Do you know what the 10 most common forklift accidents are?

Frequency: 41%

A UK study has shown that three quarters of forklift accidents are caused by a poor workplace layout and, in particular, poor segregation of vehicular and pedestrian traffic. This greatly increases the risk of collisions, so it comes as no surprise that this is the number one cause behind accidents involving a forklift. The consequences of a forklift collision should not be underestimated. They can cause serious injuries to people, for example. Alternatively, a forklift collision can cause damage to buildings, machinery, goods or other vehicles.

To prevent forklifts from crossing paths with pedestrians, your workplace should have a clear traffic plan in which vehicles and pedestrians have their own paths. 

However, it is inevitable that pedestrians and forklifts will be in close proximity at some point. This is why it is important to take both preventative and protective measures. Make forklifts more visible by painting them in an eye-catching colour, and provide fluorescent vests for pedestrians. Above all, install safety barriers where necessary. Not only will this increase awareness, but it is an effective form of protection for pedestrians, infrastructure, buildings and other vehicles if a collision occurs.

Ready to tackle workplace safety? Boplan stocks a wide range of polymer safety barrier solutions to equip your warehouse exactly as you desire.

Frequency: 17%

If a forklift makes an improper manoeuvre or has to turn unexpectedly to avoid an operator or obstacle, this may cause the load on the fork to fall. Depending on the nature of the load, this could cause serious injury or damage. Learn how to prevent falling objects in your workplace here.

Frequency: 12%

Forklifts are not aerial work platforms. Even so, forklifts are often used to lift a worker to a certain height in order to perform certain tasks. Forklift trucks are not designed to lift people. The worker has to take care not to fall. Unfortunately, they cannot always guarantee this.

Make employees aware of the risk of falling from a forklift via verbal instructions and/or a safety presentation as well as by posting safety rules in the work area. Providing safety equipment for working at heights can also help to ensure that employees will work safely in the future. 

Frequency: 7%

A forklift may tip over if it drives onto a sloping platform, over a bump or across an uneven surface. This is also the case if it has to make a sudden turn. This could result in the operator being thrown from the cab or becoming pinned between the forklift body and the ground or a wall.

You can eliminate many of the risks associated with this by capping the speed limit in the workplace. Of course, while you may agree on and inform drivers of this internally, the same drivers may still exceed the speed limit when time is tight. This places both themselves and others around them in danger. If you want to guarantee that drivers adhere to the speed limit, you can install a speed limiter in the truck. This compels the driver to work efficiently and safely without being too fast. The TruckLog Speed Zoning system is one such solution. It contains infrared technology that automatically adjusts the maximum speed to the conditions in each zone.

You can also install other safety equipment in addition to the seat belt or safety bar in the forklift itself. Seat belts are the most budget-friendly (and essential) option, but they also provide the least amount of protection. It can be tempting for the driver to simply clip the belt behind their back without using it, especially in situations where they need to get out of the forklift regularly. One possible solution is a 'stream belt'. This is a belt that is installed in front of the cab entrance, compelling the operator to put it on when entering the cab.

Brace doors also provide extra protection for the cab in the event of an accident. A swing door is a variant of this. These work on the same principle as brace doors, except the driver can open them by pushing the door upwards. This enables the driver to enter and exit the forklift in confined spaces with ease.

A fully enclosed cab is still the best solution to ensure complete safety. As well as protecting the driver from the elements, dust and debris, it minimises the risk of being crushed in a rollover – provided, of course, that the operator drives with the cab closed.

Frequency: 7%

A forklift can tip over if it is overloaded or if the load is picked up without due care. This not only endangers the operator and bystanders, but can cause serious damage to the building, the truck and the load.

Make sure you know the forklift's maximum capacity. This is usually clearly marked on the vehicle itself. It is also important to load the forklift correctly. Even if it is not at maximum capacity, the load can throw the forklift off balance if the goods are not balanced on the forks.

Frequency: 6%

There are a number of ways in which a worker can become trapped while operating a forklift. If a person puts their hand or leg too close to the truck, they can become trapped between the chain or fork. Similarly, a bystander standing too close between the forklift and a wall can be trapped when the vehicle manoeuvres.

Always provide forklifts enough space and do not force them to traverse narrow aisles. Ensure aisles are well lit and safe by using floor markings or physical safety solutions such as safety barriers. Instruct workers not to touch the forklift, even if it is not in operation. Forklift drivers must keep their arms and legs inside the cab.

Frequency: 4%

There is always a risk of becoming injured. As operators become more experienced in their daily activities, they can become nonchalent about entering and exiting the forklift. Depending on the height between the cab and the ground, simply tripping could cause an injury that would put the person out of work for a while.

The best way to avoid this is simple: pay attention. Take care when dismounting. Get out of a forklift like descending a ladder: with your back first. This will prevent sprains.

Frequency: 3%

Forklift trucks are mechanical and contain electronics, so there is always a risk of something going wrong. A fork can come loose, the brakes may lose power, the fuel line can leak, etc.

For this reason, it is very important to have forklifts inspected regularly. What’s more: It is even more important to check the internal circuits and test the forklift's main functions before starting work.

Frequency: 2%

In some warehouses, forklift trucks are used on platforms. Depending on the condition of the platform, accidents can occur due to the platform collapsing or the truck falling off the platform.

Install additional safety barriers on the platform to prevent forklift trucks from driving off the platform. Opt for heavy-duty kick rails with handrails or safety barriers with handrails. This is the best form of protection. Also avoid obstacles or uneven surfaces on platforms or mezzanine floors. Find out how to avoid falling from heights here.

Frequency: 2%

It may not sound likely, but accidents can happen even when a forklift truck is parked. A minor steering error can cause a forklift to damage a building or, worse, hit another worker when turning inwards.

Clearly mark the floors in parking areas and at forklift loading docks. Use bollards or kick rails on adjacent walls to ensure they are not damaged if a collision occurs.