphyxiation in confined spaces, exposure to thermal radiation, overpressures when hydrogen is ignited or explodes, and the potential for exposure to high-velocity projectiles when a hydrogen containment vessel ruptures under high pressure.
• Research shows that the factors that contribute to forklift incidents in the workplace include work organization, workplace design, load characteristics, mechanical conditions and forklift design, age and maintenance of the forklift, and lack of or improper operator training.
• While much is known about the hazards of hydrogen and general forklift safety, relatively little is known about the specific hazards and risks introduced by the hydrogen fuel cell power system and its interaction with the hazards that are already present. Research suggests that compared to current forklift technologies, hydrogen-powered forklifts may present a higher risk of fire and explosion.
• Both the literature review and the key informant interviews identified important knowledge gaps, as well as a need for quantitative research on likely leak scenarios (including refuelling), the risk of hydrogen exposure during indoor refuelling, and whether the replacement of an electric battery with a fuel cell introduces new hazards in the workplace.
• Despite the presence of a relatively robust regulatory framework for occupational health and safety (OHS) in Canada, there are a number of gaps and inconsistencies in how forklifts are regulated in general. At present, no jurisdiction in Canada has OHS regulations that address forklifts that use hydrogen as a fuel source.
• Six voluntary standards include requirements applicable to the design, operation, and/or maintenance of fuel cell forklifts. Only one is incorporated by reference in the forklift regulations across Canada. The six standards cross-reference each other in a number of places, which could create challenges for users who would have to track down multiple standards to comply with the requirements of one standard.

The review of CSA B335 identified a number of opportunities for improvement, including the addition of reference publications, terms, and definitions, as well as amendments to the general requirements, the operator training requirements, qualifications of the lift truck trainer, maintenance and repair practices, competence of maintenance technicians, and three of the informative annexes. Given the potential consequences of a major hydrogen release, it may also be useful for the Technical Committee in charge of the Standard to develop and include an additional informative annex that discusses the properties and hazards of hydrogen.