Looking to make your warehouse as safe as possible?
Forklift trucks are the workhorses of warehouses, construction sites, and distribution centres all over the world. They lift heavy loads, transport goods quickly and efficiently, and keep things running smoothly.
But here’s the problem…
They’re also one of the most dangerous pieces of equipment in any workplace.
According to OSHA estimates, around 11% of forklifts are involved in an accident each year. That’s a staggering 1 in 9 chance every single year.
The good news?
Most forklift truck accidents are 100% preventable. With the right best business practices, businesses can protect their workers, and avoid expensive and sometimes deadly incidents.
So Here’s What You’re Going to Discover:
- Why Forklift Safety Matters More Than Ever
- The Most Common Forklift Accidents
- Essential Safety Practices Every Operator Needs
- How to Build a Safety-First Culture
Why Forklift Safety Matters More Than Ever
Forklift truck safety isn’t just a bunch of rules.
It’s about protecting the lives of your workers. As I’ve said time and time again, if you aren’t looking after the people who work for you, then you’re failing as a business leader.
Industry bodies such as UKMHA have been campaigning for more stringent forklift truck standards and certification for years. And the data that they have collected backs up exactly why this matters so much for best business practices.
Let’s be blunt here. Every working day across the country, people are injured or killed in preventable forklift truck accidents. In fact, 70% of forklift injuries could be avoided with proper training and safety measures in place.
And here’s another uncomfortable truth…
Forklift trucks are now the single most dangerous form of workplace transport. They injure more people than heavy goods vehicles. More than large goods vehicles. More than almost any other vehicle in the workplace.
The financial cost of forklift accidents is massive too. Fines, compensation claims, damage to equipment and stock, and lost productivity all add up. But the human cost of a serious incident is incalculable.
The Most Common Forklift Accidents
The first step to preventing accidents is understanding exactly what can go wrong.
Tip-Overs and Overturns
Tip-overs and overturns are the most dangerous forklift accidents. Forklift tipping over accident statistics show that 42% of forklift fatalities involve workers being crushed under a forklift. This can happen when the truck takes a sharp turn, has an elevated load, or is driven at excessive speed.
Pedestrian Collisions
Pedestrian collisions are a huge contributor to forklift injuries. More than half of all injured in forklift accidents are pedestrians, either co-workers or visitors on site, simply in the wrong place at the wrong time.
Falling Loads
Falling loads occur when material isn’t secured properly. A shifting load while being transported or lifted can cause serious injuries to anyone nearby.
Crushing Injuries
Crushing injuries can happen when operators step out of the vehicle at the wrong moment. Or when workers get trapped between the forklift and another object like racks or walls.
Pretty alarming when you put it all like that, right?
But here’s the thing…
Each of these common types of forklift accident has a clear solution. And it all starts with these safety practices.
Essential Safety Practices Every Operator Needs
Ok, so now we know what the most important best business practices are, let’s dive into the specific safety practices that actually work.
Proper Operator Training
The single most important thing any operator can do is get trained.
Operators should be fully trained and certified before they are allowed to operate a forklift truck. Not only is this a legal requirement, but it’s just plain common sense. Training should be tailored to the specific truck type and include controls, steering, visibility limitations, and stability.
And it’s not a one-and-done thing either…
Refresher training should be conducted at regular intervals. As operators get into their work routines, they can develop bad habits. The repetitive nature of forklift work also leads to a false sense of complacency. Refresher courses at least once a year help to keep safety at the front of people’s minds.
Daily Pre-Use Inspections
Operators should conduct a thorough inspection of their forklift before every shift.
The pre-use inspection checklist should include brakes and steering responsiveness, tyre pressure and condition, horn and warning devices, hydraulic system for leaks, forks for cracks or damage, and seatbelts and other safety features.
Defects must be reported immediately. Faulty equipment should be taken out of service until repaired. There should be no exceptions to this rule.
Safe Operating Procedures
Forklifts should always be driven safely and according to the manufacturers’ instructions.
Loads should be carried as low to the ground as possible. The higher the load, the higher the centre of gravity, and the greater the risk of tipping. Turns should be taken slowly, without sharp movements or speeding.
Speed limits should be observed at all times. Operators should always be aware of their surroundings and actively look out for pedestrians.
Passengers are never allowed in a forklift. Nor should the forks be used to lift people up off the ground unless using an approved work platform. These are obvious points but important to state as people do take shortcuts.
Workplace Organisation
The work environment plays a big part in forklift safety.
Traffic routes should be clearly defined and separated from pedestrian traffic where possible. Adequate lighting should be provided in all areas. Aisles and pathways should be kept clear of obstructions.
Floor markings can help to define safe operating areas. Physical barriers are effective at protecting vulnerable zones such as the ends of racks, walkways, and work stations. Good visibility at intersections is also critical to avoid collisions.
Load Management
Loads should be handled correctly to avoid accidents.
The rated capacity of the forklift should never be exceeded. Overloading is one of the primary causes of tip-overs. Loads should be stable and evenly balanced on the forks.
Operators should travel in reverse when a load obstructs their visibility, or a spotter should be used to guide the way. Take extra care and use all available precautions when transporting awkward or unstable loads.
Creating a Safety-First Culture
All of the best safety practices in the world are not going to prevent accidents if not properly followed.
Safety culture is all about creating an environment where people make safety a priority. It starts with management setting the right example. Good safety policies should be clearly communicated and regularly reinforced.
Workers should be encouraged to report hazards and near misses. Every incident, even if no one gets hurt, should be investigated. Use these near misses as opportunities to learn and avoid larger accidents later on.
Regular safety meetings and toolbox talks are another good way to keep people engaged and make safety a regular topic of discussion. And of course, recognising and rewarding safe behaviour is a great way to encourage others to do the same.
Pulling It All Together
Ok, so that was a lot to take in.
Forklift truck safety doesn’t have to be complicated. But it does require some effort and commitment.
The essential best business practices that save lives include proper training and certification for all operators, pre-use equipment inspections, safe operating procedures at all times, and good workplace organisation with traffic management systems in place.
Safety culture ties all of these individual practices together.
The statistics are clear. Most forklift accidents are preventable. With the right practices and procedures in place, businesses can dramatically reduce their risk, and protect their most valuable asset, their people.
So don’t wait until something happens. Take action today. Review your current safety procedures. Identify areas for improvement and implement solutions.
Your workers are counting on you.
