The 10 most frequently occurring forklift accidents

Crashes involving forklift still account for a significant proportion of all work-related accidents. More precisely - it ranks at number 4 of all work-related accidents!
In 2018, the number of forklift crashes was shown to be still increasing. Several different kinds of crashes can occur with a forklift.
We list here the 10 most frequent forklift accidents and explain how to improve safety when working with trucks.

Discover our solutions

1. Crash caused by a forklift

Frequency: 41%

Still in the number one spot on the list: crashes. These involve not only people being injured, but also damage to the building, goods or other vehicles. A British study has shown that three-quarters of forklift crashes are caused by an ill-adapted layout of the work floor and, in particular, by an adequate separation of vehicle and pedestrian traffic!¹

That is why a workplace with forklifts without crash protection poses an acute risk to employees, the infrastructure and the goods. Today, it is practically inconceivable to run a warehouse without installing crash protection. The consequences of forklift crashes should not be underestimated. Boplan offers an extensive range of crash protection made of plastic, allowing you to fully customise the safety of your warehouse in the best interests of your employees and the image of your company.

2. Falling goods

Frequency: 17%

When a forklift makes a careless manoeuvre or has to swerve unexpectedly to avoid an employee or an obstacle, there is a chance that the load on the forklift will topple down. This can cause serious injury or damage, depending on the nature of the load.

To prevent forklifts and people from unexpectedly crossing each other's paths and having to take evasive action, it is best that you carry out a thorough risk analysis of your workplace. After this analysis, you will be able to better assess the hazards and draw up a clear traffic safety plan for your warehouse for your warehouse. This way, you can neatly separate moving traffic and pedestrians, and prevent painful confrontations.

In some circumstances, it is inevitable that pedestrians and forklifts will end up in each other's vicinity. Make forklifts and pedestrians stand out more clearly. Pedestrians should wear a fluorescent jacket, while forklifts can be equipped with strips in a distinctive colour. You could also attach a so-called BlueSpot or TruckSpot to the vehicles. This is a light that projects a blue dot on the floor a few metres from the vehicle. This way, they announce their arrival to everyone who is in the vicinity.

3. Falling from a height

Frequency: 12%

Although it is strongly discouraged, it often happens that a worker is lifted up to a certain height by the forklift to carry out certain tasks. Forklifts are not designed to lift people and the worker in question sometimes has to balance themselves precariously in order not to fall. Unfortunately, this does not always end well.

Make sure that your employees are aware of the danger of these kinds of falls. Not only verbally or through a presentation on safety at work, but also include posters with safety instructions in the work area as a part of this.

4. Tipping sideways

Frequency: 7%

If a forklift is on a sloping platform, drives too fast over a speed bump or an uneven surface, or has to swerve suddenly, it can tip sideways. As a result, the driver may be ejected from the cabin or trapped between the forklift body and the ground or a wall (e.g. as a result of trying to jump out of the cabin).

You can eliminate many risks by limiting the maximum speed at the workplace. This is something you can agree on internally, instruct and indicate, but it can happen during stressful moments that the driver might go a bit too fast. If you want to be absolutely sure that the speed remains limited under any circumstances, you can install a speed limiter in the forklift. This forces the driver not to work fast, but to work just that bit more efficiently and safely.

Nowadays, you can also make use of the TruckLog Speed Zoning system. This is a system with infrared technology that automatically adjusts the maximum speed to the conditions in each zone.

Forklift safety equipment

The forklift itself can be fitted with safety belts or safety bars, or you can make sure that a closed cabin is used. Safety belts are the most budget-friendly (and necessary), but also offer the least protection of the three. Moreover, it is tempting to just click the belt in behind the back without putting it on, especially in situations where the operator has to regularly get out of the forklift.

A possible solution to this is the so-called stream belt. This is a belt that is located in front of the entrance to the cabin, so that the clark driver is forced to put it on when entering the cabin.

Door bars provide extra protection for the cabin in the event of an accident with a forklift. A variant to this are swivel bars. These work on the same principle as swinging doors, with the difference that the forklift operator can open them upwards. This ensures that he or she can get on and off the forklift effortlessly, even in narrow spaces.

