EP.2 – Prevention First! How to Avoid Forklift Accidents in the Warehouse

Forklift-related incidents are among the leading causes of accidents, injuries, and damages in warehouses—yet many are entirely preventable with the right operating practices. This article outlines key risk factors and actionable prevention measures to reduce accidents not only when operating forklifts but also when using other material-handling equipment such as AGVs, pallet trucks, and hand pallet jacks.

Driving at high speeds in confined warehouse spaces is a frequent cause of accidents. Both operators and warehouse managers should prioritize safety by enforcing appropriate speed limits for each designated area. This rule should apply at all times, regardless of how busy operations may be. For example, speed should be reduced near intersections, high-traffic zones, entry/exit points, and loading bays—areas often congested with people and equipment like pallet trucks. To further reduce risks, it is recommended to request the equipment manufacturer to install a speed-limiting system on the forklift.

Improper forklift operation due to inadequate training is another major risk. Common unsafe behaviors include:

• Driving at high speed while lifting loads.
• Reversing without checking surroundings.
• Sudden acceleration, braking, or sharp turns.
• Failing to engage the brake when loading onto a transport truck.
• Performing multiple actions simultaneously, such as lifting and turning at once—this significantly destabilizes the load and increases the risk of tip-overs.

To prevent such incidents, warehouse managers must require all operators to complete certified forklift safety training programs approved by the Department of Skill Development.

Operating in shared workspaces requires clear communication. Driving without using audible (horn) or visual (lights) signals can lead to accidents in busy warehouse environments where multiple teams are simultaneously picking, dispatching, or relocating goods. Operators should use horns or two-way radios to alert others of their movements, especially when visibility is limited. When in doubt, always ask or confirm before proceeding.

Obstacles such as stored goods, moving personnel, low-clearance doors, or narrow aisles may present serious hazards. Operators should always survey their routes, observe their surroundings, and plan accordingly before moving or lifting loads. Avoiding confined spaces and setting clear traffic flow standards helps reduce collisions. Careful route planning should be a standard part of the job.

Wearing a seatbelt is essential in any vehicle, including forklifts. Even though operators often need to get on and off the vehicle frequently, seatbelts must always be worn. In the event of an accident, a seatbelt can prevent the operator from being ejected or crushed. Warehouse managers should enforce this as a mandatory safety policy.

Correct parking practices include stopping the forklift at the designated area, lowering the forks completely, engaging the parking brake, and shutting off the engine before exiting. Leaving a forklift with the forks raised poses a tripping hazard. Failing to apply the brake may allow the forklift to roll and damage goods or warehouse structures.

Examples of unsafe use include racing forklifts, riding on forklifts inappropriately (clinging or hanging), or using the forklift beyond the manufacturer's intended purpose. Such behavior puts lives and assets at serious risk and must be strictly prohibited.

Operators often become so familiar with forklifts that they overlook the risks of improper boarding or exiting. Rushing can cause slips or falls, especially with high-platform forklifts. To minimize risk, operators should:

• Wear appropriate, non-slip footwear (preferably closed-toe or safety shoes).
• Always use handholds for support.
• Follow the "three-point contact" rule: use two hands and one foot (or two feet and one hand) when getting on or off the vehicle.

Warehouse supervisors should train operators in these proper techniques and enforce the use of designated contact points for every entry and exit.