Forklifts are indispensable in the construction industry, providing the muscle to move heavy loads and streamline operations. However, they also pose a significant safety risk. Forklift accidents are among the most common workplace incidents on construction sites, often leading to severe injuries, costly downtime, and regulatory penalties. According to the National Safety Council, as many as 25,000 workers miss work or can’t perform their usual tasks due to forklift accidents each year.

Understanding the causes of forklift accidents and implementing proactive safety measures is critical for creating a safer, more efficient work environment. In this guide, we’ll explore the most common types of forklift accidents and share seven actionable tips to avoid them.

Common types of forklift accidents

  1. Tip-overs: Forklifts tipping over are among the most dangerous accidents, often caused by overloading, uneven terrain, or sharp turns.
  2. Collisions: Forklifts frequently collide with other vehicles, equipment, or structures due to poor visibility or inadequate operator training.
  3. Pedestrian incidents: Pedestrians and workers struck by forklifts are a leading cause of workplace injuries, often occurring in crowded or poorly marked areas.
  4. Falling loads: Improperly secured loads can shift or fall, endangering operators and nearby workers.
  5. Mechanical failures: Poorly maintained forklifts can experience brake failures, steering issues, or other mechanical malfunctions.

7 ways to prevent forklift accidents

1. Invest in operator training and certification
Proper training is the foundation of forklift safety. Make sure that all operators are certified and trained on the specific forklifts they’ll use. Training should cover:

    Refresher courses should be conducted regularly to keep skills sharp and update operators on new safety protocols.

    2. Conduct daily inspections
    A quick daily inspection can prevent mechanical failures that lead to accidents. Operators should check:

      • Brakes and steering
      • Tires and forks for damage
      • Lights, horns, and alarms
      • Fluid levels and battery charge

      Using a digital inspection checklist can streamline this process and make certain nothing is overlooked.

      3. Implement clear traffic management plans

      Separate forklift traffic from pedestrian areas wherever possible. Use barriers, signage, and floor markings to designate safe zones and prevent collisions. Create clear traffic flow patterns and enforce speed limits to minimize risks.

      4. Avoid overloading
      Overloading is a leading cause of forklift tip-overs. Verify that operators know the load capacity of their forklift and never exceed it. Use load backrests to secure items and distribute weight evenly to maintain balance.

      5. Maintain forklifts regularly
      Preventive maintenance is crucial for keeping forklifts in top condition. Schedule regular inspections and servicing to address wear and tear before it becomes a hazard. A comprehensive maintenance program should include:

      • Checking hydraulic systems
      • Inspecting tires for wear and adequate pressure
      • Replacing worn-out parts promptly

      6. Improve visibility
      Poor visibility contributes to many forklift accidents. Equip forklifts with safety features like mirrors, dash cameras, and backup alarms. Verify that operators have a clear line of sight and adequate lighting, especially in low-visibility areas or at night.

      7. Promote a culture of safety
      Safety starts with leadership. Foster a workplace culture that prioritizes safety by:

      • Encouraging employees to report hazards
      • Conducting regular safety audits
      • Rewarding safe behavior

      Implementing technology solutions, like Motive’s fleet safety tools can help monitor and promote safer practices in real time.

      Why forklift safety matters

      Forklift accidents can lead to serious injuries, expensive fines, and reputational damage. By investing in prevention strategies, construction companies can reduce the risk of incidents, protect their workforce, and improve l productivity.

      How Motive can help

      At Motive, we understand the unique safety challenges of construction firms. Our safety solutions help businesses proactively manage risks, from monitoring equipment performance to enhancing operator behavior. With tools like digital inspection checklists, real-time safety alerts, and advanced analytics, Motive empowers you to create a safer, more efficient worksite.

      Ready to take forklift safety to the next level? Explore how Motive’s construction fleet management solutions can help your business prevent accidents and improve safety across your fleet and equipment.