4 Common Causes of Forklift Operator Injury or Death – Forklifts are common work vehicles used by most of Kentucky’s construction and manufacturing industries. Also known as powered industrial trucks (PITS), forklifts are used most often to lift heavy loads and transport supplies and can either be operated by a trained worker or controlled by a walking driver.
Either way, these trucks can be extremely dangerous given the size and weight especially when operated by inexperienced workers, in unsafe workplace environments, or if the machinery is poorly maintained. Data from the Occupational Safety and Health Administration (OSHA) show these industrial vehicles are involved in nearly 100 worker deaths and 20,000 work-related injuries each year.
There are several types of forklifts and each comes with different hazards associated with its operation. For example, OSHA explains “the chance of a falling load accident occurring when the truck is a sit-down, counterbalanced rider truck is much greater than when the vehicle is a motorized hand truck because the height that the load can be raised on the sit-down rider truck is much greater than the hand truck.” Many workers involved in forklift incidences will become injured in these four ways:
Lift trucks are inadvertently driven off loading docks. Lifts fall between docks and an unsecured trailer while a worker in onboard. Workers (or pedestrians) can be struck by a lift truck. Trucks may fall while on elevated pallets and tines.
Workers can also be killed or seriously hurt in rollover accidents, when loads fall onto them, or tragically runover by forklift operators who are distracted or using illegal, non-prescribed substances or doctor provided substances in excess of prescribed amounts, a workplace drug abuse epidemic reaching industrial workers at skyrocketing rates.
Contents
What is the most common cause of forklift accidents?
The main reason for Forklift accidents is the lack of proper Forklift Training and lack of Forklift Certification given by the Company. There are still many companies allowing Forklift Operators drive the equipment without a Forklift License or a proper Forklift Training.
What is the cause of forklift accident?
What factors can contribute to forklift trucks incidents? – Back to top
Travelling at excessive speed. Riding with the load elevated. Improper backing up techniques. Improper turning, braking or accelerating. Improper warnings to others about a forklift in use nearby. Poor communication during shared tasks, or in shared spaces. Not being aware of the route to be travelled (e.g., narrow passages, obstacles, poor surface conditions, etc.). Riding or giving rides on forklift or load. Parking the forklift improperly. Improper blocking of wheels on semi-trailers or railway cars. Horseplay; stunt driving; jerky, erratic driving. Inadequate servicing of the forklift.
What points of a forklift can cause injuries?
3. Musculoskeletal Injuries – Forklift operators perform repetitive movements that can cause muscle tissue damage. These movements can impact the neck, upper back, forearms, and shoulders. They may cause minor pain at first. Yet, if minor musculoskeletal injuries go untreated, they can hinder a worker’s ability to drive a forklift.
- In the worst-case scenarios, these injuries can force forklift operators to miss work altogether.
- Forklift injuries can be avoided.
- Teach workers about common forklift operator injuries and offer tips and insights to help employees prevent such issues.
- Furthermore, educate workers about common causes of forklift accidents,
This can help workers identify and avoid forklift hazards that can otherwise cause accidents and injuries.
What is the most common type of forklift injury?
Why Are Forklift Accidents on the Rise? As with any piece of machinery, accidents can happen in a manufacturing setting. It is no different with forklifts. In a given year, 34,900 serious injuries result from forklift accidents, and 61,800 non-serious injuries related to forklifts happen annually.
Labor turnover A shift to 24/7 operations
Labor Turnover The “Great Resignation” is a term coined due to a shift in the labor market from the COVID-19 pandemic. Because of the record number of employees quitting jobs and the struggle for companies to retain employees, this event in time is now being called the “Great Resignation.” With the “Great Resignation,” more warehouses struggle to retain, hire, and train new employees.
As a result, forklift drivers tend to have less experience and less time for adequate safety training. Shift to 24/7 operations The pandemic has placed burdens on the warehousing industry to shift to round-the-clock operations. Employees are working longer hours, and more new employees are being hired, all of which can lead to an increase in human error.
For companies trying to keep up with customer demand, throughput is sometimes prioritized over forklift safety and forklift fleet management, Five Most Common Forklift Accidents Forklift safety incidents have increased in frequency over the years. But that does not mean that the trend cannot be reversed.