If you want to make sure you have complete safety, the fully closed cabin is still the most recommended solution. In addition to protection from the weather, dust or dirt, the risk of being trapped during a rollover is minimal. Provided, of course, that the driver actually drives with the cabin closed.

Whichever option you choose, a safety belt is always compulsory, even if there are additional safety features.

5. Tipping forward

Frequency: 7%

If the forklift is overloaded, or if the load is picked up carelessly, it can tip over. Not only does this pose a risk to the driver and bystanders, it can also cause serious damage to the building, the vehicle and the goods it is transporting.

Point out the maximum load capacity of the forklift. This is always clearly indicated on the forklift. Correct loading of a forklift is also important. The maximum load should not be reached. If the goods are not balanced properly on the forks, you run the risk that they will unbalance the forklift.

6. Being trapped or crushed

Frequency: 6%.

There are various ways in which an employee can become trapped or crushed while working with a forklift. If someone places their hand or leg too close to the lifting mechanism, it could become trapped between the chain or fork. Similarly, if a bystander gets too close between a forklift and a wall, he or she could be trapped by a manoeuvre the forklift takes.

Do not allow forklifts to pass through narrow passages, but always give them plenty of room. Ensure that the lanes are well-lit and secure Also, make it very clear to employees that they should not touch a forklift, even if it is not operational at the time. Forklift operators are required to keep their arms and legs inside the cabin.

7. Injury when getting in or out of a forklift

Frequency: 4%

The risk of sustaining a painful injury is just a fraction of a second away. As the operator becomes more proficient at his or her daily tasks, some carelessness may creep in when it comes to getting on and off the forklift. Depending on the height between the cabin and the ground, an unfortunate stumble can cause an injury that can put the person out of work for a while.

The best advice for preventing this is simple: watch out. Be careful when getting out of the forklift, and preferably step out of it like you would do climbing down a ladder: with your back facing outwards. This will help avoid any sprains or dislocations.

8. Technical errors

Frequency: 3%

Forklifts are made up of mechanics and electronics, and something can always go wrong with them. A fork can come loose, the brakes may not work as well, the fuel line may be leaking, etc.

It is therefore also very important to subject forklifts to regular technical inspections. Even more than that, checking the internal circuit and running a test of the main functions of the forklift before you start your workday are both recommended in all cases.

9. Accidents involving platforms

Frequency: 2%

In some warehouses, forklifts sometimes operate on platforms as part of their daily work. Depending on the condition of the platform, an accident may occur due to the platform collapsing, or the forklift falling off the platform. A slippery floor can also be dangerous for forklifts. Whenever you move around on a wet surface, there is a risk of slippage.

Additional crash protection should be installed on the platform to prevent forklifts from driving off it. Choose robust protection bar, they offer the best protection. Also avoid any obstructions or unevenness on platforms or mezzanines. And prevent the risk of slippages with our slip resistant solutions.

10. While parking

Frequency: 2%

It sounds almost beyond belief, but accidents do happen while parking a forklift. A small mistake in steering can cause the forklift to damage the building, or worse, hit another worker while turning in.

Set out clear floor marking tape at parking areas and loading stations for forklifts. By using safety posts or protective skirting boards against adjacent walls, you can make sure that they are not damaged in case of an error of judgement.

Conclusion: provide extra safety measures for forklifts

Which forklift accidents occur most often is in the end not important. The bottom line is that the risk of any type of accident should be minimised by all means possible and avoided at all costs. Prevention plays an important role in this.

You can get far with communication and by raising awareness, but no workplace is immune to accidents. That's why it is also absolutely essential to install the right kind of crash protection. If something does happen, expertly installed crash protection can ensure that the damage is limited.

Are you wondering how you can optimise safety within the workplace? In addition to a wide range of solutions to prevent forklift accidents, we also have host of other safety solutions for your workplace. For instance, perhaps it's important to protect sharp corners, which you can do with our column protection. Are you also looking for a solution for slippery stairs? Then be sure to discover our XTRA GRIP range. Do not hesitate to get in touch with us, we're more than happy to give you some advice and help!

N. Dickety, A. Weyman, P. Marlow - Measuring Workplace Transport Safety Performance
In "Factors affecting workplace transport safety", Health & Safety Laboratory" - Derbyshire (UK) 03/2005 - p. 4, 2.1