Top 5 Forklift Accidents & How to Prevent Them
- Alan Pacheco
- Oct 8
- 2 min read
Forklifts keep workplaces running smoothly, but when safety slips, accidents can happen fast and cause life-changing injuries. Most forklift incidents are preventable with awareness and consistent safe practices. Today, we’re covering the five most common forklift accidents and exactly how you can avoid them.
1. Tip-Overs
The risk: Forklifts tip when their center of gravity shifts outside the stability triangle — usually due to heavy or unbalanced loads, sharp turns, or uneven surfaces.
Prevention tips:
Keep loads low and stable.
Avoid sudden stops and sharp turns.
Drive slowly over ramps and inclines.
Always wear your seatbelt.
2. Pedestrian Collisions
The risk: Workers on foot can be struck by forklifts in busy warehouses.
Prevention tips:
Use horns at blind corners.
Follow designated forklift lanes.
Install and obey mirrors and warning signs.
Pedestrians should wear high-visibility vests.
3. Falling Loads
The risk: Poorly stacked or unsecured loads can slide off forks, striking operators or bystanders.
Prevention tips:
Center and secure the load.
Don’t exceed weight limits.
Tilt the mast back slightly when moving.
Avoid quick lifts or drops.
4. Mechanical Failures
The risk: Equipment malfunctions — like brake failure or mast issues — can lead to serious accidents.
Prevention tips:
Conduct daily inspections.
Report and repair issues immediately.
Keep up with scheduled maintenance.
5. Operator Ejection
The risk: If a forklift tips or hits an obstacle, an unbelted operator may be thrown.
Prevention tips:
Always buckle up.
Stay inside the protective cage — never jump.
Keep limbs inside the vehicle.
Most forklift accidents come from avoidable errors: rushing, skipping inspections, or not following safety zones. By learning these risks and practicing good habits, you can protect yourself and your coworkers.
Tomorrow, we’ll switch gears and look at life-saving medical skills with Hands-Only CPR vs Full CPR: What’s the Difference?
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