Forklift Rollovers Pedestrian Collisions Falling Loads Mechanical Failure Emissions Poisoning
Forklift Rollovers A forklift rollover is when a forklift of any type tips over. Forklift rollovers are the most common type of forklift accident found in warehouses. A forklift turnover typically happens if the load is overextended or out of balance, shifting the center of gravity of the entire mass (truck + load) to a tipping point.
Forklifts rollovers can also happen with abrupt movements, like sharp turns, turns on inclines, or uneven driving substrate. A forklift turnover accounts for nearly 24% of all forklift accidents, Forklift turnovers are very hazardous to the driver and others in the vicinity. It can cost companies a lot of money when accidents like forklift rollovers happen.
OSHA fines can be $13,500 for serious violations, and damages from forklifts tipping over can estimate at as much as $86M per year from improper equipment handling. Employers must follow OSHA-created regulations and safety training. Forklift turnovers can be prevented by following OSHA-required speed limits and slowing down when rounding corners.
- OEM forklifts have different equipment centers of gravity, so operators need to know how much a forklift can handle.
- Pedestrian Collisions A pedestrian collision is when a forklift strikes, bumps into, or rolls over a person (or any part of their body).
- This type of forklift accident happens from the failure of a forklift driver and pedestrian to see each other clearly and communicate travel intentions or yield right of way.
Pedestrian collisions can also occur due to a lack of signaling between the operator and the pedestrian. Nearly 20% of all forklift accidents involve pedestrian s, and 36% of fatal forklift accidents involve pedestrians. Proper safety training could reduce forklift pedestrian accidents.
Training will help operators and pedestrians around forklift equipment in the long run. According to the CDC, productivity loss from injured workers could cost around $225.8B each year. Many of these accidents are attributed to undertrained employees who do not understand the risks of operating warehouse equipment.
Implementing consistent forklift training could help mitigate these risks and ensure operators have a high sense of awareness. Falling Loads Falling loads occur when a load slides, tips, or falls off the forks of a forklift so that it can no longer be safely transported.
- This type of accident usually happens when the load is off-center, loose, or unsecured.
- Loads may fall due to moving, shifting, or tilting the mast too fast.
- Falling loads account for 8% of all forklift-related fatalities but cause some of the most common forklift injuries in the workplace.
- Even though operators are trying to move as fast as possible to get the job done, it is still essential to use care when lifting any load and ensure the product is centered and secured.
Checking on the small details can help significantly reduce and prevent forklift injuries. Mechanical Failure Forklift mechanical failure is when a forklift part fails to operate in its intended manner. Mechanical failure is usually a result of improper operation or maintenance.
Most of the time, it is an operator mishandling issue, although it can also be a failure from a faulty component. Creating forklift operator checklists and consistently maintaining warehouse equipment can reduce the chances of mechanical failures happening in operations and the expensive maintenance costs to fix the equipment that come with it.
Emissions Poisoning Emissions poisoning occurs when forklift operators suffer health consequences (sometimes severe) due to exposure to toxic fumes or liquids emitted by forklifts. Emission poisoning typically only happens with internal combustion forklifts, although it can also occur from lead acid batteries due to a lack of ventilation, PPE, or prolonged exposure to fumes.
- Internal combustion engine forklifts can cause emission poisoning from poor ventilation, incorrect fuel mixture, leaking exhaust, and excessive idling.
- Operators can reduce these emission poisoning causes by installing carbon monitors and scheduling regular maintenance.
- When operators do regular maintenance checks, it is important to adjust the fuel mixture and check for leaks to ensure no carbon monoxide gas is building up.
Lead acid batteries emit hazardous fumes when charging. Well-ventilated rooms are essential to control fumes from lead acid batteries and prevent emission poisoning. On the other hand, lithium-ion battery packs do not emit any hazardous materials, making them safer in indoor workplaces.
- If companies want to reduce hazards in the workplace, lithium-ion battery packs would be the best choice for emission reduction.
- How to Prevent Forklift Accidents & Improve Forklift Safety Switching to lithium-ion technology can often be the easiest and most cost-effective solution to improving forklift safety.
