Quick stats: In U.S. workplaces, forklifts were the source of 67 fatalities in 2023 and about 25,000 nonfatal injuries in 2021–22. The leading fatal event is tip‑overs (~25%); prevention hinges on OSHA‑compliant operator training [1910.178(l)], daily equipment exams [1910.178(q)(7)], low travel speeds, clear pedestrian separation, and impact protection for racking.
source: injuryfacts.nsc.org/work/safety-topics/forklifts
Often referred to as the “workhorses” of both the warehousing and construction industries, the forklift is a powerful industrial truck used to lift, carry, and unload heavy goods over short distances. For the efficient management of a warehouse and a good flow of production activities, you can count on a forklift to deliver quick results.
At the same time, operating a forklift involves a certain amount of risk. Weighing up to 9,000 pounds, these trucks are three times heavier than a car. They can reach speeds upwards of 18 miles per hour and only have brakes in the front, making them harder to stop. Rear-wheel drive increases the chance of tip-overs, especially when uneven weight distribution of load is added to the equation. As fun as forklifts may look to drive, these vehicles have the potential to be dangerous hazards.
Forklift Accident Statistics (2025)
Knowing how many forklift accidents happen every year can be eye-opening for anyone working in the material handling and supply chain industry. But with each shocking statistic, there is an opportunity to learn and do better. Below are three forklift truck accident statistics out of the United States, according to the Occupational Safety and Health Administration (OSHA):
- 1 in 6 workplace deaths involves a forklift
- Forklift accidents account for around 85 deaths per year
- 34,900 serious forklift injuries result from accidents annually
The Most Common Forklift Accidents (and How to Prevent Them)
Nearly all incidents involving forklifts can be broken down into one of the following four scenarios. With each example, we explore several solutions and give you tips on forklift accident prevention.
1) A forklift rolls or overturns.
Overturns are the leading cause of forklift fatalities; they represent about 25% of all forklift-related deaths. Under which conditions can forklifts overturn? Below are the three most common reasons:
- Improper turning
- Driving with an elevated load
- Excessive speed
How to Prevent Forklift Accidents:
To avoid dangerous overturns, it is important to load carefully, stay within the truck’s load capacity, and avoid driving with a raised load. OSHA regulations encourage drivers to carry loads as near to the ground as possible, approximately 4 inches from the floor. It is best practice to lower forks when the forklift truck is parked. When maneuvering a load into a rack, this should be done at a very low speed. Lastly, the overall environment and floor surface condition must be taken into consideration when operating a forklift truck. Is there oil, ice, or water on the floor? Are there slopes that need to be driven over? Are there many sharp corners to get around obstacles in the aisles? If the answer is “yes” to any of these questions, you need to slow down. Forklift drivers, because of the repetitive nature of their work, tend to get too comfortable and drive irresponsibly. Traveling too fast shortens reaction time, causing accidents.
2) Workers are hit, struck, crushed, or pinned by a forklift.
Being crushed by a forklift accounts for 42% of forklift deaths each year. Since most people are concerned about being run over by a forklift from the front, they tend to stand beside the forklift, where they believe they are safest. However, statistics show that the greatest danger is being crushed by a forklift that tips over sideways.
How to Prevent Forklift Accidents:
The safest place for a pedestrian is on a designated walkway where forklifts are not permitted. Signs should be prominently displayed for easy visual recognition. In addition, forklift operators should always make sure they are looking in the direction in which they are driving, always maintaining an appropriate speed.
3) A warehouse worker falls from a forklift.
At first glance, you may ask yourself: “How could someone possibly fall from a forklift?” The concept seems impossible, yet this type of accident accounts for one of the most common forklift truck accidents every year. As warehouses are trying to find ways to stack their inventory higher and higher, many warehouse employees often find themselves trying to reach items at those higher levels. Many decide to climb onto a forklift truck; however, forklifts are not able to support the uneven distribution of weight. This causes the forklift to wobble or even tip over, causing the person to slip and fall, resulting in serious injury or death.
