What Are the Most Common Forklift Accidents and How Can Training Prevent Them?

Forklifts are very useful pieces of equipment, but they can be used in a wide variety of applications, resulting in forklifts working side by side with pedestrian traffic and many different types of motor vehicles.

Therefore, if the correct safety measures and training for operating a forklift are not followed, accidents can occur. For example, one of the most important safety measures to implement would be to install polymer safety barriers.

Common Forklift Accident Reasons

The following is a list of the ten most frequently occurring forklift accidents:

1. Collision with Another Forklift

According to recent research, 75% of all forklift accidents result from poor design/layout of the workplace used by the forklifts (specifically as it relates to the segregation of vehicle traffic and pedestrian traffic).

As a consequence, collisions are much more likely, making this the most common cause of forklift accidents. The consequences of a collision between two or more forklifts can vary from serious injury to significant property damage to other people's property (buildings, stored products, etc.) or the equipment used to store the goods.

In order to avoid the likelihood of the forklifts and the pedestrians crossing paths, all workplaces should develop and enforce a clearly defined traffic plan that provides for separate, designated pathways for both vehicle and pedestrian traffic.

Likewise, even if a workplace has designated pedestrian and vehicle pathways, there will be times when the pedestrian and the forklift operator will be in close proximity to each other. Therefore, it is important to take both preventative and protective measures.

Some of the ways to make the forklift operators more visible when operating their equipment are to paint them in bright colors, provide the pedestrians with bright-colored vests, and use polymer safety barriers.

Using polymer safety barriers not only increases the visibility of pedestrians and forklifts to one another but will also provide protection to pedestrians, to the infrastructure of the building, and to other vehicle operators in case of an accident.

If you want to learn how to make your workplace safer, Safety Counseling offers forklift safety training every month. Click here to register for the next available training course.

2. Falling Load

If a forklift operator does not make the necessary maneuver required of the equipment appropriately or is forced to turn suddenly (to avoid colliding with another forklift or another obstacle), it is possible that the load could fall from the forks. Depending on the size of the load, there is a high probability the individual below will suffer injury or, in some instances, property damage.

3. Falling from Heights

Forklifts should not be used to hoist employees up to perform specific job duties. However, there are occasions when forklift operators do lift employees to perform their jobs. Employees should take precautions to avoid falling from the upper deck of the equipment. However, it will not always be possible to prevent the employee from falling.

Employee education is critical in training employees about the risk of falling off the forks of a forklift. Companies can provide either verbal instructions and/or safety meetings for employees to develop their knowledge of employee safety while using a forklift. In addition, having visible postings that outline the safety rules governing the operations of forklifts is very important. Another key element that will enhance employee safety while using forklifts is providing safety equipment that can be utilized by employees that will allow them to work safely above the ground.

4. Forklift Tipping Over (Lateral/Sideways)

A forklift can tip over laterally/sideways when it operates off of a slope or defective/uneven surface or through a sudden directional change from a straight path. The operator could potentially become either ejected outside of the forklift if he/she is not restrained by a seatbelt or pinned between the forklift and the ground or against a wall or another piece of equipment.

Many of the risks identified above could be eliminated through the usage of a capped speed limit that has been recognized and communicated throughout the workplace. However, it is possible that even though a speed limit has been established and communicated, some drivers will still exceed the speed limit (this is especially true when the driver is under pressure to arrive at his destination).

To ensure that forklift operators work within the defined speed limit, the operators should utilize a speed cap in their respective piece of equipment. This ensures that the operator can continue to complete their job safely and efficiently without compromising the safety of themselves or others.

Even better, additional safety equipment should be added to the operator’s cab other than simply a seat belt or safety bar. Seat belts will provide some protection to the operator, but as they are typically the least expensive type of restraint system, they provide the least amount of protection to those that utilize them.

There may be a temptation for the driver to loop the seat belt behind himself while he is operating the forklift, particularly if he is frequently getting out of his forklift..

This belt must be worn by the operator before entering the cab of the truck, it is located in front of the cab entrance and has to be worn before entering. Brace doors also help protect the cab from damage in the event of an accident. The swing door works on the same principle as a brace door, but it is opened by pressing upward instead of pulling and allows easy access for the driver when entering or exiting the forklift within a small area.

A fully enclosed cab is the safest way to operate a forklift. It protects the driver from weather conditions, debris, and dirt. Also, it reduces the risk of being crushed if the operator operates with the cab closed while driving the forklift.

5. Reducing the Risk of Tipping Over

Forklifts can tip if the operator overloads or lifts an improperly loaded item, endangering the operator and others nearby and causing damage to the building, the truck and the load.

It is important for an operator to know what the maximum capacity of the forklift is before operating and how to load it properly, as improper loading on the forks or not properly balancing the goods on the forks may cause the forklift to tip over, even if the rating is below maximum.

6. PIN

An operator can become pinned by the forklift when operating it. An operator can become pinned if they put a hand or foot too close to the truck, and it will pin them between a chain, fork, or another item. Also, when a bystander stands too close to the truck side while the truck is moving.

A forklift needs enough space to operate, and narrow aisles should not be used to force the forklift through. Aisles should have proper lighting and safety zones using floor markings or physical barriers, and an operator should advise employees against touching a forklift even if it is not in use. An operator must always keep their arms and legs inside the cab when operating.

7. Risk of Injury

There is always a risk of injury when operating a forklift, and as operators gain experience with their daily operations, they may be less careful when entering and leaving the forklift. Depending on the distance between the cab and the ground, an injury could occur from tripping while exiting the forklift.

The best way to prevent these types of injuries is quite simple; pay attention to what you are doing. Be careful getting off the forklift after use. Use the same method to exit a forklift as if you were climbing down a ladder; face away from the direction of the exit. This will help avoid image sprains to an operator.

8. Safety and Awareness of Potential Equipment Failure

Forklifts are both mechanical and electrical, and therefore can experience malfunctions, such as forks falling off or losing brakes, etc.

It is therefore important to have your forklift inspected on a regular basis and to check internal circuits before operating or performing any function on the forklift as part of the forklift inspection.

9. Forklift Accidents on Platforms

Many forklifts in warehouses are used on raised platforms. As a result, accidents can occur due to the condition of the platform itself (i.e., the platform could collapse) or the truck could fall off the platform.

Extra safety barriers should be installed on elevated platforms to prevent the forklift from falling off the platform. Heavy-duty kick rails with handrails or permanent safety barriers with handrails offer the most protection. Also, do not place any obstacles in the path or on the platform that would obstruct a driver's safe exit from the platform.

10. Forklift Accidents While Parked

Incidents may also occur when forklifts are parked. If an operator were to misjudge the direction they are turning, the operator can cause the forklift to collide with the building or even worse, cause an accident with another person.

All parking zones must have floor markings to indicate where to park a forklift, and to the left or right of the operator, kick rails or post must be used on the walls to prevent damage during an impact.

Final Recommendations for Forklift Safety and Accident Prevention

Following safety training and protocols is the best method to prevent forklift accidents and injuries. OSHA forklift training classes offered in New Mexico are held once a month by Safety Counselling. Please visit their website here to locate the next class to sign-up.