Common Forklift Accidents and How to Prevent Them

Forklifts are essential in warehouses, construction sites, and logistics centres, but they also pose significant safety risks if not operated correctly. Every year, workplace incidents involving forklifts result in injuries, damage to goods, and operational downtime.

Understanding common forklift accidents and how to prevent them is crucial for maintaining a safe and productive work environment.

Forklift Tip-Overs

A forklift can tip over due to improper loading, excessive speed, or unstable surfaces. These incidents are not only dangerous for the operator but can also cause severe damage to inventory and equipment. Prevention Tips:

• Always ensure loads are evenly distributed and within the forklift’s capacity.
• Drive at a controlled speed, especially when turning or navigating slopes.
• Avoid sudden braking or accelerating, as this can destabilise the machine.

Pedestrian Collisions

One of the most serious forklift-related accidents involves collisions with pedestrians. Poor visibility, blind spots, and lack of awareness contribute to these incidents. Prevention Tips:

• Implement a forklift collision avoidance system to detect pedestrians and improve situational awareness.
• Clearly mark pedestrian walkways and restrict forklift access in high-foot-traffic areas.
• Train operators to use horns at intersections and maintain a clear line of sight.

Load Falling Incidents

Incorrectly secured or imbalanced loads can shift and fall, posing a hazard to both operators and bystanders. Prevention Tips:

• Ensure all loads are stacked correctly and do not exceed the forklift’s weight limit.
• Use load stabilisation tools such as straps and racks where necessary.
• Train operators on proper load handling techniques to reduce the risk of shifting or falling items.

Forklift Crashes

Collisions between forklifts or between forklifts and stationary objects are common, often caused by reckless driving, obstructed views, or lack of communication. Prevention Tips:

• Install mirrors and barriers to enhance visibility in busy areas.
• Enforce strict speed limits and operational guidelines within the workplace.
• Use technology such as proximity sensors and cameras to assist drivers in avoiding crashes.

Improper Forklift Operation

Many accidents occur due to insufficient operator training, leading to misuse of the equipment or failure to follow safety procedures. Prevention Tips:

• Ensure all forklift operators are properly trained and certified.
• Conduct regular refresher courses to reinforce safety practices.
• Encourage a culture of accountability where unsafe behaviour is reported and corrected.

Creating a Safer Workplace

Reducing forklift-related accidents requires a combination of proper training, the right technology, and a commitment to workplace safety. By implementing preventive measures and investing in safety systems like pedestrian detection and collision avoidance technologies, businesses can significantly reduce risks and improve overall efficiency.

Prioritising forklift safety not only protects employees but also enhances productivity and minimises costly disruptions. A proactive approach to risk management ensures that forklifts remain valuable assets rather than workplace hazards.