Forklifts are essential tools in warehouses, factories, and construction sites—but they can also be dangerous if not handled properly. According to recent data, around 20,000 forklift-related injuries occur in the U.S. every year. Even more concerning, many of these accidents are fatal.
Whether you’re a warehouse owner, supervisor, or operator, safety must come first. The good news? Most forklift accidents are completely preventable—if you know what to look out for.
In this guide, we’ll cover five of the most common forklift accidents and give you practical tips to prevent them.
1. Forklift Overturns: The #1 Cause of Fatalities
Forklift overturns are the leading cause of forklift-related deaths. These typically happen due to:
Driving too fast
Turning too sharply
Uneven surfaces
Inclines
Malfunctioning parts
Unbalanced or top-heavy loads
✅ How to Prevent Overturns:
Drive slowly, especially when turning or on inclines
Keep the load low and centered while moving
Only raise/lower loads when the forklift is stationary
Always wear a seatbelt
In case of a tip-over, stay in the cabin—do not try to jump out
Invest in forklifts with functioning safety features and always check before use
2. Inattentive Operation: Distraction Equals Danger
Forklift operators need to be alert at all times. Distractions, fatigue, or even overconfidence can lead to costly or fatal accidents.
✅ How to Keep Operators Focused:
Use shift rotations to avoid fatigue
Encourage frequent breaks
Promote proper hydration and nutrition
Avoid phone use or other distractions while operating machinery
3. Loads Falling on Operators
While forklifts come with overhead guards, they are not indestructible. A heavy load that isn’t properly secured can break through and cause serious injuries.
✅ Safety Tips:
Inspect forks and ensure they are evenly spaced
Use a load extension backrest
Maintain at least 6 inches of clearance between the load and any racking
Always inspect the overhead guard for cracks or damage during pre-checks
Be aware of low-hanging fixtures like lights or pipes
4. Lack of Forklift Training
Untrained or poorly trained operators are one of the biggest safety risks in any warehouse.
✅ What You Can Do:
Ensure all forklift drivers complete OSHA-certified training
Provide regular refresher courses
Train pedestrians working near forklifts on safety awareness
Make training mandatory before operating any forklift
5. Poorly Balanced or Overloaded Forklifts
Carrying more than the forklift’s rated capacity can cause it to tip over—or worse, spill the load on someone nearby.
✅ Prevent Load-Related Incidents:
Never exceed the load capacity listed on the forklift’s data plate
Know your lift height, load center, and how attachments may affect balance
Inspect pallets and loads to ensure they are stable and properly secured
Place heavier items at the bottom of the stack
Final Thoughts: Safety is a Daily Practice
Even with proper training, accidents can still happen. But taking consistent preventive steps greatly reduces the risk.
Conduct daily pre-operation inspections
Schedule regular maintenance checks
Don’t ignore warning signs—fix any issues before putting a forklift to work
Remember: a safe warehouse is a productive warehouse. Investing time and resources into forklift safety isn’t just smart—it can save lives.
🙋♂️ Frequently Asked Questions (FAQs)
Q1: What is the most common type of forklift accident?
The most common—and deadly—forklift accident is overturning, usually caused by speeding, uneven loads, or sharp turns.
Q2: Do forklift operators need special training?
Yes. Operators must complete OSHA-approved forklift training to legally and safely operate lift trucks.
Q3: How often should forklifts be inspected?
Forklifts should undergo a pre-operation inspection every day before use, and routine maintenance should be done monthly or as recommended by the manufacturer.
Q4: Can pedestrians be injured in forklift accidents?
Absolutely. Pedestrians working near forklifts are at high risk, especially if the operator is inattentive or if the load is unstable.
Q5: What’s the best way to avoid forklift tip-overs?
Stick to safe speeds, avoid sharp turns, never overload, and always keep the load low and balanced.
