Forklift Trucks - Common Factors in Forklift Incidents

Many work-related factors can cause incidents. Grouping them into specific categories may help to analyze incidents and, eventually, to prevent them.

• Production factors such as speed or stress.
• Lack of proper tools, attachments and accessories.
• Improper assignment of forklifts and operators.
• Poor maintenance of forklifts.
• Age of forklifts.
• Lack of training or improper training of workers who have to operate forklift trucks.

• 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.

• Narrow aisles.
• Crowded, cluttered aisles.
• Shelving that has components that could hit or intrude into the operator area.
• Obstructions at intersections and doors.
• Volume of traffic in work area.
• Pedestrians who are walking and working in the general area of forklift operations.
• Other workplace conditions such as noise, odours, toxic gases, dust, or poor lighting.
• Ramps or flooring with different surfaces.
• Condition of loading dock.

• Goods are poorly stacked or piled on the pallet in a way that result in an unstable load.
• Pallets are in poor repair.
• Load is too heavy.
• Load is unstable or blocking vision.

• Malfunction of brakes.
• Malfunction of steering.
• Malfunction of clutch, shift linkage, or transmission.
• Malfunction of mast assembly.
• Leaks in hydraulic systems or transmission.
• Safety devices lacking, inadequate, or malfunctioning.
• Emissions from forklifts.
• Blind spots or obstructions blocking driver's view.
• Poor layout of controls and displays.

• Separate the pedestrian and forklift traffic by creating designated walkways or travel ways.
• Restrict people from entering areas where the forklift is operating. If not possible, develop safe work procedures to protect workers when they must enter areas where forklifts are operating.
• Keep a safe distance from the forklift whenever possible.
• Pedestrians should always let the driver know they are in the area. Make eye contact with the driver to ensure your presence is known.
• Make sure the area is well lit and there are no obstructions.
• Be cautious near blind corners, doorways, and narrow aisles. Sound the forklift horn at intersections.
• Use high-visibility clothing, where appropriate.
• Limit forklift travel speed.
• Do not walk near or under raised forks.
• Do not load the forklift in a way that restricts the driver's viewing area.
• Avoid driving forklift near areas where pedestrian traffic is high (e.g., lunch rooms, time clocks, entrances/exits).