Forklifts are essential for moving heavy loads efficiently across warehouses and industrial sites. Yet these powerful machines are also responsible for significant workplace accidents. In the UK, lift truck mishaps account for a quarter of all workplace transport-related harm, on average.
Understanding the leading accident types is the first step to instilling workplace safety, where you can help prevent forklift injuries. We’ll unpack the common causes of forklift accidents and provide practical forklift safety advice.
The 10 Most Common Forklift Accidents
To prevent accidents related to workplace forklift trucks, it’s most helpful to understand what each type involves.
1. Tip-Overs and Rollovers
Rollovers are one of the most common – and dangerous – types of accidents with forklift operation. When a forklift tips onto its side, operators risk being crushed beneath the weight of the machine. Typical causes include:
- Excessive speed around corners
- Carrying unbalanced loads
- Uneven surfaces
- Sudden braking
How to prevent: Enforce clear speed limits and safety measures throughout your site. For your forklift drivers, help establish proper training to keep loads low whilst travelling and always use seatbelts.
2. Forklift Collisions With Pedestrians
Poor workplace layout and inadequate space between vehicles and pedestrians create serious risks. In the food and drinks factories alone, there are over 200 injuries each year due to this. Large loads can completely block an operator’s line of sight, making it difficult to see nearby workers.
How to prevent: Create clear floor markings and pedestrian walkways to help prevent severe accidents. Physical barriers are also helpful to ensure your employees’ health and safety are considered effectively. Warning alarms on the forklifts can help alert nearby pedestrians, and ensuring all staff wear high-visibility clothing can help lessen the risk of collisions.
3. Falling Loads
Loads that fall from the fork can cause severe injuries, including crushed limbs and head trauma. This can occur when operators make sudden movements or fail to secure loads properly.
How to prevent: Appropriate forklift attachments can help secure difficult items. Additionally, operators should ensure the forks are fully inserted under the pallet before lifting. Proper safety gear, like hard hats, should also be required for anyone using or working near forklifts in your workplace. Fallen loads can also create hazards, so securing them through stringent safety measures helps reduce the likelihood of added obstacles.
4. Crushing and Entrapment
Workers can get trapped or crushed between the forklift machinery and fixed objects such as racking or walls. This includes operators getting their hands caught in the mast.
How to prevent: Ensure aisles are wide enough for safe manoeuvring, and make use of camera and audible alarms. All operators should keep their hands and feet inside the cab at all times.
5. Falls From Height
Some warehouses use forklifts to lift workers on platforms to access high shelving. This practice can be dangerous and lead to fatalities when not handled with proper caution.
How to prevent: Never use a forklift to lift personnel unless a properly designed work platform with safety barriers or guardrails is securely attached. For regular work at height, consider hiring dedicated access platforms instead.
6. Dismounting Injuries
Operators get in and out of forklifts dozens of times each day, whether at construction sites, warehouses, or loading docks. Rushing when dismounting can lead to slips, trips, and falls.
How to prevent: Always use the three-point contact rule when entering or exiting the cab. Even if you or a team member is in a hurry, avoid jumping from the forklift.
7. Mechanical Failures
Faulty steering, brakes, hydraulic leaks, and worn tyres can all cause serious injuries to the driver if an incident occurs.
How to prevent: Operators should carry out daily pre-use checks. Any defects must be reported immediately, and regular professional servicing is advised to catch problems early.
8. Overloading
Carrying loads that exceed the forklift’s rated capacity affects stability. When unstable, the machinery is more prone to tipping, which can lead to damage and harm.
How to prevent: Make sure anyone using the forklift is aware of the maximum weight capacity and doesn’t exceed it. When in doubt, try to split heavy loads into two trips.
9. Insufficient Observations
Failing to check the surroundings properly before moving can lead to colliding with pedestrians and other obstacles.
How to prevent: Operators should perform complete 360-degree checks before moving off. When approaching corners or areas with less visibility, sound the horn to alert any non-operators.
10. Speeding
Excessive speed increases stopping distance and destabilises the forklift. This raises the likelihood of collisions or tip-overs. Manufacturer information typically includes the maximum speeds your machine can travel. But this also depends on the layout and foot traffic of the operational area.
How to prevent: Within the work environment, post speed limits, and ensure they’re strictly enforced for safety.
The Importance of Training Programmes for Forklift Operators
Proper forklift training is one of the most effective ways to prevent accidents. As an employer, you need to make sure each team member who uses a forklift has the appropriate experience and training. Operators need to understand:
- Load capacity
- Stability principles
- Safe speed limits
Forklift refresher training is just as important as initial certification to maintain high safety standards.
Keep Your Workplace Safe With TAG Forklifts
Many forklift accidents are preventable with the right training, safety tips, equipment, and maintenance. When you incorporate safety checks and operator rules, you can protect your team and keep tasks running smoothly.
TAG Forklifts offers comprehensive forklift training courses covering safe operation and accident prevention. We also provide expert servicing and maintenance to keep your fleet in top condition. Whether you need new or used forklifts for hire or purchase, our team can help you find the right solution.
Contact our experienced team today to talk through your forklift and access equipment requirements.