Many incidents that occur with forklifts happen because the operator was not trained in the specific model and type of forklift they tried to use.
Forklifts are powerful machines that can weigh several tons and are capable of lifting heavy materials in tight spaces, on uneven ground, or around pedestrians and other equipment. When something goes wrong, incidents can quickly become catastrophic. Tip-overs, struck-by incidents, crushing injuries, and falling loads are among the most serious hazards associated with forklift use. Even experienced operators can become involved in an incident if they become complacent, rush a task, or operate equipment they are unfamiliar with.
Forklift Training
OSHA Standard 1910.178(l)(1)(i) states the employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this [standard].
Forklift training is not a one-size-fits-all requirement. OSHA requires operators to be trained and evaluated on the specific type of powered industrial truck they will operate and the hazards of the workplace where it will be used. A worker trained to use one type of forklift may not automatically be qualified to safely operate another. For example, a sit-down warehouse forklift operates very differently than a rough-terrain forklift or telehandler used on construction sites. Differences in stability, steering, attachments, visibility, load capacity, and operating surfaces can all affect safe operation.
Forklift incidents involving tip-overs are especially dangerous. The center of gravity can quickly shift if equipment is overloaded, driven too fast, operated on uneven terrain, or used improperly. In many cases, workers underestimate how quickly a forklift can become unstable.
Incidents like this one can often be prevented by ensuring that all forklift operators have the proper training and ensuring all crew members, on and off the forklift, are always taking proper precautions around forklifts and on the jobsite.
Training alone is not enough. Forklift safety depends on operators performing inspections, following safe operating procedures, wearing seat belts when equipped, understanding load limits, and remaining aware of changing jobsite conditions. Workers on foot must also recognize forklift hazards and stay clear of operating zones, blind spots, and suspended loads.
Common Causes of Forklift Accidents
Many forklift incidents happen because operators move too quickly for conditions, carry unstable loads, or fail to recognize surface hazards. Uneven terrain, soft soil, curbs, ramps, and slopes can all increase the risk of a tip-over, especially with rough-terrain forklifts and telehandlers.
Visibility is another common issue. Loads can block the operator’s line of sight, creating struck-by hazards for nearby workers. In busy work areas, spotters, designated travel paths, and communication between crews may be necessary to prevent incidents.
Equipment inspections are also critical. Hydraulic leaks, damaged tires, steering problems, faulty brakes, or malfunctioning warning devices can all contribute to serious incidents if equipment is not removed from service when problems are identified.
This was the scene at another forklift incident...
Incidents like these will happen if operators are not trained on the model and type of forklift they are attempting to use. Not all forklifts are the same!
Lessons Learned From Forklift Incidents
Both incidents shown above highlight an important reality: forklift incidents are often preventable. Proper training, equipment inspections, safe speeds, understanding load limitations, and using the right machine for the job can significantly reduce the risk of serious injury or death.
No employee should ever feel pressured to operate equipment they have not been trained to use. Supervisors and workers should stop the task, ask questions, and verify qualifications before operating unfamiliar equipment. Taking a few minutes to make sure the right person is using the right forklift can prevent life-changing injuries and fatalities.
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