Quick stats: In warehousing, forklifts remain one of OSHA’s most frequently cited hazards. Turnovers (tip-overs) account for a significant share of forklift fatalities. Prevention hinges on OSHA-compliant operator training (29 CFR 1910.178), pre-shift equipment checks, maintaining conservative travel speeds, ensuring clear pedestrian separation, and implementing proper rack impact protection.
Often called the “workhorses” of warehousing and construction, forklifts lift, carry, and unload heavy goods over short distances. For the efficient management of warehouse operations, you can count on them to deliver—when they’re used safely.
At the same time, operating a forklift involves risk. Forklifts can weigh several tons, multiple times the weight of a car. They’re rear-wheel steered, which alters turning dynamics, and most braking is applied to the front axle. As capable as they are, these vehicles can become dangerous when operated improperly or in unsafe environments.
Rather than chase competing year-to-year figures, focus on the risk patterns that don’t change:
Most incidents fall into the scenarios below. Use these controls to reduce the likelihood and severity of issues.
Why it happens: sharp/fast turns, elevated loads while traveling, and excessive speed.
Side crush during a tip-over is a major danger.
Forklifts are not designed to elevate people unless using an approved work platform designed for that truck.
Racking isn’t designed to absorb repeated impacts. Seemingly “minor” hits compound over time and can lead to serious structural degradation or collapse. To understand common impact patterns, see frequent ways forklifts damage racks and key lessons from rack collapse videos.
Responsibility depends on causation. If an operator fails to follow safe practices, they may be at fault. Employers may be liable for inadequate training or unsafe conditions. The Occupational Safety and Health Act requires employers to provide a workplace free from recognized hazards. Consult with legal counsel for jurisdiction-specific guidance.
Ensure all operators are trained, evaluated, and certified on the truck type and workplace conditions. Provide refresher training when conditions, truck types, or behavior warrant it. Before each shift, perform a pre-use inspection and remove any unsafe trucks from service.
Tip: Use OSHA’s sample pre-shift checklist as a baseline, then tailor to your fleet and environment.
Safe operation is also about the environment. Keep aisles clear, protect rack frames and building columns at fork level, minimize mixed traffic at workstations, and post clear pedestrian and wet-floor signage. Where damage is found, document, prioritize by severity, and act—repair or unload as required.
Partner with a provider that offers engineered inspections, load capacity calculations, rack safety training, repair solutions, protection products, and software to track issues. Look for engineering expertise and national coverage to support ongoing compliance and continuous improvement.