Most forklift accidents come down to a short list of preventable causes, overloading, poor maintenance, weak communication, excess speed and limited visibility among them, and good safety training addresses every one of them. According to the UK’s Health and Safety Executive there were 622,000 non-fatal and 144 fatal, self-reported workplace accidents during 2015/2016. Of the non-fatal injuries 44,000 involved making contact with machinery, 61,000 being hit by a moving object and 122,000 handling, lifting or carrying.
Forklift truck accidents are the most common workplace accidents that involve vehicles. In order to correctly assess and mitigate against the risks involved with forklift trucks and provide the best in counterbalance forklift training, it is necessary to first understand the reasons behind these accidents. We look at the top 10 reasons there are so many forklift accidents.
TL;DR
- Overloading and capacity errors are a leading cause, so operators must check the data plate and load capacity at the start of every shift.
- Skipped maintenance and pre-shift checks make accidents far more likely, so daily checks must be built into every operator’s schedule.
- Poor communication and limited visibility put nearby staff at risk, so signalling, audible warnings and clear movement plans are essential.
- Speed, unsecured loads and careless parking are avoidable behaviours that training and clear site rules control.
- Slips and trips getting on and off the truck cause a high share of injuries, so correct steps, handholds and footwear matter.
- Regular, expert forklift training is the common thread, and AFTT is an AITT-accredited training provider offering safety training at all levels.
Why can overloading a forklift make it unstable?
Overloading makes a forklift unstable because it shifts the truck’s centre of gravity beyond its designed limit, and it is often caused by operators being unaware of the capacity of their vehicle. Forklift accidents due to capacity can also occur when lifting at height or using attachments, both of which reduce the safe rated load. Data plates should include the required information and it is the employer’s responsibility to ensure that these are correct and visible. Counterbalance forklift training should ensure that operators know to check the load capacity of their vehicle at the start of each shift.
Why are poorly maintained or unchecked forklift trucks a hazard?
Poorly maintained trucks are a hazard because faults that a check would have caught are left to fail in use. Carrying out the essential pre-shift and regular maintenance checks is a vital element in ensuring forklift safety. When these checks are neglected, maybe for time or financial reasons, accidents are far more likely to occur. All forklift operators should have time built into their schedule for daily checks, and operators should be encouraged to report arising maintenance issues promptly.
How can unfamiliarity with a route raise safety issues?
Unfamiliarity raises safety issues because an operator who does not know a route cannot anticipate its hazards. Every time an operator takes a forklift truck on a route through a workplace he encounters obstacles. These could be narrow passages, other people or uneven floor levels. In an unfamiliar or complicated environment, operators should be encouraged and given time to familiarise themselves with a route on foot before undertaking it with a loaded forklift.
Why does communication between the forklift operator and other staff matter?
Communication matters because a forklift is a heavy vehicle sharing space with people on foot, and unannounced movements put them at risk. In a busy and potentially dangerous environment such as a warehouse there will be lots of people engaged in their own activity. If the forklift operator does not ensure that those around him understand his planned movements he may be putting them at risk. Communication should be encouraged, and counterbalance forklift training should include advice on how and when to communicate with colleagues and visitors.
Why do forklift trucks rely on adequate hydraulic and battery fluid levels?
Forklift trucks rely on adequate fluid levels because running low can stop the truck mid-task and leave a load stranded. Stopping part way through a job can cause danger to both the forklift operator and other members of the workforce. It is important to regularly check fluid levels to ensure that this does not happen.
Why are incorrectly secured forklift loads dangerous?
Incorrectly secured loads are dangerous because they can fall or shift and upset the truck’s balance. Not every forklift load is easy to secure, and it can be tempting for operators to save time by leaving a load unsecured for a quick journey. A pallet is a flat item and, unless it is overloaded, does not present much risk. A load that is unusually tall, wide or shaped, however, can be prone to falling and may affect the balance and manoeuvrability of the forklift.
Why are operators under pressure tempted to speed?
Operators under pressure are tempted to speed because moving faster feels like a way to hit targets, but moving too fast in a forklift truck can be dangerous. Speed limits should be made clear to all operators. Forklift speed is sometimes manually limited, but otherwise the use of speed bumps and allowing adequate time for jobs can help to avoid this risk.
How should forklift trucks be parked safely?
Forklift trucks should be parked only in authorised areas and left fully shut down so they cannot move or be misused. When parked, the forks should be lowered, direction controls should be set to neutral, the parking brake should be applied and the ignition should be turned off.
