Forklifts are commonly used in construction, manufacturing, and warehouse operations to move heavy materials. However, when not operated properly, they can lead to serious hazards. According to the Bureau of Labor Statistics (BLS), forklift accidents are among the leading causes of workplace injuries and fatalities. Understanding the most common forklift accidents and how to prevent them is important for maintaining a safe work environment.

• Create designated pedestrian zones with clear markings, barriers, and signs.
• Require operators to use horns when approaching intersections or blind spots.
• Use high-visibility clothing to help workers stand out in active areas.
• Provide regular training on safe forklift operation and pedestrian awareness.

3. Falling Loads

A load can fall from the forklift’s tines or forks if not properly secured, leading to serious injuries or death.

• Make sure loads are balanced and properly stacked.
• Do not exceed the forklift’s rated load capacity.
• Keep loads low to the ground while moving, and use proper lifting techniques.
• Inspect the forklift regularly for any damage or issues that could affect load stability.

4. Improper Training of Operators

Operators who are untrained or lack proper instruction are more likely to cause accidents due to limited knowledge of safe operating practices, load handling, and equipment controls.

• Allow only trained and certified individuals to operate forklifts.
• Provide refresher training to keep operators current with safety requirements.
• Confirm that operators know how to handle different site conditions like wet floors, narrow aisles, and uneven surfaces.

5. Mechanical Failures

Forklifts, like any machinery, require regular maintenance. Mechanical failures, such as brake failures, steering malfunctions, or issues with the lifting mechanism, can lead to accidents.

• Perform regular inspections and maintenance on forklifts, focusing on brakes, tires, steering, and lifting mechanisms.
• Use a checklist for daily pre-operation forklift inspections.
• Assign repair tasks to trained maintenance personnel and complete them without delay.

6. Poor Visibility

Limited visibility, whether caused by the forklift’s design or a blocked view from large loads, may lead to collisions with pedestrians, other vehicles, or obstacles.

• Install rear-view cameras or additional mirrors to improve the operator’s visibility.
• Position loads to keep the operator’s view clear.
• Use proper lighting in dim areas and advise operators to drive carefully.

Online Forklift Safety Awareness Training by OSHA Training School

OSHA Training School offers an online Forklift Safety Awareness Training program. This self-paced course allows individuals to complete the training at their own convenience, with six months to complete. Upon completion, students will receive a printable certificate. Please note, this training is designed solely for safety awareness and does not include hands-on operation or certification for forklift operators.

Conclusion

Forklift accidents can lead to severe injuries, fatalities, and costly property damage. Understanding common accidents and taking preventive steps improves workplace safety. Regular training, proper maintenance, and strong safety protocols contribute to safer forklift operations, protecting both operators and workers on the ground.