The Industrial Truck Association estimates that 4.5 million people in the United States operate forklifts across over 300 different industries [1], making them one of the most common industry vehicles in the country.
Depending on their size, these vehicles can carry thousands of pounds of weight and are easy to maneuver, allowing workers to carry everything from hay bales to pallets of merchandise.
However, with such ubiquity comes serious risk. There are thousands of accidents a year involving forklifts. The enormous weight and instability of these tools make them highly susceptible to overturning or running over a worker, causing serious injury or death.
Read on to explore forklift accident statistics that shed light on the severity of this occupational risk.
Why Are Forklift Accidents So Dangerous?
- Forklifts can weigh over 9,000 pounds, compared to the 3,000 pounds of a typical automobile. They also have an average speed of 18 miles per hour. [2].
- A forklift has an uneven weight distribution to counterbalance elevated forks.
- When operating with a raised mast or tall loads, blocked sight lines can cause the forklift operator to stride a pedestrian.
- When a forklift turns from the rear end, the rear wheels swing outward, which can lead to tipping over during tight turns.
- These vehicles only have brakes on the front wheels, making stopping a forklift difficult.
- Unlike a scissor lift, which provides a safe and stable platform for elevated work, forklifts are designed to be mobile, meaning they could hit a worker who crosses in front of the path of travel.
How Common Are Forklift Accidents?
- 90% of all forklift trucks will be involved in an accident over their useful lifespan [3].
- Forklift accidents resulting in serious injury total around 34,900 annually [4].
- There are approximately 61,800 non-serious injuries related to forklifts every year [4].
- Between 2021 and 2022, the Bureau of Labor Statistics reported 24,960 DART (Days Away from Work, Restriction, or Transfer) cases related to nonfatal injuries from forklift accidents [6].
- In 2022, there were 73 forklift fatalities across the United States [6].
- 25% of all transported-related workplace injuries are directly related to forklifts [8].
Most Common Forklift Accidents
- According to the National Safety Council, from 2021-2022, 53% of DART cases related to forklift accidents resulted from a transportation accident, such as forklift operators losing control of the vehicle [9].
- Approximately 25% of all forklift accidents are due to the forklift overturning [10].
- Although forklift overturns account for only 24% of all accidents, they account for 42% of fatalities [11].
- 17% of forklift accidents involve a worker struck by materials [12].
- Workers falling from or being struck by forklifts account for 14% of all accidents [13].
Forklift Accidents by Industry
Any workplace that utilizes these vehicles may pose a risk to workers, but the top industries for forklift accidents include the following.
- Accidents in a warehouse account for 30% of all forklift accidents [14].
- 42.5% of fatal forklift accidents involve manufacturing [15].
- 23.8% of deadly accidents involving a forklift truck are in the construction industry [16].
- Fatal workplace accidents in wholesaling account for 12.5% of forklift accidents [17].
Causes of Forklift Accidents
Many forklift accidents are a result of these major hazards, including:
- Unclear line of sight
- Mechanical failures
- Emissions intoxication
- Uneven surfaces
- Damaged tires
- Falling loads
- Truck instability
- Failure to follow safety procedures
- Pedestrian impacts
- Trailer personnel falling from forks
The Impact of Training Policies on Forklift Accidents
The Occupational Safety and Health Administration asserts that better training policies could prevent 70% of forklift accidents [18]. Undertrained forklift operators pose serious dangers to themselves and others.
In-person forklift training programs take approximately 6-8 hours to complete [19]. According to OSHA, proper training should include the following topics:
- Surface conditions
- Maneuvering and controlling the vehicle
- Forklift attachments and other tools
- Load stability
- Vehicle capacity and stability
- Inspection and maintenance
- Workplace hazard mitigation
- Safety of pedestrians and other workers [20]
Top 5 OSHA Safety Violation Citations
In 2023, the top five forklift-related safety violations were the following.
- Unsafe Operations include speeding with heavy loads, driving too close to impact barriers, and ignoring safety procedures. Additionally, operators may fail to communicate dangers to other workers in the area, which can lead to striking a pedestrian.
- Failure to Provide Refresher Training – Forklift operators must be recertified every three years, or they may be asked to complete additional training sooner if they have demonstrated improper use of these dangerous tools.
- Missing or Inadequate Operator Certification – Anyone who uses a forklift must have the proper certification to prevent serious injuries.
- Failure to Remove Dangerous Forklifts from Service – All operators should be aware of any warning signs that the forklift truck is damaged and follow proper lockout/tagout procedures. They should clearly and immediately inform their colleagues if they suspect there may be an issue with a particular forklift.
- Failure to Perform Inspections – All forklifts should receive pre-shift inspections to ensure their safety for operators [21].
