Forklift Safety Matters: Learning from Past Incidents

Forklifts are essential tools in many workplaces, from warehouses to construction sites, but they also come with serious risks. In fact, past incidents have shown just how dangerous forklifts can be when safety isn’t prioritized. By looking at real examples from OSHA investigations, we can understand why proper forklift operation, training, and awareness are crucial. This blog dives into these forklift-related incidents, focusing on lessons we can learn to keep workers safe and prevent similar tragedies.

Employee Struck by Forklift – The Risks of Obstructed Views and Poor Awareness

One major cause of forklift-related fatalities is when workers are struck by moving forklifts. OSHA investigations from 1997 and 1998 highlight several incidents where employees lost their lives after being struck by forklifts. In many cases, these tragic events were preventable. Factors like obstructed views, improper parking, and lack of operator awareness all contributed to these incidents.

When a forklift operator’s view is blocked, they can’t see workers or obstacles in their path. This is especially risky in busy areas, where workers are frequently moving between shelves or pallet stacks. Proper forklift training emphasizes the importance of clear sightlines and the dangers of “blind spots.” Ensuring that operators park in designated areas and always maintain awareness of their surroundings can prevent these types of accidents.

Keeping workspaces organized and maintaining communication between workers and forklift operators are also essential safety steps. These practices reduce the chance of surprise encounters between workers on foot and moving forklifts, making a safer workplace for everyone.

Preventing Forklift Tipovers – The Importance of Speed Control and Seatbelt Use

Forklift tipovers are another leading cause of fatal accidents, with multiple incidents reported where operators were crushed or fatally injured. OSHA’s investigations found that forklifts often tipped over because of excessive speed, sharp turns, or operators not wearing seatbelts. Each of these factors can make a forklift unstable, especially when carrying heavy loads or navigating uneven surfaces.

Speed control is essential when operating a forklift. Unlike other vehicles, forklifts have a higher center of gravity, making them more prone to tipping over. Operators should be trained to drive slowly, especially when turning or moving up and down ramps. A sharp turn at high speeds can cause a forklift to lose stability and tip over, endangering the operator and anyone nearby.

Using seatbelts is another critical safety measure that saves lives. When a forklift does tip over, a seatbelt keeps the operator securely in place, preventing them from being thrown out or crushed. Enforcing strict seatbelt use policies and providing regular reminders can make a huge difference in reducing injuries and fatalities from forklift tipovers.

By keeping speeds low, avoiding sudden turns, and always wearing seatbelts, forklift operators can stay safe and reduce the risk of accidents. Simple changes like these help create a safer environment and keep every worker out of harm’s way.

Avoiding Falls from Forklift Platforms – The Dangers of Unsecured Lifting

Falls from forklift platforms are a serious hazard that can lead to severe injuries or even fatalities. OSHA’s investigations have documented incidents where workers were raised on unsecured pallets or makeshift platforms, leading to tragic falls. Forklifts are not designed to lift people, especially when using pallets or other unapproved equipment, making these setups incredibly risky.

When employees are lifted by forklifts on platforms not intended for safe standing, any sudden movement can cause them to lose balance and fall. A sudden shift or bump in the floor can cause the platform to tilt, and without proper fall protection, workers can easily fall from these heights. Proper forklift safety training emphasizes that only approved and secure man-lift platforms should be used when lifting workers, and all workers should be equipped with safety harnesses when elevated.

Employers and workers alike must recognize the dangers of using forklifts to lift workers improperly. Ensuring that only authorized equipment is used and following OSHA guidelines on fall protection are essential steps to keeping workers safe and avoiding deadly falls. Remember, a forklift is for lifting loads, not people, and safety should always come first.

Preventing Crush Accidents – Proper Operation and Awareness of Forklift Movements

Crush accidents are some of the most devastating forklift-related incidents. OSHA’s records include cases where employees were tragically crushed by forklifts, often due to improper operation or unexpected, sudden movements. Forklifts are powerful machines, and without careful handling, they can easily cause severe injuries to anyone in their path.

Proper forklift operation means more than just knowing how to drive; it’s about being aware of the surroundings and moving with caution. Operators must be vigilant to prevent sudden or unexpected movements, especially in crowded areas or narrow aisles. Poor communication, rushed movements, and failing to check blind spots often contribute to these dangerous situations. Ensuring that operators are well-trained on how to safely maneuver and stop the forklift can help prevent such tragic outcomes.

