What are the Most Common Causes of a Forklift Tip-Over?

Forklift tip-overs are among the most serious and potentially fatal accidents that can occur in warehouses and construction sites. Understanding the common causes of forklift tip-overs is crucial for maintaining a safe working environment and preventing accidents. 

That’s why we break down the four main reasons why a lift truck can tip over sideways, as well as other factors that can contribute to forklift instability.

Why Is Forklift Stability So Important?

Forklift stability is critical for safe operation. A stable forklift is less likely to tip over, reducing the risk of accidents, injuries, and fatalities. The stability of a forklift depends on its centre of gravity. This is the point where the weight of the forklift and its load are evenly distributed.

In turn, the forklift’s centre of gravity must remain within the stability triangle. This imaginary triangle is formed by the front wheels and the pivot point of the rear axle. If the centre of gravity shifts outside this triangle, the forklift becomes unstable and may tip over.

4 Reasons Why a Lift Truck Can Tip Over Sideways

1. The Forklift Is on Uneven Ground

Uneven ground is one of the most common causes of sideways forklift tip-overs. When an operator drives a forklift on an uneven surface, the wheels on one side may be raised off the ground. This can cause the forklift to become imbalanced and tip.

To avoid this:

• Always inspect the working area for uneven surfaces, potholes, or obstacles that can cause instability.
• Use forklifts with wider wheelbases or all-terrain capabilities when working on uneven ground.
• Consider renting or purchasing specialised equipment from a forklift specialist like TAG Forklift Trucks for challenging terrain.

2. The Forklift Turns Too Quickly

Turning too quickly or sharply can cause a forklift to tip over sideways. This is because rapid turns can shift the forklift’s centre of gravity outside the stability triangle.

To prevent this:

• Always maintain a safe speed when operating a forklift, especially when turning.
• Slow down before making turns, not during the turn.
• Avoid sudden changes in direction.

3. The Forklift Is Carrying an Off-Centre Load

Carrying an off-centre or unevenly distributed load can significantly increase the risk of a sideways tip-over. When a load is not centred on the forks, it can cause the forklift’s centre of gravity to shift to one side, potentially leading to instability.

To mitigate this risk:

• Always centre loads on the forks before lifting.
• Use appropriate forklift attachments to handle irregularly shaped loads safely.
• Never exceed the forklift’s rated capacity.

4. The Forklift Is Driving on a Slope

Driving on a slope, especially when the forklift is loaded, can cause a sideways tip-over if not done correctly. The incline can shift the forklift’s centre of gravity, potentially causing it to tip.

To avoid this:

• Always drive straight up or down slopes, never at an angle.
• Keep the load uphill when travelling on a slope.
• Don’t turn on a slope if possible.

What Other Factors Can Cause a Forklift to Tip Over?

While we’ve focused on sideways tip-overs, it’s important to note that forklifts can also tip over forwards or backwards. Here are some additional factors that can cause forklift instability:

Overloading the Forklift

Overloading a forklift is a common cause of tip-overs. When a forklift carries a load that exceeds its rated capacity, the centre of gravity can shift too far forward, resulting in a forward tip.

To prevent overloading:

• Always check the forklift’s load capacity before lifting.
• Use the correct forklift for the job.
• Ensure loads are within the forklift’s rated capacity.

Lifting Loads Too High

Yes, lifting loads too high can cause a forklift to tip over forwards or backwards. When a load is raised, it shifts the forklift’s centre of gravity upwards, making the forklift less stable.

To avoid this:

• Keep loads as low to the ground as possible when travelling.
• Only raise the load when necessary for stacking or unstacking.
• Ensure the mast is tilted back slightly when lifting.

Travelling with a Raised Load

Travelling with a raised load is a significant risk factor for forklift tip-overs. A raised load shifts the forklift’s centre of gravity upwards and forwards, making it more likely to tip over forwards or sideways.

To prevent this:

• Always lower the load before travelling.
• Keep the forks about 15-20 cm off the ground when moving.
• Tilt the mast back slightly to cradle the load.

Stopping or Starting Suddenly

Sudden stops or starts can cause the load to shift, potentially leading to a tip-over. The momentum of a sudden stop can cause the forklift’s centre of gravity to shift forwards, while a sudden start can cause it to shift backwards.

To avoid this:

• Accelerate and brake smoothly.
• Allow plenty of stopping distance.
• Be aware of the load’s weight and how it might shift during movement.

How Can Forklift Tip-Overs Be Prevented?

Preventing forklift tip-overs requires a combination of proper training, equipment maintenance, and safe operating procedures. Here are some key strategies:

1. Proper training – Before operating a forklift, it’s crucial that your workers receive comprehensive forklift operator training. TAG Forklift Trucks offers certified training programmes to ensure your operators are fully competent.
2. Regular maintenance – Keep your forklift in good working condition with regular servicing and maintenance. TAG Forklift Trucks provides professional servicing and repair services to keep your equipment running safely and efficiently.
3. Implement safe operating procedures – Develop and enforce safe operating procedures, including load handling guidelines, speed limits, and rules for operating on inclines.
4. Regular workplace inspections – Regularly inspect your workplace for potential hazards like uneven surfaces, obstacles, or areas with poor visibility.
5. Use appropriate attachments – Use forklift attachments designed for specific tasks to improve stability and safety. 

Putting Forklift Safety First

Understanding the common causes of forklift tip-overs is essential for maintaining a safe working environment. By being aware of the reasons why a lift truck can tip over sideways and other factors that can cause instability, operators can take steps to prevent accidents.

Finding Stability with TAG Forklift Trucks

At TAG Forklift Trucks, we’re committed to helping you maintain a safe and efficient operation. Whether you need forklift hire, servicing and repairs, or operator training, we’re here to support you.

Don’t let forklift tip-overs put your operation at risk. Contact TAG Forklift Trucks today to discuss how we can help improve your forklift safety and efficiency.