The Most Common Forklift Accidents (and OSHA-Approved Ways to Prevent Them in 2025)

Quick Facts About Forklift Accidents in 2025

• Forklifts cause about 7,500 injuries and nearly 100 deaths each year in the U.S.
• The most common accidents include tip-overs, collisions, falling loads, pedestrian incidents, and improper use.
• Most accidents happen in warehouses and loading docks with high traffic.
• OSHA requires operator training and daily inspections to reduce risks.
• Prevention comes down to safe driving, clear walkways, and regular equipment checks.

Why Forklift Accidents Are Still a Problem

Even with safety programs in place, forklift accidents remain one of the top causes of warehouse injuries. Most incidents don’t come from rare equipment failures – they happen because of preventable mistakes: rushing, skipping inspections, or ignoring load limits.

The good news? OSHA guidelines give clear steps to prevent these issues, and with the right training and support, accidents can be reduced dramatically.

The Most Common Forklift Accidents and How to Prevent Them

1. Forklift Tip-Overs

Tip-overs are the leading cause of forklift-related deaths. They usually happen when:

• Loads are too heavy or unbalanced
• Operators turn too quickly
• The forklift is used on uneven ground

Prevention tips:

• Keep loads low and tilted back while moving
• Slow down around corners
• Never exceed the rated load capacity
• Use the right forklift for the surface (pneumatic vs. cushion tires)

2. Collisions with People or Equipment

Forklifts often operate in crowded spaces. Collisions can involve pedestrians, racking, or other forklifts.

Prevention tips:

• Always sound the horn at intersections and blind spots
• Maintain clear aisles and floor markings
• Install mirrors and warning lights in high-traffic areas
• Separate pedestrian walkways from forklift routes whenever possible

3. Falling Loads

Loads that aren’t secured properly can slide off the forks, causing injuries or damaged goods.

Prevention tips:

• Center the loads on the forks and keep them stable
• Avoid lifting damaged pallets
• Tilt the mast back slightly while transporting
• Don’t overload or stack items too high

4. Pedestrian Incidents

People working near forklifts are at risk if operators or coworkers aren’t paying attention.

Prevention tips:

• Train both operators and pedestrians on safety rules
• Require hi-vis clothing in warehouse environments
• Use audible alarms and blue spotlights on forklifts
• Establish “no-go zones” for pedestrians during peak hours

5. Improper Use or Horseplay

Using a forklift the wrong way – carrying passengers, speeding, or using forks to lift people – can be just as dangerous as mechanical failure.

Prevention tips:

• Enforce OSHA operator training standards
• Ban passengers unless the forklift is designed for it
• Never let anyone ride on the forks or load
• Create a zero-tolerance policy for unsafe behavior

OSHA Requirements That Reduce Accidents

• Operator certification and training – required for anyone using a forklift
• Daily inspections – to check brakes, steering, hydraulics, forks, and safety features
• Load capacity limits – forklifts must display and follow manufacturer ratings
• Worksite safety measures – clear signage, proper lighting, and traffic management

Meeting these requirements isn’t just about avoiding fines – it’s about protecting workers and keeping operations productive.

How Thompson Lift Truck Helps Keep Teams Safe

• OSHA-compliant operator training programs
• Easy-to-use inspection checklists
• Preventive maintenance that keeps forklifts in safe working order
• Guidance on choosing the right forklift for your environment

Final Word

Forklift accidents are common, but almost always preventable. By following OSHA requirements and focusing on training, inspections, and workplace design, businesses can reduce risks and keep employees safe.

Looking to improve safety in 2025? Thompson Lift Truck offers the training, tools, and service to keep your team OSHA-compliant and accident-free.