A key safety tip is for operators to always use their horn when reversing or turning in blind spots to alert nearby workers. Additionally, workers should be trained to maintain a safe distance from moving forklifts and to remain visible to the operator at all times. Establishing clear zones for pedestrian traffic and forklift operation can further reduce the risk of crush injuries, creating a safer environment for everyone on site.

By following these safety practices and maintaining constant awareness, crush accidents involving forklifts can be drastically reduced, making workplaces safer for everyone involved.

Protecting Workers from Falling Loads – Ensuring Secure and Stable Forklift Loads

Another serious hazard in forklift operations is the risk of loads toppling off and striking nearby workers. OSHA investigations have documented fatalities where improperly secured loads fell from forklifts, causing fatal injuries to those nearby. These incidents highlight the importance of proper load handling and securing practices to prevent tragic accidents.

One of the most important forklift safety measures is to make sure that loads are balanced and securely fastened before moving. Overloading or stacking items too high on the forks can make the load unstable, increasing the chances of tipping or falling off. Forklift operators should also ensure that heavy items are placed at the bottom of the stack and lighter items on top to help maintain a stable center of gravity.

Operating at slow speeds, especially when turning or moving on uneven surfaces, also helps prevent loads from shifting or falling. Workers on foot should be trained to keep a safe distance from moving forklifts and to stay clear of the forklift’s path. For operators, using pallet straps, stretch wrap, or other securing tools can add extra stability, especially when moving bulky or irregularly shaped items.

By ensuring that loads are stable and properly secured, forklift operators can prevent these deadly incidents, creating a safer work environment for everyone. Taking these extra precautions with load handling not only protects workers but also helps maintain efficient and safe operations.

The Dangers of Riding on Forklift Loads – Why Forks Are Not for Lifting People

A particularly dangerous and often misunderstood forklift practice is allowing workers to ride on the forks or loads being lifted. OSHA reports have shown tragic results from such unsafe practices, including one incident where two employees were standing on a load lifted by a forklift and an overhead crane. When the load shifted, both men were thrown 23 feet to the ground, resulting in serious injury for one and a fatality for the other. This incident underscores why forklifts should never be used to lift workers on unsecured loads.

Forklift forks and loads are not designed for standing or lifting people. Any slight shift or imbalance can cause the load to slip or fall, putting anyone riding on it at serious risk. Additionally, using a crane in combination with a forklift can introduce additional instability, making the entire setup even more hazardous. Proper forklift safety guidelines strictly prohibit standing on forks or loads, as they lack the necessary safety features to prevent falls.

To prevent such incidents, workplaces must ensure that forklifts are used only as intended: to lift materials, not people. If lifting workers is necessary, approved personnel lifts or man-lift platforms with secure guardrails and fall protection must be used. This simple rule could save lives, making it clear that safety always comes first when using forklifts.

Preventing “Struck By” Accidents – The Importance of Clear Visibility and Awareness

One of the common risks in forklift operations is the danger of workers being struck by moving forklifts, especially when the operator’s view is obstructed by a load. In one OSHA-reported incident, a forklift operator was driving forward with a load on the forks that blocked his view, leading to a tragic accident where a nearby employee was struck and injured. This highlights a crucial safety practice: always maintaining clear visibility when operating a forklift.

When loads obstruct the operator’s forward view, the safest practice is to drive in reverse whenever possible, as this allows a clear view of the path ahead. Forklift operators should be trained to assess the load size and, if visibility is compromised, either use a spotter or reverse to maintain awareness of their surroundings.

Another key safety measure is creating designated pedestrian paths that are well-separated from forklift operation zones. When workers and forklifts share close quarters, ensuring proper communication, awareness, and separation can drastically reduce the risk of accidental impacts. Operators should also use their horn to alert nearby workers whenever approaching blind corners or intersections.

By prioritizing visibility and awareness, companies can significantly reduce “struck by” incidents and create a safer work environment for both forklift operators and nearby workers.

Forklift Tipovers on Ramps – The Critical Role of Seatbelt Use and Proper Technique

Operating a forklift on a ramp presents unique risks, as even unloaded forklifts can tip over if not handled with care. OSHA reports include a tragic incident where a forklift tipped on a 13% slope, leading the operator to attempt jumping clear. Unfortunately, the forklift’s Roll Over Protection (ROP) crushed the operator, who was not wearing his seatbelt, resulting in a fatality. This heartbreaking event emphasizes the importance of seatbelt use and correct driving methods when on a slope.

