Common forklift accidents: Causes and PreventionReading Time: 9 minutes 1 second SummaryThis article discusses the most common types of forklift accidents, their reasons, and the means to prevent them. Table of Contents
Forklift accidents: Some numbersForklift accidents are very common in workplaces. While they are much slower than their bigger, street-roaming cousins, they can weigh up to twice as much. Forklifts can be quite dangerous when handled irresponsibly. Because of their compact size and nature of the operation, they cause many accidents in workplaces each year. Here are some important facts regarding forklift accidents that you should know :
![]() Figure: A forklift accident can lead to serious injury or even death
Forklift OverturnsAmong all the forklift accidents, forklifts overturn are the most common. Almost a quarter of forklift accidents happen due to overturns. Yet, operators are still not very aware of this danger. A forklift overturns when it loses its center of balance. It happens mostly because of:
![]() Figure: A forklift tip-over due to elevated load
Here is a simple animation showing how a forklift can roll over on its side while turning at high speed:
To avoid overturning, you can follow these preventive steps: Maintain a safe speed: Although OSHA does not have a set limit for forklift speed, they recommend maintaining a low speed, especially when loaded. In many forklifts, speed can be limited from the control panel with restricted access. This will prevent over-speeding by the employees.
Keep the load low: Keeping the load low helps stabilize the forklift and prevents tip-over and rollover. ![]()
Figure: A forklift with a lowered load is very stable and very unlikely to tip over
Consult data tag: If you are unsure about a load, always consult your lift truck's data tag to see if you can handle it safely. ![]()
To avoid 2 and 3, the operator must wear seat belts to secure him to the seat. To avoid scenario 1, you can use the following accessories:
At Lifts Part Warehouse, we offer all kinds of safety gear and accessories such as seatbelts, safety vests, proximity sensors, forklift safety lights, and strobe lights. Falling personnelThis is another common forklift accident. This happens when a person rides the forklift without proper seating arrangement or uses the forks as an elevated platform. The latter is very common where workers stand over the forks and use them to reach heights. Since the forks are not designed to carry or elevate workers, people often slip and fall from them. The main reasons for this accident are:
![]() Figure: Carrying a person unsecured on the forks can lead to a nasty forklift accident
A safety cage is a particularly efficient solution as it requires a much smaller investment than a MEWP. These cages have proper railings and provisions for attaching safety belts. ![]()
Falling loadsLoads falling from the fork are another reason for forklift-related accidents. Loads can fall from the fork because of the following reasons:
![]() Figure: Loads falling from elevated mast can cause serious harm to a pedestrian
The following measures can be taken to prevent such incidents:
Secured load: The best way to prevent loads from falling is obviously, securing them. You can secure the loads with tie-down clamps, lifting belts, or ropes. Using tie-down clamps is particularly a very effective way to secure the loads. Using a load backrest is also necessary for securing the load. You can buy load backrests at Lifts Parts Warehouse at great prices! ![]()
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Load balancing: Balancing or centering loads on the fork before carrying them is very important. According to OSHA guidelines, carrying a load with a backward tilt is much safer as it moves the center of gravity towards the forklift. ![]()
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Pedestrian accidentsIn most cases, forklifts operate in busy environments with many workers working around. Hence, getting hit or run over by a forklift is quite common. The following reasons are the most frequent ones behind this type of accident:
![]() Figure: Blocked vision and bends are two of the biggest reasons for pedestrian accidents by forklifts.
Floor marking: Marking permanent aisles and passageways with floor marking tapes is a cheap and effective way to prevent pedestrian accidents. It is also a strict requirement of OSHA to put floor markings. Floor markings separate the walking passageway from the forklift's path and thus avoid an accident.
![]() Figure: Floor markings are a requirement by OSHA to avoid pedestrian mishaps
![]() Figure: Mirrors help avoid forklift accidents by extending your line of sight
Safety accessories: Many pedestrian accidents can be averted by using proper safety accessories. The Canadian Centre for Occupational Health and Safety (CCOHS) recommends the following accessories to minimize the risk :
Anti-collision warning systems and proximity sensors sound alarms when a person or another forklift is approaching. Some systems even override operator controls and slow down forklifts. ![]()
Backup alarms are also very effective in avoiding pedestrian accidents when driving in reverse. These alarms sound varying warnings as the forklift starts going reverse. Some backup alarms are smarter and sound alarms only when there's an obstacle behind the forklift. Here is a DIY video on how to easily install a backup alarm in your forklift:
Emission PoisoningThis problem is prevalent with I.C. engine forklifts. It happens when carbon monoxide is accumulated in a confined space due to incomplete combustion of the fuel. Since CO is a tasteless, colorless, and odorless gas, it is hard to detect it with the human senses. It can accumulate to a dangerous level without anyone detecting it. Emission poisoning can cause damage in two ways:
![]() Figure: Carbon monoxide poisoning shows signs like dizziness
![]() Figure: Black smoke from the exhaust can be an early sign of C.O. poisoning
Our recommendationOSHA found in a study that over 70% of forklift accidents can be avoided with basic training and safety accessories. We recommend training your operators and equipping your forklifts with safety accessories. While training and forklift safety accessories require some investment, they will save you much more in the future. If you want to buy forklift safety accessories at a very reasonable price, please visit Lift Parts Warehouse. We offer accessories such as safety lights, seatbelts, backup alarms, forklift cages, and many more. Order now and enjoy same-day shipment from our 21 warehouses in the USA. We also offer a limited warranty and guaranteed fit for all our parts. Takeaways
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