Forklifts are powerful machines that help move heavy materials every day across construction sites, warehouses, and loading docks. However, without clear safety habits, serious injuries can happen fast. Everyone, from operators to supervisors, must understand that safety always comes first. Those who cause a forklift accident due to their negligence or carelessness may be liable for any injuries or losses others suffer as a result.
In honor of National Forklift Safety Day, we’re discussing the top five ways to stay safe on a forklift and reduce the risk of forklift accidents. Some of these tips might sound like common sense to some. However, these simple practices often mean the difference between going home safely or heading to the emergency room.
You’ll also learn helpful information on what to do if you or someone you love gets hurt and how injured workers can protect their legal rights. For advice and guidance on your particular injury case resulting from negligent forklift operations, contact a Virginia personal injury attorney near you today for a free consultation.
Forklift accident statistics and workplace safety importance
According to the Material Handling Equipment Distributors Association (MHEDA), 40,513 forklift-related incidents occurred in a recent year that led to workers missing time, being reassigned, being placed under restrictions, or resulting in death.
Of these, 24,960 were classified as DART cases, meaning they involved Days Away from work, Job Restrictions, or Transfers. Within that group, 15,480 cases specifically involved time off from work. Over a recent two-year period, 143 workers lost their lives in forklift accidents, with 70 deaths in 2021 and 73 in 2022.
Most nonfatal forklift injuries involve workers between the ages of 25 and 34. On the other hand, fatal incidents are more likely to involve workers aged 55 to 64. Women made up 17.4% of DART cases and 9.6% of the fatal cases in recent data.
The trade, transportation, and utilities sector reported the highest number of fatal forklift accidents, with 36 deaths. That same sector also had the most DAFW cases, totaling 9,540. Overall, DART cases peaked at 14,700 in this industry.
Many accidents stem from rushing, skipping safety checks, or poor training. Others happen because of damaged equipment or crowded workplaces. Every time a job requires a forklift, safety has to be a top priority, not an afterthought.
Creating safer habits not only protects workers from injury but also helps companies avoid fines, lost work time, and legal trouble.
1. Obtain essential forklift safety training and certification
Forklift training helps operators know how to control the equipment, spot hazards, and avoid dangerous mistakes. OSHA requires every forklift operator to complete proper training and get certified before operating one.
OSHA-required training components
OSHA standards say training must include both classroom instruction and hands-on practice. Operators learn about load handling, steering, turning, braking, and how different forklift types handle differently. Training also covers how to check for hazards, handle loads safely, and follow rules specific to the job site.
Regular refresher courses and updates
Operators don’t just train once and forget everything. Employers must provide refresher training if a worker has been involved in an accident, is assigned to a different type of forklift, or is observed operating a forklift in an unsafe way. Even without any incidents, scheduled refresher courses help keep everyone sharp.
Employer’s responsibilities for proper training
Employers must make sure all operators receive proper training. This includes covering both general forklift safety and specific workplace conditions. Employers also need to keep training records and verify that workers are certified before assigning them forklift duties.
2. Perform critical pre-operation safety checks
Before anyone climbs onto a forklift, they need to make sure it’s safe to use. Skipping these checks can lead to serious injuries or damaged equipment.
Daily equipment inspection requirements
OSHA requires forklift inspections before every shift. Operators should check brakes, steering, lights, tires, seat belts, horn, forks, and fluid levels. If anything looks worn out or broken, the forklift should be pulled from service right away.
Load capacity and stability verification
Every forklift has a load chart that shows its weight limit. Exceeding this limit can tip the machine over or snap the forks. Operators need to match the load to the forklift’s capacity and ensure it’s balanced and secure before moving.
Environmental hazard assessment
Forklift operators must check the area for hazards like slick floors, uneven surfaces, ramps, low-clearance areas, or tight turns. They should also look for other vehicles or foot traffic nearby. Fixing or removing obstacles before starting helps prevent collisions and falls.
3. Utilize proper load handling and maneuvering techniques
Even a well-maintained forklift can become dangerous if the load isn’t handled correctly. Safe load techniques prevent tip-overs, spills, and injuries to others nearby.
Load positioning and securing methods
The load should rest squarely on both forks, not tilted to one side or hanging over the edges. Forks must be spread wide enough to support the load. Operators should avoid stacking loads too high, which limits visibility and increases the chance of tipping.
Safe lifting and lowering procedures
Lift and lower loads smoothly. Jerky movements or sudden stops can throw the load off balance. The load should always be tilted slightly back during travel to help stabilize it. Forks must be lowered fully when parking the forklift to avoid tripping hazards.
Turning and backing safety protocols
Operators need to slow down before turning. Sharp turns at high speed can cause rollovers, especially when carrying heavy loads. When backing up, drivers should check mirrors, sound the horn, and make eye contact with nearby workers. If vision is blocked, someone should guide the operator.
4. Maintain awareness of your surroundings
Forklift drivers don’t work in a vacuum. Most worksites are full of other people, machines, and moving parts. Paying close attention helps avoid collisions and injuries.
