Forklift trucks have proved to be an invaluable part of reducing worker load by assisting in the transport of materials across the workplace. The use of forklifts has helped reduce common musculoskeletal injuries that are caused by repetitive lifting and carrying activities.  Unfortunately, improperly maintained or operated forklifts cause a large number of accidents in the workplace.

According to OSHA estimates, approximately 680,400 forklift accidents take place each year. These result in injuries to approximately 9,000 employees, most of whom are pedestrian workers.

Common Forklift Accidents

• Employees struck by falling load
• Employees struck by powered forklifts
• Forklift tip over
• Electrocutions
• Falls from forklift

Causes of Forklift Accidents

Many times, forklift accidents take place because of improper design of the workplace. Narrow aisles, blind spots, presence of building columns, poor turning radius, intersection or door obstructions, the presence of ramps, and the condition of the loading dock can all contribute to an inefficient and unsafe workplace that can lead to forklift accidents.

A forklift load may be too heavy or may be unstable or obstruct vision, creating conditions for a forklift accident. The forklift truck itself may be in poor condition because of inadequate maintenance.  Mechanical failures like malfunctioning brakes and clutch can create unsafe driving conditions for the forklift operator and can endanger other workers where it is operating.

Without adequate training in safe forklift operation, a forklift operator may adopt poor techniques like dangerous turning and backing methods, improper parking, and failure to warn others about the presence of the forklift nearby. Miscommunication between operators and pedestrian workers while a forklift is in operation, can often lead to collisions.

Prevention of Forklift Accidents

• Any safety devices on the forklift must be sufficient and properly functioning, and controls and displays must be well laid out and visible.
• The forklift must include all extra tools and accessories that are necessary for safe operation.
• The assignment of forklift operators should be done in a diligent manner to ensure that all forklifts are handled only by trained operators.
• Employee training is the most important factor in the prevention of forklift accidents. Many accidents can be prevented if OSHA requirements related to forklift operation are followed religiously. These include checking fluid levels, and for leaks, and the condition of tires before operation. After a pre-operation inspection, the operator must undertake a complete inspection while the engine is running, checking the condition of the brakes, lights, horn and back up alarms.
• While the forklift is in operation, the operator must look for signs of potential dangers, like sparks and flames, over heating and leakage.
• Any defects must be repaired before the forklift is put into operation again.
• Employers must undertake preventive maintenance of the forklift in accordance with the recommendations of the manufacturer.
• The workplace must be kept free of obstructions that impact visibility, or affect the safe and smooth operation of the forklift.