When forklift accidents happen, they usually aren’t unpredictable circumstances. In fact, there are often repeated patterns that happen on the job site, resulting in some of the most common forklift accidents that cause serious injuries and/or damage to the loads.
It’s estimated that 70% of forklift accidents could have been prevented with proper training, equipment maintenance, and operator behavior. Instead of wishing for luck and hoping that nothing happens, your team needs to be proactive about the best safety protocols to reduce the likelihood of an accident.
The 10 Most Common Forklift Accidents
These are the most common causes of forklift accidents, which every operator needs to understand in order to proactively avoid these issues:
- Tip-Overs: The forklift falls over and rolls onto its side or front. Tip-overs are typically caused when the operator turns too sharply, the forklift is overloaded, or it is being used on uneven ground surfaces.
- Pedestrian Accidents: A worker is walking in the area and is hit by the forklift. These types of collisions usually happen in the forklift’s blind spots or intersections. The risk is much higher in areas without proper traffic separation.
- Falling from the Forks: A worker is lifted by climbing on the forks instead of using an approved platform, then falls while the forks are at height.
- Load Falling on a Worker: If the load is improperly secured, stacked, or overloaded, then the materials can shift and fall from the forks or racking. Workers below can be seriously injured by the falling load.
- Collisions with Racking or Structures: The forklift runs into shelving, doorframes, or building structures. Not only does the collision cause damage to the forklift and/or rack or structure, but it can also result in more danger if the racking collapses from the impact.
- Falls from Loading Docks: The operator accidentally drives the forklift off an unguarded dock edge. Or, a fall from the loading dock can occur when the forklift goes through a gap between the dock and trailer.
- Crushing Injuries: A worker is getting on or off the forklift and is pinned between the forklift and a structure, rack, or other object. Another cause of a crushing injury is when the forklift rolls because the parking brake wasn’t properly set.
- Overhead Obstruction Collisions: The mast or raised load hits an obstruction above the forklift, such as overhead pipes, sprinklers, wiring, or low clearances.
- Rear-End and Intersection Collisions: Two forklifts, or a forklift and another vehicle, run into each other. This can be caused by limited visibility or failure to use horns/mirrors when moving around blind corners.
- Fuel or Battery-Related Incidents: Various factors can cause fires, explosions, or chemical exposure. The risk increases with improper refueling or charging practices or damage to the propane/battery systems.
Common Causes of Forklift Accidents: Safety Factors That Prevent Accidents
Human error is often the root cause of forklift accidents. Even the smallest mistakes can turn into a devastating accident, which is why operators and loaders need to be highly trained in forklift safety and the nuances of the different types of equipment they are using.
Some of the most common types of human error include:
- Training gaps
- Operator fatigue
- Distracted driving
- Speeding
- Overloading the forklift
Additionally, equipment factors can increase the likelihood of forklift accidents. For example, if the forklift is poorly maintained or being operated with worn components, then the risk of an accident increases.
Finally, consider how environmental factors play a role in forklift safety. The facility layout and limited lighting matter for safety. Also consider how the traffic flow patterns are set up. Ideally, foot traffic and vehicles should be separated, with designated areas for each.
Forklift Safety Tips: How to Prevent Forklift Accidents
Follow these best practices to reduce the risk of forklift accidents in your workplace:
- Training: Every operator should be well trained, including the initial training when they start the job and ongoing training to keep all operators up to date. Each operator should have proper certifications and credentials for the type of equipment being used.
- Pre-Shift Inspections: Before the forklift is used, it must be inspected. This checklist helps to identify any mechanical issues that need to be addressed. Proactive inspections reduce the likelihood of equipment failure that can cause serious injuries.
- Load Management: Capacity limits must always be respected. Loads should be within the rated capacity limit, based on the type of forklift and the attachments that are being used. Proper management of the loads will help to reduce the risk of tip-overs.
- Traffic Management: When the spaces are shared with multiple vehicles and/or pedestrians, the risk of injury increases dramatically. Make sure that pedestrians have dedicated walking areas where the forklifts are not operating.
- Maintenance and Repairs: Stay consistent with regular maintenance, including quality tires for the forklift. Preventing equipment failure is an important step to reducing the risk of accidents.
- Safety Culture: The way management talks about safety and leads the group will have a direct influence on operator behavior. Infuse a strong safety culture that starts with clear leadership to ensure that all safety practices are maintained and respected every step of the way.
FAQs
What is the most common cause of forklift accidents?
Most forklift accidents happen because of human factors such as insufficient training, operator fatigue, and unsafe handling. Other factors can increase the risk of forklift accidents, such as equipment failure or environmental issues.
What are 7 hazards in a forklift operating area?
The most common hazards in areas where forklifts are being used include blind corners, uneven surfaces, pedestrian traffic, poor lighting, wet floors, overhead obstructions, and congested aisles.
The Best Forklift Safety Practices for Your Fleet
At BullDog Forklifts, our team is here to help you implement the best safety practices to protect your crew. Not only will we help you choose the ideal equipment based on your unique needs, but we also offer ongoing maintenance and servicing to ensure that your forklifts are in the best condition possible.
Quality equipment and safety practices are investments that you won’t regret. For more information about forklift rentals, maintenance, sales, and more, reach out to our team at BullDog Forklifts. Contact us for personalized recommendations.