Forklift Accident Victim Statistics
- 20% of all forklifts involve hitting a pedestrian [22].
- According to OSHA forklift accident statistics, workers working more than 12 hours are 37% more likely to be in an accident [23].
- From 2021 to 2022, 84.59% of forklift injuries occurred in men, with only 15.41% occurring in women [24].
- On average, forklift injuries require 18 days off work [25].
- Workers aged 25 to 34 had the highest injury rate [26].
Forklift Injury Statistics
According to the Bureau of Labor Statistics, the most common forklift injuries requiring medical attention include:
- Soreness and pain
- Fractures
- Bruises and contusions
- Sprains, strains, and tears
- Cuts, lacerations, and punctures
- Multiple traumatic injuries, including head trauma
- Amputations
- Punctures
- Heat burns [27]
Fatal Forklift Accident Statistics
- Around 75 and 100 people are killed annually because of forklifts, with a rough average of around 87 [28].
- In 2022, there were 73 forklift fatalities [29].
- According to recent Occupational Safety and Health Administration estimates, 36% of all forklift fatalities involve pedestrians [30].
- In 2022, fatalities peaked among workers aged 55 to 64 [31].
- 90.41% of forklift deaths in 2022 were men, with only 9.59% being women [32].
Forklift Accident Prevention
Many common forklift accidents are wholly preventable. To ensure the safety of yourself and others, follow these tips:
- Always inspect your forklift to prevent mechanical failures.
- Properly secure all equipment and packages to avoid falling loads.
- Ensure strategic placement of loads to keep a clear line of sight.
- Install floor tape to identify out-of-bounds areas.
- Slow down when you have a heavy load.
- Honk your horn when turning into blind spots.
- Set up barriers to protect pedestrians when working.
- Always set the brake when leaving the vehicle.
- Always look in the direction of travel, especially when backing up.
- Don’t overload the vehicle to prevent overturning.
Statistics About Forklift-Related Workers’ Compensation Claims
- The average workers’ compensation claim for a forklift accident is around $41,003 [33].
- In 2020 and 2021, an amputation claim cost approximately $126,033 [34].
- Head injury or central nervous system damage cost employers approximately $94,285 per claim in 2020-2021 [35].
- Injuries resulting from fracture, crush, or dislocation cost approximately $62,240 per claim in 2020-2021 [36].
Forklift Accident Settlement Statistics
Rosenfeld Injury Lawyers has secured millions for our clients, including those injured in forklift accidents.
- $3,500,000 – Our client suffered severe injuries when a forklift struck him while working at a factory. This settlement included workers’ compensation and a third-party claim against the forklift operator.
- $11,000,000 – This wrongful death suit was filed on behalf of the family of a laborer who was crushed to death when a forklift backed into him. We resolved the case in mediation with the company despite claims that the temporary worker was violating company policy.
- $4,400,000 – A settlement for a worker who suffered crush injuries when a forklift overturned onto him, causing severe injury to his legs and pelvis.
- $990,000 – An unlicensed forklift operator hit a construction worker, causing major injuries.
- $1,250,000 – Settlement for a customer of a home improvement store when he was struck in the parking lot by a forklift driver.
- $575,000 – A food delivery driver was pinned by the prongs of a forklift, causing significant injuries.
Recovering Compensation
As forklift accident statistics reveal, these useful workplace vehicles can also be dangerous or deadly. If you’ve been harmed due to workplace negligence, Rosenfeld Injury Lawyers can assist you in recovering damages through workers’ compensation or a civil lawsuit. We’ve recovered millions on behalf of our clients and work on a contingency fee basis, meaning that you owe us nothing unless we can win your case.
To schedule a free consultation, call us at (888) 424-5757 or fill out our online contact form.
References: [1] Texas Department of Insurance, [2] Illinois Lift Equipment, [3] OSHA Safety Manuals, [4] McCue, [5] McCue, [6] National Safety Council, [7] National Safety Council, [8] Forkify, [9] National Safety Council, [10] Warehouse Wiz, [11] OSHA.com, [12] ROI Safety Services, [13] ROI Safety Services, [14] Forkify, [15] Forkify, [16] Forkify, [17] Forkify, [18] Forkify, [19] Schneider Jobs, [20] Occupational Safety and Health Administration, [21] Southern States Toyotalift, [22] OSHA.com, [23] Forkify, [24] National Safety Council, [25] National Safety Council, [26] National Safety Council, [27] National Safety Council, [28] Conger, [29] National Safety Council, [30] OSHA.com, [31] National Safety Council, [32] National Safety Council, [33] WarehouseWiz, [34] National Safety Council, [35] National Safety Council, [36] National Safety Council,