How to Prevent Forklift Accidents:
Firstly, forklift operators should be wearing the proper personal protective equipment (PPE), such as hard hats and suitable footwear, to mitigate the risk of slipping. And instead of using a forklift to reach something, a man lift would be a much safer alternative because it is designed to safely carry people (and not pallet loads) to greater heights in a safe and efficient manner.
4) Forklifts repeatedly crashing into racking systems.
Forklifts striking people have already been mentioned above, but what about racking systems? Racking is not designed to resist impact, and although some damages could be minor, accumulated damages over time can result in catastrophic consequences such as the complete collapse of a racking system. Five examples of forklift accident videos can be viewed on our blog: Top Warehouse Rack Collapse Video Fails.
Picking up and setting down a pallet can sometimes be tricky if the operator’s view is obstructed, especially at higher levels. This low visibility, combined with the hasty way in which forklifts are operated, makes them the main cause of rack damage in a warehouse. To learn more about the frequent ways forklift trucks damage racks, read this article.
How to Prevent Forklift Accidents:
Equipping forklifts with proper rear-view mirrors, mast-mounted cameras, and proximity sensors to prevent backing incidents can increase the operator’s visibility and, therefore, increase productivity – all while minimizing the risk of an accident. Protecting the racking systems from forklift impact also comes into play. Using base guards and/or column guards to protect column base and anchors are essential in keeping the forklift operator and other warehouse employees safe. And if the damage is already done, there are rack repair solutions that offer permanent protection from all future forklift collisions. Warehouse managers should also ensure that aisles are free of clutter and well-lit.
Who is Responsible if a Forklift Accident Occurs?
When a forklift warehouse accident occurs, liable parties vary depending on what is deemed to be the primary cause of the accident. If the forklift operator causes the accident, he or she is responsible for it. In some situations, the employer could be liable if they failed to properly train their forklift drivers or did not provide a safe environment in which the forklift operators could work.
The Occupational Safety and Health Act was created to give all workers a safe workplace environment and reduce the number of annual injuries and fatalities. According to the act, all employers must provide employees with a safe work environment and protect them from hazards. For a more comprehensive list of employer responsibilities, read this. If an accident occurred due to negligence on the part of the forklift manufacturer or vendor, they could potentially be held legally responsible as well. Since laws regarding forklift accidents will differ depending on country or state, it is wise for someone involved in a serious forklift accident to seek legal advice from a forklift accident lawyer.
OSHA Requirements: Training, Daily Exams & Safe Travel
Ensuring that all forklift operators have gone through formal training (and subsequent “refresher” pieces of training) is key in accident prevention. OSHA requires education and certification (requiring an in-person component) before you can hop on and operate a forklift.
If companies implemented stricter training policies, OSHA estimates that about 70% of forklift accidents in the U.S. could be prevented.
Before an operator starts a shift, OSHA recommends a daily inspection of the equipment.
Daily Forklift Safety and Operational Check List:
- Are the forks in good condition?
- Is the battery restraint system intact?
- Is the horn working?
- Are there any oil leaks?
- Is the tire pressure adequate?
- Is my truck equipped with the proper safety warnings?
- Is the load capacity plate properly attached?
- Is the seat belt functional?
- Are the front, tail, and brake lights working?
- Is the Operator’s Manual located on the truck?
Forklifts and Pallet Rack Damage: What to Do After an Impact
Besides the daily inspection of the forklift’s condition, there is another factor that greatly impacts safe forklift operation: the workplace environment. Since forklifts are mostly used in warehouses for loading and unloading goods, the safety of the warehouse is the first place to start, even before the forklift enters the equation.
For example, all obstructions should be removed from doors and intersections, and aisles need to be kept clutter-free. Racking systems and building columns should be protected at the fork level with end-of-aisle protection guards and high-impact column shields. Traffic volume should also be kept to a minimum in work areas. And lastly, safety signage should be visible throughout the warehouse, specifically indicating pedestrian walkways and areas where the floor may be wet or have a ramp.
