Workplace Injuries Commonly Caused by Forklifts

Forklifts are common and essential tools in many warehouses, construction sites, and industrial workplaces, but they also pose significant risks. When not operated safely, these powerful machines can cause severe injuries, leading to lost work time, costly medical bills, and even permanent disabilities.

Being aware of the most common types of forklift-related injuries can help both employers and workers implement better safety measures and reduce the likelihood of accidents.

Forklift Tip-Overs and Falling Loads

One of the most frequent and dangerous forklift-related incidents involves tip-overs. Forklifts can tip easily when carrying an unbalanced load, making sharp turns, or moving over uneven ground. When a tip-over occurs, the operator may instinctively try to jump out, which often results in crushing injuries.

Staying inside the forklift’s cabin with a seatbelt fastened is the safest response to a tipping forklift.

Falling loads also pose a serious hazard. If a load is not properly secured or stacked too high, it may become unstable and fall, potentially striking nearby workers. This can result in head injuries, fractures, and even fatalities.

Proper training on load handling and securing materials correctly can minimize these risks.

Pedestrian Accidents and Collisions

Forklift operators must stay aware of their surroundings, as collisions with other workers are a leading cause of workplace injuries. A forklift’s blind spots and high speed can make it difficult to see workers walking nearby. Pedestrians struck by forklifts often suffer broken bones, internal injuries, or traumatic head wounds.

Collisions between two forklifts or with other equipment or structures can also lead to severe injuries.

A distracted or poorly trained operator may misjudge distances, resulting in crashes that harm both the operator and nearby workers.

Clear signage, designated pedestrian walkways, and strict adherence to speed limits can help prevent these accidents and reduce workers’ compensation claims.

Caught-In and Crush Injuries

Those who operate or work near forklifts also face the risk of caught-in-between or crush injuries.

If a worker gets trapped between a forklift and a stationary object, they may suffer broken bones, severe bruising, or severe, even deadly compression injuries. Operators who don’t check their surroundings before driving in reverse could accidentally pin someone against a wall or shelving.

Additionally, workers can get caught in moving parts, such as the mast or lift mechanism. Loose clothing, jewelry, or hair can become entangled in these components, leading to serious cuts or even amputations.

Employers should enforce strict dress codes and safety procedures to prevent these types of injuries.

Falls From Forklifts

Forklifts are not designed to transport workers on their forks, yet some employees attempt to ride on them or use them as makeshift lifting devices. Falls from forklifts can result in head trauma, spinal cord injuries, or broken limbs. Even standing on the forks to reach high shelves can be incredibly dangerous.

Using proper equipment, such as ladders or aerial lifts, for elevated tasks is crucial. Employers should also ensure that workers are trained to understand the dangers of misusing forklifts and strictly enforce safety protocols to prevent falls.

Carbon Monoxide Poisoning From Forklift Emissions

Forklifts often run on propane, gasoline, or diesel and produce carbon monoxide (CO) as a byproduct.

In poorly ventilated areas, this CO can build up to dangerous levels, causing workers to experience dizziness, nausea, confusion, or even unconsciousness. Prolonged exposure to high CO levels can be fatal.

Proper ventilation in indoor workspaces and routine emissions checks on forklifts are critical in preventing CO poisoning. Employers should also provide CO detectors and educate workers on the signs of poisoning to ensure a safe working environment.

Preventing Forklift Injuries

Worker injuries from forklifts can be lessened through comprehensive training, strict adherence to safety rules, and proper maintenance. Employers should require all operators to complete forklift certification courses, emphasizing hazard awareness and safe operation practices.

Regular inspections ensure that forklifts are in good working condition and reduce the risk of mechanical failures resulting in accidents.

Workplaces should implement clear communication systems between forklift operators and other employees. Hand signals, warning lights, and audible alarms help ensure that all workers remain aware of forklift movements.

At Belsky & Horowitz, LLC, we believe that by prioritizing safety and awareness, businesses can significantly decrease the number of forklift-related injuries, creating a safer and more productive work environment.