Industrial and warehouse settings are incomplete without the presence of forklifts. These machines are extremely necessary for moving heavy loads from one place to another.

As awesome as forklifts are at making our lives easier, they're not exactly gentle giants. Forklift accidents can be severe, leading to injuries, fatalities, and costly damages.

Imagine you're busy navigating a warehouse, focusing on your tasks, when suddenly a forklift veers into your path. Suddenly your day goes from productive to painful. It’s a harsh reality that many workers face, but with the right precautions, it’s entirely preventable.

This is why forklift safety should be a top priority in any workplace where these machines are used.

Pro Tip: Looking to improve forklift safety in your workplace? Download our free Transportation and Logistics Industry Guide, which gives a comprehensive overview of workplace health and safety requirements unique to your industry.

What is Forklift Safety? 

Forklift safety is all about implementing practices and protocols that can reduce the risks of forklift operations. These practices are important for preventing workplace accidents that could lead to injuries or even forklift fatalities. 

Forklift safety helps ensure that every worker, whether operating lift trucks, electric forklifts, or working nearby, goes home safely at the end of the day. 

Common Forklift Hazards and How to Avoid Them

1. The "Just One More Box" Syndrome (AKA Overloading)

We get it. That "just one more box" temptation is real. But here's the deal: forklifts aren't magical. They have weight limits for a reason. Ignore those limits, and you might find your forklift doing an unplanned impression of the Leaning Tower of Pisa.

When this happens, it’s not just the operator whose life is in danger but also nearby pedestrians who are at risk. 

Make it a rule to always check the forklift’s lifting capacity before lifting. Distribute the load evenly, and if it is tall or bulky, double-check that it doesn’t block the operator’s view. 

Pro Tip: Use additional correct equipment like forklift safety cages if necessary to secure the load. 

2. The "I Got This" Attitude (AKA Inadequate Training)

Improper forklift training is not just a contributor but one of the leading causes of forklift-related accidents in the workplace. According to the Occupational Safety & Health Administration (OSHA), approximately 70% of forklift accidents could be prevented with stricter training protocols. This statistic makes it clear that comprehensive training programs that go beyond just the basics of operating a forklift are important.

Effective forklift training should cover more than just operational mechanics—it needs to focus on hazard awareness, proper load handling, and navigating specific workplace environments. For instance, operators must be able to assess risk factors like uneven surfaces or pedestrian traffic. 

Pro Tip: Incorporating refresher courses annually ensures that operators stay updated on safety protocols and can adapt to any new risks that arise in their workplace.

3. The "It'll Be Fine" Mentality (AKA Poor Maintenance)

Forklifts are like any other machine – they need some TLC to keep running smoothly. Neglecting maintenance is like ignoring that weird noise your car makes. Sure, it might be fine... until it's really, really not.

Neglecting maintenance can lead to mechanical failures, and that’s only just the beginning. 

You should perform machinery pre-starts regularly as they help in addressing issues immediately. Regular professional servicing can also help in keeping the forklift in good working order. 

4. The "Didn't See You There" Scenario (AKA Pedestrian Collisions)

Forklifts and pedestrians mix about as well as oil and water. To avoid turning your warehouse into a real-life game of Frogger, communication is key.

Use warning signals like lights and horns when operating forklifts in areas where pedestrians are present. Additionally, train workers on both sides—operators and pedestrians—about the importance of being aware of each other’s presence to avoid any risk of accidents. 

5. The "What Blind Spot?" Problem

Forklifts have blind spots that can make it difficult for operators to see what’s around them, especially when carrying large loads. This can lead to collisions with objects, other vehicles, or people. 

Erase these blind spots, and encourage operators to use mirrors and other aids to improve visibility. Implement the use of spotters in areas where visibility is limited and instruct operators to drive slowly because it is better to arrive safely than quickly.

Forklift Safety Training: Essential Skills and Knowledge

Do not make the mistake of handing over the keys to a new operator and hoping for the best. 

Your forklift operators must be well-trained and aware of how to use the forklift safely. 

Key Areas of Forklift Safety Training

1. Understanding Forklift Controls: Operators must be thoroughly familiar with all controls and functions of the forklift. This includes knowing how to start, steer, and stop the machine, as well as how to control the forks and mast.
2. Safe Load Handling: Operators need to know the correct techniques for picking up, carrying, and placing loads. This includes understanding how to balance loads and avoid overloading the forklift.
3. Awareness of Surroundings: A good operator is always aware of their surroundings. This includes knowing the layout of the workspace, being aware of other workers, and foreseeing potential hazards.
4. Emergency Procedures: Operators must be trained in what to do in an emergency, such as if the forklift tips over or if there is a fire. This training can be the difference between a minor incident and a major accident.

Daily Forklift Inspection Checklist

Daily inspections are an important part of forklift safety. Before each shift, operators should perform a thorough inspection to ensure the forklift is in good working condition. This prevents accidents caused by mechanical failures and ensures industrial safety. 

Your Daily Forklift Inspection Checklist

• Check Fluid Levels: Make sure that fuel, oil, and hydraulic fluids are at the correct levels. Low fluid levels can lead to mechanical failures.
• Inspect Tires: Look for signs of wear, damage, or low pressure. Damaged tires can affect the stability of the forklift.
• Test Brakes and Steering: Make sure that both the brakes and steering are functioning properly. These are important for maintaining control of the forklift.
• Examine the Mast and Forks: Check that the mast is operating smoothly and that the forks are not damaged. Any issues here could lead to load instability.
• Verify Lights and Alarms: Make sure that all lights and alarms are working. These are important for visibility and for warning others of the forklift’s presence.

Performing these daily checks guarantees that the forklift is safe to use and also helps in identifying potential issues before they become serious problems. Check out our EHS Audit Checklist.

Real-Life Forklift Fails: Case Studies about Forklift Accidents

Learning from past accidents is one of the best ways to improve forklift safety. Here are a few case studies that highlight the importance of following safety protocols:

“Seatbelt? What seatbelt?” OSHA reports a Forklift incident in this report:

In 2013, a 27-year-old employee at Kockenbagner Brewing Co., DBA Stone Brewery, was killed after being ejected from his forklift. The employee was not wearing a seatbelt, which led to his fatal injury when the forklift tipped over after hitting a concrete bollard. The incident emphasizes the importance of using operator restraint systems to prevent such accidents​.

“I didn’t see it coming.” Another incident reported by OSHA in this report:

A forklift operator at Frito-Lay was killed after being crushed between a manually operated forklift and an automatically guided vehicle (AGV) in 2008. The AGV's collision avoidance system failed to detect the older manual forklift, and the employee had not set a safety cone that might have helped avoid the accident​.

Key Takeaways

Forklifts are an essential part of many industrial and warehouse operations, but without proper safety measures, they can turn into serious hazards. From ensuring operators are well-trained to maintaining equipment and implementing daily safety checks, every step matters when it comes to preventing accidents.

Want to take your forklift safety efforts to the next level? Get in touch with us at SafetyIQ for a detailed overview of best practices, safety requirements, and more tips to keep your workplace accident-free.

Frequently Asked Questions