7 Common Causes of Forklift Injuries and How to Prevent Them

7 Common Causes of Forklift Injuries:

Speeding & Why Control is Better

Just like a car on a road, when driving a forklift, speed kills. Forklifts are designed for stacking, lifting, and moving heavy materials, not time trials. Driving too quickly reduces reaction time and control over the FLT, which causes accidents.

To prevent operators from driving too fast, you can put up signage with clear speed limits and provide thorough training on the consequences of speeding.

Preventing Overloading and Tipping Risks

Forklifts can only hold so much weight. Overloading forklifts or stacking materials high above the masts changes the centre of mass, increasing the risk of tipping. Overloading your forklift will damage the FLT and risk injuries.

You can find out the capacity of your FLT by checking the data plate on the side of the vehicle. Weigh all loads before you lift them, and be confident you’re that bit safer.

Close the Skills Gap with Effective FLT Training

70% of forklift truck accidents could have been prevented by following British safety guidelines. Provide operators with training that includes:

• What to check during inspections
• Using signs and posters as training tools and reminders
• What to do if a fault is found and who to report it to
• Who has the authority to remove unsafe equipment from service

Using real-life examples in training sessions helps operators understand the consequences of missed defects and motivates them to stay compliant.

Poor Driving

Drivers who require training don’t know any better—train them properly to prevent accidents. Drivers who have already been trained should be reminded of the risks of poor driving and held accountable to site safety standards.

Improving Workplace Design for Safer Traffic Flow

Workplaces where FLTs are used should be suitably adapted. Create clear gangways and routes for forklifts to travel down and use signage to warn pedestrians. Make sure no objects are left in the routes and that driving surfaces are smooth and free of hazards like potholes.

Protecting Pedestrians in High-Risk FLT Zones

Pedestrians are involved in 43% of forklift accidents and account for 57% of injuries or deaths. Any staff, visitors, or contractors on your site must know how to act safely in areas where FLTs operate. They must complete site inductions and be provided with constant visual reminders through safety signage.

Eliminating Risks from Faulty Equipment and Missed Inspections

If a faulty forklift truck leads to an injury, you, as an employer, are liable. The best way to ensure forklifts are safe to use is to complete daily pre-use inspections. Each day, operators should ensure that each component of the FLT is working properly. Any faults should be reported, and the forklift should not be used until repairs are made.

Turn Prevention into Practice with SG World

Understanding the causes of forklift accidents is the first step, but prevention requires the right tools on the ground. Whether it is managing pedestrian flow or ensuring that "Faulty Equipment" never leaves the charging bay, SG World provides the physical solutions to back up your safety policy.

Targeted Safety Solutions

• Prevent Faulty Equipment Use: Catch defects before they cause an injury with Forklift Pre-Use Inspection Books.
• Manage Pedestrian Safety: Create clear boundaries with Safety Signage and Floor Indicators.
• Professional Oversight: Centralise your records with FLT Inspection Stations.

Take the guesswork out of site safety.
Shop the SG World Forklift Safety Range