Why are slips and trips a risk when entering or leaving a forklift?
Slips and trips are a risk when getting on and off because that is the moment an operator is climbing, often carrying nothing to steady themselves. Slips and trips cause a high proportion of workplace accidents. Entering and leaving a forklift should be done safely using the correct steps and handles if necessary. Suitable footwear can help control this risk, as can keeping all floors clear of liquids.
Why is limited visibility a forklift hazard?
Limited visibility is a hazard because a large load or blind spot can hide people and obstacles from the operator. When a heavy vehicle like a forklift has limited visibility, it is important that it is fitted with working audible signals and flashing lights to give the rest of the workforce an awareness of its movements.
How do the top forklift accident causes compare, and how are they controlled?
The quickest way to prioritise safety is to see each common cause alongside the control that prevents it. The table below summarises the reasons above and the practical step that addresses each one.
| Common cause | Main control |
|---|---|
| Overloading or capacity error | Check the data plate and rated capacity every shift |
| Poor or skipped maintenance | Build daily pre-shift checks into the schedule |
| Unfamiliar route | Walk the route on foot before driving it loaded |
| Weak communication | Agree signals and announce planned movements |
| Low hydraulic or battery fluid | Check fluid levels regularly |
| Unsecured loads | Secure tall, wide or awkward loads before moving |
| Excess speed | Set and enforce speed limits, allow enough time |
| Careless parking | Park in authorised areas, forks down, brake on, ignition off |
| Slips and trips | Use correct steps and handles, wear suitable footwear |
| Limited visibility | Fit and use audible signals and flashing lights |
Frequently Asked Questions
What is the most common cause of forklift accidents?
There is no single cause, but overloading and capacity errors, poor maintenance, weak communication and excess speed all feature heavily. Most incidents trace back to a handful of preventable behaviours rather than random bad luck. This is why structured safety training focuses on those recurring causes.
How can forklift accidents be prevented?
Forklift accidents are prevented by combining trained operators, well maintained trucks and clear site rules. Daily pre-shift checks, respecting rated capacity, securing loads, managing speed and using audible warnings all reduce risk. Regular refresher training keeps these habits sharp over time.
Is forklift safety training a legal requirement in the UK?
Employers have a legal duty to ensure that forklift operators are adequately trained and competent, and the HSE sets out this expectation. There is no single government-issued licence, but accredited training and a certificate of basic training are how employers demonstrate they have met that duty. Failing to train operators exposes both staff and the business to serious risk.
How often should forklift refresher training take place?
Refresher training should take place whenever an operator’s practice slips, after an incident or near miss, following a long break from driving, or when they move to a different truck or site. There is no fixed legal interval, so employers should judge it on risk and performance. Regular refreshers help correct bad habits before they cause an accident.
Who is responsible for forklift data plates and capacity information?
It is the employer’s responsibility to ensure data plates are correct and visible, because they carry the capacity information operators rely on. Operators, in turn, should check the plate and the rated load at the start of each shift. Together this keeps loads within safe limits.
Why do pre-shift checks matter so much?
Pre-shift checks matter because they catch faults before the truck is put under load, when a failure could injure the operator or nearby staff. Skipping them, often to save time, is a frequent factor in accidents. Building the checks into the working schedule makes them routine rather than optional.
How should a forklift be left when parked?
A forklift should be parked only in authorised areas with the forks lowered, direction controls in neutral, the parking brake applied and the ignition turned off. This prevents the truck from rolling, being driven by an untrained person, or becoming an obstruction. It is a simple routine that removes several risks at once.
What safety equipment helps with limited forklift visibility?
Working audible signals and flashing lights are the main aids, because they alert people on foot to the truck’s presence and movement. Clear sightlines, good site layout and safe communication further reduce the danger from blind spots. Operators should slow down and check when visibility is poor.
Does AFTT provide forklift safety training?
Yes. AFTT is an AITT-accredited training provider offering professional forklift safety training at all levels. Training can be arranged around your operation and site, and you can contact us for a discussion of your needs and a no-obligation quote.
All forklift operators work within a risky environment with potentially hazardous equipment. These facts highlight the importance of regular and expert forklift training. AFTT (Advanced Fork Truck Training) offer professional forklift safety training at all levels. Contact us now for a discussion of your needs and a no-obligation quote.
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