Seatbelts are essential safety features on forklifts. In a tipover, a seatbelt keeps the operator securely in the seat, within the ROP zone, reducing the chance of being crushed. Without a seatbelt, attempting to jump from a tipping forklift can lead to serious or fatal injuries, as seen in this case. Ensuring that all operators wear their seatbelts at all times, even when driving unloaded, is crucial for forklift safety.

When driving on a ramp, operators should keep the forklift facing uphill, regardless of whether they are going up or down. This means backing down a slope to maintain stability and prevent tipping. Lowering the forks and reducing speed can also help stabilize the forklift, minimizing the risk of a tipover.

By enforcing seatbelt use, maintaining safe speeds, and following proper slope-handling techniques, employers can help protect operators and prevent tipover-related fatalities.

Avoiding “Struck By” Accidents Between Forklifts – The Need for Safe Spacing and Communication

Fatal accidents can occur not only between forklifts and pedestrians but also between multiple forklifts operating in the same area. In one tragic incident documented by OSHA, an operator of a stand-up forklift collided with a parked sit-down forklift due to insufficient spacing, limited visibility, and a slippery, water-covered floor. The combination of these factors led to a fatal injury for the operator of the stand-up forklift, underscoring the importance of safe spacing, communication, and environmental awareness in forklift operations.

One key rule for forklift safety is maintaining a minimum distance of three truck lengths between forklifts. This spacing allows adequate time for operators to react to sudden stops or changes in direction. In this case, the lack of required spacing left no room for maneuvering when the aisle was narrowed by other materials, creating a hazardous bottleneck. Proper spacing and clear communication between operators can help prevent such tragic incidents, especially in busy or crowded areas.

Another critical factor is environmental safety. Forklift operators should be aware of floor conditions, especially wet or slippery areas. Water from a leaking steam pipe in this incident contributed to reduced traction, increasing the risk of skidding and loss of control. Regular inspections and maintenance to address leaks, along with using signs or barriers to warn operators of hazards, can help prevent such conditions from turning deadly.

By enforcing safe distances between forklifts, encouraging clear communication, and ensuring clear, dry pathways, workplaces can minimize the risk of collisions and create a safer environment for all forklift operators.

Dangers of Improperly Towing Forklifts – Why Forklifts Are Not Designed for Towing

Forklifts are built for lifting and transporting loads over short distances—not for being towed. OSHA’s records include a tragic incident where a forklift tipped over while being towed, resulting in the operator’s fatality. In this case, the forklift was operational but was towed down a two-lane road at around 15 to 18 miles per hour to save time and shield the operator from cold weather. Unfortunately, the operator lost control, causing the forklift to veer into a ditch and flip, trapping the operator underneath. This incident highlights the critical risks of towing forklifts and the importance of proper transportation methods.

Unlike cars or trucks, forklifts are not equipped for road speeds or for being towed by other vehicles. Their high center of gravity and narrow wheelbase make them especially vulnerable to tipping when towed or driven at higher speeds. Furthermore, in this incident, the forklift lacked seatbelts, which could have kept the operator secure and reduced injury risks in the event of a tipover.

If a forklift needs to be transported over a distance, using a flatbed truck or trailer is the safest option. This method ensures that the forklift remains stable, protecting both the equipment and the operator. Additionally, regular training on forklift operation should emphasize that towing forklifts is extremely dangerous and should be avoided under all circumstances.

By recognizing the limits of forklifts and ensuring they are transported safely, employers and operators can prevent these types of tragic incidents and uphold safer working practices for all employees.

Risks of Improper Work Platforms – Why Only Approved Equipment Should Be Used for Elevated Work

Using makeshift platforms on forklifts for elevated work is a hazardous practice that has led to serious and fatal injuries. OSHA documented an incident in which a worker fell 17 feet from a forklift platform when standing on a wooden appliance pallet placed atop the squeeze clamps of a three-stage forklift. When the forklift operator began to lower the platform, the worker lost balance, falling headfirst onto the concrete below. This tragedy underscores the need for proper work platforms and fall protection when using forklifts for elevated tasks.

Forklifts are not designed to elevate workers using pallets, clamps, or other improvised setups. These makeshift platforms lack stability and necessary safety features, such as guardrails and secure footing, making falls a constant risk. Only approved man-lift platforms, equipped with guardrails and secure mounting points, should be used when workers need to be elevated by a forklift. These platforms are specifically designed to keep workers safe, reducing the risk of falls during elevation or lowering.