A few benefits of lithium-ion batteries that can help dramatically enhance warehouse safety include:
More compact – Lithium-ion batteries are more compact, making it easier to navigate tight spaces, allowing for more visibility in tight spaces, and increasing headroom.
Built-in BMS – A built-in BMS monitors cell temperature, balances cells, and reduces the chance for human error, unlike lead acid batteries and their maintenance requirements.
Safer battery charging and maintenance routines – Lithium-ion packs are maintenance-free forklift batteries that do not need to be watered and can charge the battery in the forklift. Having the capability to charge the battery in the forklift reduces ergonomic hazards and operator pinch points when maintaining the batteries and equipment.
Do not emit toxic fumes – Lithium-ion battery charging does not require a dedicated and ventilated room. Because the cells are enclosed, no hazardous fumes can escape and cause emission poisoning.
Make the Switch to Lithium-ion Forklift Batteries to Prevent Forklift Accidents Forklift accidents have been an ongoing concern in warehouses for decades. Many factors have played a role in forklift accidents increasing, such as labor turnovers and making a shift in operational hours.
Because of these factors, operations will see more forklift rollovers, pedestrian collisions, falling loads, mechanical failures, emission poisoning, and other types of hazards. But fortunately, there is an easy way to help improve forklift safety and reduce your overall forklift accident incident rate.
Switching to lithium-ion battery packs can help forklift safety, in numerous ways. Lithium-ion battery packs have safer charging and maintenance practices and a built-in BMS designed to monitor the battery. Lithium-ion batteries are also more compact than lead acid batteries helping forklifts navigate in tighter spaces. 
What are the biggest hazards with forklifts?
Even at low speeds, forklifts can cause serious injuries and fatalities. It’s not just the employee using the forklift who can be injured; pedestrians can be crushed against a wall or an object or another vehicle.
Which of the following is one of the three most common types of forklift accidents?
The forklift is the most common type of powered industrial truck (PIT). A forklift is a type of “powered industrial truck” (PIT) covered by OSHA standards. Like other powered industrial trucks, its purpose is to move, carry, push, pull, and lift a material load then stack it or place it in a storage rack (tier).
Forklifts come in many sizes and capacities. They can be powered by batteries, propane, gasoline, or diesel fuel. Some are designed to be used in a hazardous location or atmosphere where an ordinary forklift might cause a fire or explosion. NIOSH states that the three most common types of injuries occur when: A forklift overturns; workers are struck, crushed, or pinned by a forklift; and workers fall from a forklift.
However, no matter what the task, there is always a great risk of injury or death when a forklift operator:
- has not been trained in the principles of physics that allows a forklift to lift heavy loads
- is not familiar with how a particular forklift operates
- operates the forklift carelessly
- uses a forklift that is not safe due to malfunctioning or missing parts
Read the material in each section to find the correct answers to each of the questions. After answering all questions, click the “Check Quiz Answers” button to see your score and a list of missed questions. To correct a question, return to the question, review the material, change your answer, and return to the last section page.
- Click the “Check Quiz Answers” again to recheck the results.
- Do not use the browser’s “Back” arrow or “Refresh” button to navigate course section pages.
- Use the dark tabs above (1.1, 1.2, 1.3, etc.) to review/change missed questions.
- Note : Videos and exercises in our courses are for information only and not required to view.
Final exam questions will not be derived from the videos. OSHAcademy is not responsible for video content.1. Which of the following is one of the three most common types of forklift accidents? a. Overexposure to indoor air pollutants b. Worker is driving too fast c. The backrest extension protects the operator. Left: “Old design” Right: “New design” Seat belts save lives!
What is forklift injury?
I WANT TO TALK TO AN ATTORNEY A forklift is mainly used in the workplace to transport and carry heavy materials in non-roadway areas. Powered platform trucks and order pickers fall under the forklift category. A forklift-related injury is also cross-categorized by the event type, typically as a transportation accident or an incident that involves contact with equipment or an object.
What are the problems with forklift drivers?
Sitting for long periods, twisting into awkward positions and spending all day riding in a machine with no suspension are just a few reasons forklift operators find themselves with musculoskeletal and repetitive use injuries. Lower back pain, musculoskeletal and repetitive strain injuries are some of the most common reasons for absenteeism and workers comp claims.
