15 Most Common Forklift Accidents and How to Prevent Them

Forklifts are essential in warehouses and industrial sites, but they come with risks. Understanding the most common forklift accidents can help prevent injuries and save lives. Let’s break down the top 15 forklift accidents and explore how to mitigate them.

The Top 15 Most Common Forklift Accidents

1. Forklift rollovers or tip-overs – Account for 24% of all forklift accidents. [1][9]
2. Pedestrian collisions – Represent 20% of forklift accidents. [1][3]
3. Crushing a pedestrian against a stationary object – Causes 25% of recorded forklift injuries. [1]
4. Striking or running over a pedestrian – Makes up 11% of injuries. [1]
5. Crushing a pedestrian between two vehicles – Also 11% of injuries. [1]
6. Falling loads or cargo loss – Common in poorly secured operations. [7][9]
7. Operator falling from forklift – Happens due to lack of safety equipment or improper behavior. [3]
8. Knocking over equipment or shelving – Disrupts operations and risks injury. [3]
9. Collisions with other vehicles or structures – Often occur in crowded areas. [5]
10. Falling from height – Dangerous for operators and bystanders. [5]
11. Tipping over sideways – Results from sharp turns or improper load balance. [5]
12. Injury while entering or exiting the forklift – Accounts for 4% of accidents. [5]
13. Technical or mechanical failure – Involves 3% of forklift accidents. [5][9]
14. Accidents due to improper maintenance – A preventable cause of many mishaps. [2]
15. Accidents caused by unsecured loads – Leads to falling cargo and workplace hazards. [2]

Prevention Measures

1. OSHA-standard training and certification – Equip operators with proper knowledge and skills. [2]
2. Establish clear traffic plans – Separate paths for vehicles and pedestrians to minimize collisions. [5]
3. Ensure proper load securing and weight distribution – Prevent falling loads and tip-overs. [2]
4. Regular forklift maintenance and pre-operation checks – Identify and fix mechanical issues early. [2][5]
5. Enforce speed limits and proper operating procedures – Reduce risks of rollovers and collisions. [4]
6. Use safety equipment – Seatbelts and proper mounting techniques can prevent operator injuries. [5]
7. Improve workplace layout – Eliminate blind spots and potential collision areas. [1][4]

Conclusion

By understanding the causes of forklift accidents and implementing effective safety measures, companies can create safer workplaces and protect both operators and pedestrians. Prioritize safety to reduce injuries and maintain productivity.

Sources

• [1] https://www.osha.com/blog/5-most-common-forklift-accidents-and-how-to-prevent-them
• [2] https://www.linkedin.com/pulse/forklift-safety-12-hazards-solutions-safer-warehouse-joel-norris
• [3] https://www.creativesafetysupply.com/qa/forklift-safety/what-are-the-most-common-forklift-accidents
• [4] https://www.irp.net.au/common-forklift-hazards
• [5] https://www.boplan.com/en-uk/knowledge-hub/10-most-common-forklift-accidents
• [6] https://www.mccue.com/blog/forklift-accident-statistics
• [7] https://www.friedmansimon.com/faqs/most-common-forklift-injuries/
• [8] https://warehousewiz.com/blogs/news/forklift-accident-statistics-canada
• [9] https://www.fluxpower.com/blog/the-top-5-forklift-accidents-and-why-they-happen