Furthermore, workers on elevated platforms should always wear proper fall protection, such as harnesses, when working at heights. Training forklift operators and workers on the hazards of makeshift platforms and enforcing the use of proper equipment are crucial steps in preventing falls and serious injuries.

By using approved equipment and adhering to safe practices, employers can significantly reduce the risk of falls and create a safer workplace for everyone involved in elevated tasks.

Forklift Tipovers on Ramps – Controlling Speed and Wearing Seatbelts

Driving a forklift on a ramp requires careful handling, as speed and sharp turns can easily cause a tipover. In one heartbreaking incident, an operator unfamiliar with a new forklift’s handling took a sharp turn at the bottom of a ramp at high speed, causing the forklift to overturn. Because the operator wasn’t wearing a seatbelt, he was thrown from the seat, and his head became trapped under the overhead protective cage, leading to a fatal injury. This incident highlights the dangers of quick turns on ramps and the critical importance of seatbelt use.

Forklifts, especially newer models, often have a quick response and tight turning radius that operators must adapt to gradually. When navigating ramps, reducing speed and avoiding sharp turns are essential for maintaining control and preventing tipovers. Taking turns too quickly or driving too fast on an incline increases the risk of instability, particularly if the operator is not familiar with the forklift’s handling.

Seatbelts are one of the most effective safety tools in preventing serious injuries during tipovers. A properly fastened seatbelt keeps the operator securely in the seat within the forklift’s protective frame, significantly reducing the risk of being thrown or trapped. Providing thorough training on each model’s unique handling features and reinforcing seatbelt use can prevent these tragic outcomes.

By emphasizing cautious driving on ramps and making seatbelt use mandatory, workplaces can reduce the risk of tipovers and keep forklift operators safe from life-threatening injuries.

Dangers of Using Unsecured Pallets as Work Platforms – Why Proper Equipment and Securing Methods Are Essential

Using pallets as makeshift work platforms on forklifts is a dangerous practice that can have fatal consequences. In one OSHA-documented case, an employee was pulling items from high storage racks while standing on a wooden pallet placed on the forks of a forklift. The pallet and worker were unsecured, and when the forklift made a sudden stop, the employee was thrown from the pallet and fell to the concrete floor, suffering fatal head injuries. This tragedy highlights the need for secure, approved platforms and the risks of using unsecured setups for elevated work.

Pallets are not designed to serve as work platforms and lack the necessary stability and safety features, such as guardrails and secure attachment points. Without these safety features, workers are at significant risk of falling if the forklift stops suddenly, shifts, or bumps into an obstacle. Approved man-lift platforms, designed specifically for elevating workers, come equipped with guardrails, proper footholds, and secure attachment mechanisms to the forks, ensuring a safer work environment.

In addition to using the correct platform, all elevated work requires securing both the platform and the worker. This includes using fall protection gear like harnesses and ensuring the platform itself is firmly locked to the forklift forks. Employees should be trained on the hazards of using unsecured pallets and instructed only to use OSHA-compliant equipment for elevated work.

By strictly enforcing the use of approved work platforms and requiring proper securing methods, employers can prevent falls and protect workers from fatal injuries, creating a safer and more compliant workplace for all.

Ladder and Stand Safety Near Forklift Operations – Avoiding Falls and Jostling Hazards

Using portable ladders or stairway stands near active forklift operations poses serious risks, as seen in a tragic OSHA-reported incident. An inventory control employee was standing on a portable stairway stand to access items on a rack when a forklift operator, carrying a large carpet roll, turned a corner. The carpet roll on the forklift caught the rear leg of the stairway stand, causing the employee to lose balance, fall three feet to the concrete floor, and suffer fatal head injuries. This incident underscores the importance of maintaining safe distances between ladders, stands, and forklift operations to prevent falls and jostling hazards.

Forklift operators and other employees should be trained to recognize the risks of operating in close proximity to ladders or stands. Maintaining clear communication and designated areas for forklift activity and ladder use can help prevent these types of accidents. For example, using visual indicators like cones or warning signs can help operators know when other workers are nearby, especially around corners and narrow aisles.

Additionally, ladders and portable stands should only be used in areas where forklift activity is not actively taking place, or after securing communication with the forklift operator. By keeping ladder stands out of forklift pathways and designating safe zones for these tasks, companies can reduce the risk of accidental impacts, falls, and serious injuries.

Prioritizing clear communication and safe spacing between forklifts and elevated work stands creates a safer environment for all employees, preventing avoidable accidents and protecting workers from harm.

Source

https://www.osha.gov/sites/default/files/training-library_fatalities_sum.pdf