According to a report on OSHA’s website : Work-related musculoskeletal disorders are the most widespread occupational health hazard facing our Nation today. Nearly two million workers suffer work-related musculoskeletal disorders every year, and about 600,000 lose time from work as a result. Although the median number of lost workdays associated with these incidents is seven days, the most severe injuries can put people out of work for months and even permanently disable them.
In addition, $1 of every $3 spent on workers’ compensation stems from insufficient ergonomic protection. The direct costs attributable to MSDs are $15 to $20 billion per year, with total annual costs reaching $45 to $54 billion. In today’s post, we’ll uncover the most common injuries forklift operators experience, and how operators, facility managers, and fleet managers can prevent them.
Neck and back pain due to vibration, sitting for long periods of time, poor posture and shifting into an awkward position to maintain visibility Whiplash Injuries such as headaches, dizziness, and difficulty concentrating from abrupt stops and starts Musculoskeletal injuries from repetitive movements Lower back issues associated with prolonged sitting in combination with shock/vibration caused during travel
Some of the issues described above start as a nagging pain at the end of the day, but can turn into chronic pain, reduced movement and even inability to work. To prevent some of the issues above, forklift operators should : – Stretch their hands, shoulders and neck regularly: before and after each shift and during breaks – Never drive with a wallet or other bulky object in a back pocket – Position the seat so their feet can easily reach the pedals – Adjust the backrest so it is tilted slightly backward – Slow Down! Faster speeds increase shock and vibration that can cause bad posture and fatigued muscles Facility managers can prevent injuries by : – Fixing rough, broken floor surfaces and potholes. Ergonomic forklift accessories can reduce stress on the body : – Look for an ergonomic operator seat that tilts, swivels and has a weighted suspension – Replace the seat every three years, or use an anti-vibration seat cushion – Install a grab handle-mounted horn button, so drivers don’t have to push a button on the steering wheel while traveling in reverse. – Invest in telemetry devices that offer multi-view cameras, pre-shift checklists and more in a single device. We recommend the GEM Sapphire, 
When buying a new forklift, look for ergonomic features such as: – A vibration-dampening steering column – A mast designed for the best possible visibility – Angled cross braces so looking up through the overhead guard is easy without neck strain – Low step height for easy entry and exit – A small steering wheel combined with a large operator cabin – For stand-up lift trucks, look for intuitive, low force single-hand control operation and low-vibration suspended floorboards Learn more about the ergonomic extras that come standard on Toyota forklifts. 
Topics: Safety, Forklift Safety, Forklift FAQs
What are the 3 points of a forklift?
Use the correct procedure when mounting or dismounting a vehicle or forklift, you must have three points of contact – either two feet and one hand, or two hands and one foot and must be facing the lift truck. –
Avoid Dismounting the vehicle when in motion. Only dismount when it has come to a complete stop. Avoid Jumping from the vehicle which can cause an unbalanced landing or a fall. Avoid wearing loose clothing as it can catch on equipment
What are 5 safety rules for forklift?
Keep your arms, legs, head, and feet inside the forklift when driving. Never drive with the forks up, and never use the forklift to push other vehicles. Never pass a forklift going in the same direction, especially at blind spots, intersections, or other dangerous areas.
Which of the following is one of the three most common types of forklift accidents?
The forklift is the most common type of powered industrial truck (PIT). A forklift is a type of “powered industrial truck” (PIT) covered by OSHA standards. Like other powered industrial trucks, its purpose is to move, carry, push, pull, and lift a material load then stack it or place it in a storage rack (tier).
Forklifts come in many sizes and capacities. They can be powered by batteries, propane, gasoline, or diesel fuel. Some are designed to be used in a hazardous location or atmosphere where an ordinary forklift might cause a fire or explosion. NIOSH states that the three most common types of injuries occur when: A forklift overturns; workers are struck, crushed, or pinned by a forklift; and workers fall from a forklift.
However, no matter what the task, there is always a great risk of injury or death when a forklift operator:
- has not been trained in the principles of physics that allows a forklift to lift heavy loads
- is not familiar with how a particular forklift operates
- operates the forklift carelessly
- uses a forklift that is not safe due to malfunctioning or missing parts
Read the material in each section to find the correct answers to each of the questions. After answering all questions, click the “Check Quiz Answers” button to see your score and a list of missed questions. To correct a question, return to the question, review the material, change your answer, and return to the last section page.
