Forklifts are one of the most commonly used pieces of machinery in the world.

Unfortunately, that means they’re also one of the most common places for workplace accidents.

What makes this even worse is how easy it would be to prevent most of them.

We’ve put together this guide to forklift accident stats so you can learn more about what causes these accidents and how to prevent them.

Forklift Accident Stats

The statistics around forklift accidents are sobering. OSHA reports that there are more than 100,000 forklift accidents each year.

Considering there are just over 800,000 forklifts working in the US, this means more than 1 out of every 10 forklifts will be involved in an accident.

Of those 100,000 accidents about two-thirds result in only minor injuries. Around 35,000 though cause serious injuries with potentially life-altering consequences.

Even more unsettling, there are 85 fatal accidents involving forklifts every year.

The industry you work in also affects how likely you are to have an accident. Almost half of all forklift accidents occur in the manufacturing sector. Another 20% take place in the construction trades.

Before you start your day on a forklift do a basic safety check. Test the brakes, steering, and acceleration to make sure everything is okay.

Make sure you test the horn several times. Being able to warn someone that a forklift is approaching can prevent a lot of accidents.

Who’s Hurt in Forklift Accidents

What many people find surprising is that forklift operators aren’t usually the ones being injured. Nearly four out of five forklift accidents involve pedestrians.

In layman’s terms, a pedestrian is anyone walking around a factory or distribution center floor. What makes it even worse is that it often isn’t the forklift operator’s fault.

Safety in a manufacturing or warehouse setting requires everyone to do their part. Many forklift-related incidents occur because a pedestrian was somewhere they shouldn’t have been.

A lot of times it comes down to doing something that’s against company policy. If a worker is walking past a moving forklift without proper signaling it’s just asking for trouble.

The same is true for pedestrians who wander into assigned forklift lanes. If they followed policy correctly and kept to their lane they wouldn’t have a problem.

For forklift operators, it’s less clear how to help. Most of the accidents they deal with relate to toppled forklifts or dropped product.

This makes it essential they follow proper speed limits, safety rules, and standard operating procedures. OSHA estimates that 70% of the more than 100,000 forklift accidents each year could have been prevented with proper training and policies.

Most Common Forklift Injuries

We’ve established that forklift accidents are common, but many people wonder what the actual accidents are. Here are a few of the most common accidents and injuries related to forklifts.

Collisions

Just about the most common type of forklift-related accidents deals with collisions. It’s very common for a forklift to collide with another person, structure, or vehicle.

Usually, this comes down to people and forklifts working in close quarters. All it takes is one second of carelessness or a mechanical malfunction for something to happen.

The best way to deal with this type of accident is to establish clear movement and working paths. You should separate forklifts and people whenever possible.

Another important safety measure is requiring all employees to wear high visibility clothing. Many forklift drivers simply didn’t see coworkers in dark clothing or conditions.

Collisions account for more than one in four fatal forklift incidents.

Topplings

Topplings occur when a forklift rolls over and flips on its side. There are a number of causes for this kind of incident, though the most common have to do with operator error or ground conditions.

Driving too fast and taking turns without properly dropping speed is one of the leading causes of toppled forklifts. Driving with a heavy load suspended in the air is another.

If you’re working on uneven ground or with slippery conditions you must take them into account. Failure to adjust speed and movement methods can result in serious injuries or death.

Topplings are the leading cause of death to forklift operators.

Drops and Falls

Drops and falls relate to both the forklift and its load. Some drops take place on a loading dock or other areas where a forklift can run off a higher surface.

That kind of fall in a forklift is just as dangerous as driving off a platform in a car. Special care should be taken around loading docks and when moving forklifts into and out of trucks.

Depending on what a forklift is moving dropped product can pose a significant hazard. Most of the time drops are caused by poorly maintained pallets, overburdened lifting tines, or failure to follow proper procedure.

If a forklift isn’t lined up correctly when picking up a heavy pallet there’s a good chance it will give way. All that product dropping down can seriously injure anyone nearby.

Preventing Forklift Injuries

The first step to preventing forklift accidents is making sure everyone is fully trained and certified. OSHA requires that all drivers go through a training and safety course and be properly licensed.

This course includes a comprehensive rundown of safety regulations and practices.

That’s only the first part of accident prevention. It’s up to employers to set and enforce proper safety rules. Forklifts are heavy duty machines that can do serious damage.

You have to respect them and understand how to safely work with them.

Don’t Become a Statistic

If you found these forklift accident stats unsettling you’re not alone. It’s crazy to think that over 100,000 people are injured using forklifts each year. Don’t let yourself become one of them.

Make sure you have the knowledge and training needed to do your job right. If possible only work for a company that has well thought out safety rules and enforces them.

If you found this article useful or informative check out some of our other useful tips articles located here.