How A Rack Safety Partner Can Help
Lastly, find a reliable and experienced rack safety partner who can guide you in finding the most suitable and efficient rack safety solutions to not only prevent or repair damage to your racking systems caused by forklifts but also to help you improve the overall safety of your warehouse. A wise choice would be to find a company that is an active ProGMA member, an MHI group composed of the racking industry’s leading suppliers of fixed protective guarding products. Some rack safety solutions providers even offer on-site rack damage assessment services performed by experienced rack safety experts. These professionals will share helpful advice on how to ensure your racking systems will stand up permanently to the repeated impacts from forklifts.
Frequently Asked Questions: Common Forklift Accidents & How to Prevent Them
How common are forklift accidents in U.S. warehouses?
What are the most common types of forklift accidents?
The four primary types are:
- Overturns or tip-overs (about 25% of all forklift fatalities)
- Pedestrian struck-by or crushed incidents
- Falls from forklifts
- Collisions with racking systems
Each type can cause severe injuries or damage, particularly if proper safety measures, training, and maintenance aren’t in place.
Why do forklifts overturn?
Forklifts have a high center of gravity and use rear-wheel steering, making them less stable during fast turns, when carrying elevated loads, or when operating on uneven or slippery floors.
Prevention tips:
- Keep loads as low as possible (around 4 inches off the ground) when moving.
- Lower forks when parked.
- Reduce speed before turning.
- Remain alert to floor hazards such as oil, ice, or debris.
How can warehouses protect pedestrians from forklift accidents?
Pedestrians should remain in clearly designated walkways, separated from forklift routes. Operators must:
- Look in the direction of travel
- Sound horns at intersections
- Maintain a safe speed and distance
Employers should use floor striping, mirrors, guard rails, fencing, and warning signage to improve visibility and separate pedestrians from forklifts. Physical barriers offer the highest protection.
How do forklifts damage pallet racks?
What safety equipment can reduce forklift-related rack impacts?
To minimize accidents, consider installing:
- Base and column guards to protect upright legs and anchors
- End-of-aisle protection barriers
- Rear-view mirrors, mast-mounted cameras, and sensors on forklifts
- Adequate lighting and uncluttered aisles
These measures improve driver visibility, protect rack structures, and reduce costly downtime.
Who is responsible when a forklift accident occurs?
Responsibility depends on the root cause:
- The operator is responsible if negligence is involved.
- The employer is liable if they fail to provide training, safe equipment, or a hazard-free workplace.
- The manufacturer may be liable for mechanical defects.
Under the Occupational Safety and Health Act , employers must ensure a safe workplace and provide appropriate forklift operator training.
What training does OSHA require for forklift operators?
Per OSHA 29 CFR 1910.178(l), operators must receive:
- Formal classroom and hands-on training before operating a forklift
- Refresher training every three years or after unsafe behavior/incidents
- Daily pre-shift inspections of the forklift’s key systems
OSHA estimates that robust training and strict adherence to safety procedures could prevent up to 70% of forklift accidents.
What should be included in a daily forklift safety inspection?
Before each shift, operators should check:
- Fork condition and alignment
- Horn and warning devices
- Hydraulic leaks or oil spots
- Tire pressure and condition
- Seat belt functionality
- Lights and battery restraints
- Load capacity plate visibility
- Presence of the operator’s manual
Documented inspections help ensure compliance and allow for early detection of problems.
How can warehouse design reduce forklift accidents?
A safe warehouse layout should:
- Maintain wide, well-lit aisles
- Remove obstructions from intersections
- Use column and rack protection at the fork level
- Clearly mark pedestrian zones and turning areas
Proactive layout design reduces traffic congestion, minimizes impacts, and supports safer material handling. Want to know how your facility measures up? Take our quiz to assess your warehouse safety level and uncover opportunities for improvement.
What should I do if rack damage from a forklift looks severe or uncertain?
How can partnering with a rack safety expert help prevent forklift accidents?
A professional rack safety partner can:
- Evaluate your warehouse
- Perform routine inspections
- Recommend long-term solutions to prevent structural damage
Damotech, an active ProGMA (MHI) member, offers on-site evaluations, rack protection products, and engineered repairs to help facilities maintain compliance, reduce downtime, and safeguard employees. Talk to our experts.