- Click the “Check Quiz Answers” again to recheck the results.
- Do not use the browser’s “Back” arrow or “Refresh” button to navigate course section pages.
- Use the dark tabs above (1.1, 1.2, 1.3, etc.) to review/change missed questions.
- Note : Videos and exercises in our courses are for information only and not required to view.
Final exam questions will not be derived from the videos. OSHAcademy is not responsible for video content.1. Which of the following is one of the three most common types of forklift accidents? a. Overexposure to indoor air pollutants b. Worker is driving too fast c. The backrest extension protects the operator. Left: “Old design” Right: “New design” Seat belts save lives!
What is the most common cause of a forklift accident quizlet?
The most common cause of forklift accidents is human error. Drivers with more than a year of experience are more likely
What are the 3 points of a forklift?
Use the correct procedure when mounting or dismounting a vehicle or forklift, you must have three points of contact – either two feet and one hand, or two hands and one foot and must be facing the lift truck. –
Avoid Dismounting the vehicle when in motion. Only dismount when it has come to a complete stop. Avoid Jumping from the vehicle which can cause an unbalanced landing or a fall. Avoid wearing loose clothing as it can catch on equipment
What body part is most likely to be injured in a forklift accident?
Sitting for long periods, twisting into awkward positions and spending all day riding in a machine with no suspension are just a few reasons forklift operators find themselves with musculoskeletal and repetitive use injuries. Lower back pain, musculoskeletal and repetitive strain injuries are some of the most common reasons for absenteeism and workers comp claims.
According to a report on OSHA’s website : Work-related musculoskeletal disorders are the most widespread occupational health hazard facing our Nation today. Nearly two million workers suffer work-related musculoskeletal disorders every year, and about 600,000 lose time from work as a result. Although the median number of lost workdays associated with these incidents is seven days, the most severe injuries can put people out of work for months and even permanently disable them.
In addition, $1 of every $3 spent on workers’ compensation stems from insufficient ergonomic protection. The direct costs attributable to MSDs are $15 to $20 billion per year, with total annual costs reaching $45 to $54 billion. In today’s post, we’ll uncover the most common injuries forklift operators experience, and how operators, facility managers, and fleet managers can prevent them.
Neck and back pain due to vibration, sitting for long periods of time, poor posture and shifting into an awkward position to maintain visibility Whiplash Injuries such as headaches, dizziness, and difficulty concentrating from abrupt stops and starts Musculoskeletal injuries from repetitive movements Lower back issues associated with prolonged sitting in combination with shock/vibration caused during travel
Some of the issues described above start as a nagging pain at the end of the day, but can turn into chronic pain, reduced movement and even inability to work. To prevent some of the issues above, forklift operators should : – Stretch their hands, shoulders and neck regularly: before and after each shift and during breaks – Never drive with a wallet or other bulky object in a back pocket – Position the seat so their feet can easily reach the pedals – Adjust the backrest so it is tilted slightly backward – Slow Down! Faster speeds increase shock and vibration that can cause bad posture and fatigued muscles Facility managers can prevent injuries by : – Fixing rough, broken floor surfaces and potholes. Ergonomic forklift accessories can reduce stress on the body : – Look for an ergonomic operator seat that tilts, swivels and has a weighted suspension – Replace the seat every three years, or use an anti-vibration seat cushion – Install a grab handle-mounted horn button, so drivers don’t have to push a button on the steering wheel while traveling in reverse. – Invest in telemetry devices that offer multi-view cameras, pre-shift checklists and more in a single device. We recommend the GEM Sapphire, When buying a new forklift, look for ergonomic features such as: – A vibration-dampening steering column – A mast designed for the best possible visibility – Angled cross braces so looking up through the overhead guard is easy without neck strain – Low step height for easy entry and exit – A small steering wheel combined with a large operator cabin – For stand-up lift trucks, look for intuitive, low force single-hand control operation and low-vibration suspended floorboards Learn more about the ergonomic extras that come standard on Toyota forklifts. Topics: Safety, Forklift Safety, Forklift FAQs