Pedestrian and vehicle traffic management
Forklift zones should be clearly marked. Employers can use signs, painted lines, or barriers to separate forklifts from pedestrians. Operators should never assume people see them coming. Slowing down in busy areas and using the horn can help prevent accidents.
Blind spot recognition and mitigation
Forklifts have large blind spots, especially when carrying bulky loads. Mirrors and cameras can help, but they don’t replace careful driving. If a driver can’t see well enough, they should stop or ask for help before moving forward.
Communication systems and warning devices
Forklifts come equipped with horns, backup alarms, and sometimes lights. These tools alert others when the machine is moving. Operators and workers should also use hand signals, radios, or other communication tools when needed to coordinate movement.
5. Address equipment malfunctions promptly
Even with inspections and maintenance, forklifts can break down. Operators must know how to react and report problems right away to avoid putting themselves or others at risk.
Immediate response to mechanical failures
If the forklift doesn’t respond as expected or something seems off, the operator should stop using it. Strange noises, trouble steering, fluid leaks, or difficulty braking all require immediate attention.
Proper reporting and documentation procedures
Any problems should be written up and shared with supervisors immediately. Some workplaces use paper forms, while others have digital systems. Either way, quick reporting helps get repairs started and prevents other workers from using unsafe equipment.
When to remove equipment from service
Forklifts with mechanical issues must be removed from service and clearly marked as out of order. They should not return to use until a qualified technician confirms they’re safe. Letting workers use faulty forklifts puts everyone in danger.
How a personal injury attorney can help after a forklift accident
After a forklift accident, dealing with medical treatment, missed work, and a pile of paperwork can feel like too much to handle alone. A personal injury attorney helps injured workers take control of the situation and pursue the full compensation they’re owed.
Understanding your rights under workers’ compensation
Most employers in Virginia must carry workers’ compensation insurance. This system is meant to provide benefits to employees who get hurt on the job, no matter who caused the accident. These benefits can include coverage for medical bills, wage replacement, and support for long-term injuries. A personal injury attorney helps you file a strong claim, tracks deadlines, and steps in when the insurance company delays or refuses to pay what it should.
Third-party liability claims and product defects
In some cases, someone outside of your employer may be responsible for the accident. For example, a forklift might malfunction because of a defect the manufacturer failed to fix. Or a subcontractor might create unsafe conditions on a shared job site. When someone else’s negligence contributed to the accident, an attorney can file a third-party claim to seek additional compensation that goes beyond what workers’ comp provides.
Maximizing your recovery for medical bills and lost wages
Insurance companies often try to limit payouts. They may question your need for certain treatments or downplay the seriousness of your injuries. A personal injury attorney builds a strong case using medical records, expert opinions, and other evidence to show the true impact of your injury. That can make a major difference in recovering full payment for your medical expenses, lost income, and future care needs.
FAQs about forklift safety and accidents
What should I do after a forklift accident?
After a forklift accident, report the incident to your supervisor right away, even if the injury seems minor. Get medical attention as soon as possible and follow all treatment instructions. If possible, take photos of the scene, your injuries, and the equipment involved. Collect names of any witnesses and write down what happened while it’s still fresh.
Avoid giving recorded statements to insurance companies before speaking with an attorney. Filing a workers’ compensation claim quickly helps protect your rights, and talking with a personal injury attorney can help you understand your options for pursuing full compensation.
How long do I have to file a claim after a forklift accident?
Filing deadlines vary by state. In Virginia, injured workers typically have 30 days to report the injury to their employer and up to two years to file a claim with the Workers’ Compensation Commission. Injured parties also have two years to file a third-party injury claim. Waiting too long could affect your ability to receive benefits.
Can I sue my employer for a forklift injury at work?
In most cases, workers’ compensation is the only option for suing an employer directly. However, if someone else caused the accident or if gross negligence occurred, you may be able to take separate legal action.
What if the forklift manufacturer knew about a safety defect?
If a forklift malfunctioned due to a known defect, and the maker failed to fix it or warn users, the manufacturer could be held responsible. This falls under product liability law and may allow you to seek compensation for injuries.
Will I lose my job if I file a workers’ compensation claim?
It’s against the law for employers to fire workers just for filing a claim. If your employer tries to punish or terminate you for reporting an injury, you may have grounds for a separate legal claim.
How much does it cost to hire a personal injury attorney?
Most personal injury attorneys work on a contingency fee basis. That means you don’t pay any upfront costs. Instead, the attorney receives a portion of any compensation recovered on your behalf.
Contact our forklift accident lawyers now
A forklift accident can change your life in an instant. You may need medical care, time away from work, and help getting your bills paid. Talking with an attorney right after the accident gives you a better chance of protecting your rights and securing the support you need.
At Allen & Allen, our team offers free case evaluations and has decades of experience helping people injured in workplace accidents. Virginia law limits the amount of time you have to file a claim, so don’t wait.
If someone else’s actions caused your forklift accident, our attorneys will treat your case like their own. We’ll fight for every dollar you’re owed for the injuries and losses you’ve suffered.
Contact Allen & Allen today at 866-388-1307 for your free consultation. Let us help you take the next step toward recovery.
