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Forklift Accidents in Workplace
1.
A worker used a sling to suspend a tree stump on a cargo pallet, walked on a narrow path, and tried to turn right onto the main road. The forklift’s tire slipped off the edge during the turn and the vehicle overturned.
✅ Solution: Never transport unstable loads on narrow paths. Assess route conditions and avoid elevated or sloped paths with heavy or suspended loads.
2.
A forklift driver stood on a running forklift to straighten a tilted load. He accidentally stepped on the tilt handle, causing the forks to tilt back and crush him between the mast and the cabin.
✅ Solution: Always turn off the forklift when dismounting. Never stand on a running forklift to adjust loads.
3.
One worker drove the forklift while another stood on the pallet to paint indoor steel structures. The worker on the pallet lost balance.
✅ Solution: Do not use forklifts as lifts or platforms. Use proper aerial work platforms for elevated tasks.
4.
A forklift driver left the seat and tried to reposition the goods on the pallet by hand.
✅ Solution: Never leave the operator’s seat while the forklift is running. Always stop the engine before adjusting loads manually.
5.
An experienced forklift driver sat on the forklift instructing a novice. The novice made a wrong move and pinned the trainer between the forklift and a column.
✅ Solution: Provide training in an open area under professional supervision, not near fixed structures or hazards.
6.
A worker stood on the truck to guide the forklift loading 12-meter H-beams. The beam suddenly slipped from the forks and crushed him.
✅ Solution: Never stand under or beside suspended loads. Use restraints or secure methods to prevent slipping.
7.
While transporting two large ton bags, the forklift reversed sharply and overturned.
✅ Solution: Operate at safe speeds, avoid sharp turns, and secure heavy loads properly.
8.
While reversing toward a truck, the forklift’s load slipped and the forklift tipped over.
✅ Solution: Secure loads tightly and approach vehicles slowly and on level ground.
9.
A pedestrian suddenly walked from a walkway into the vehicle path. The forklift braked hard, causing a roll to fall and injure the pedestrian.
✅ Solution: Implement barriers between pedestrian and vehicle zones. Ensure all paths are clearly marked.
10.
During unloading, the driver left the forklift, and it slid, pinching a loader.
✅ Solution: Always engage the handbrake and turn off the engine before dismounting.
11.
A worker stood on stacked pallets using the forklift as a ladder, causing it to overturn.
✅ Solution: Never use pallets or forklifts as ladders. Use certified lifting equipment.
12.
The forklift was loading cargo when the truck suddenly moved, dragging and overturning the forklift.
✅ Solution: Secure the truck with brakes and chocks before loading/unloading.
13.
A worker fell from a pallet during loading.
✅ Solution: Never ride or stand on forklift pallets. Use man baskets with guardrails if lifting personnel.
14.
A worker stood illegally on the forks for painting; the driver accidentally released the brake, injuring the worker.
✅ Solution: Strictly prohibit standing on forks. Use elevated platforms designed for personnel.
15.
The forklift tip over while reversing uphill with a load.
✅ Solution: Avoid reversing uphill with heavy loads. Use forward motion when possible and assess gradients before operating.
16.
A worker stood on the forks as counterweight, causing the forklift to tip and injure him.
✅ Solution: Never use human weight for counterbalance. Maintain correct load distribution.
17.
While placing planks under a metal rack, a wire rope detached from the forks and crushed the worker.
✅ Solution: Use certified lifting accessories and inspect them regularly for wear or looseness.
18.
During vehicle repair, the hopper fell unexpectedly, crushing the technician.
✅ Solution: Always use locking devices and props when servicing vehicles.
19.
While dumping sludge, the bin was lifted too high and caused the forklift to tip.
✅ Solution: Follow load height limits. Avoid lifting heavy bins too high.
20.
During a reverse turn in a warehouse, the forklift struck a worker in a blind spot.
✅ Solution: Use spotters or rear cameras and mirrors. Implement slow speed limits in warehouses.
21.
The forklift crushed a storm drain cover, causing a pipe to fall and injure a supervisor.
✅ Solution: Inspect routes for hidden hazards and reinforce weak ground covers.
22.
Improper use of a truck to tow a forklift caused it to overturn.
✅ Solution: Do not tow forklifts with trucks unless using certified towing equipment.
23.
The forklift’s rear tire struck a curb, causing it to tip over.
✅ Solution: Maintain safe distances from edges, curbs, and road boundaries.
24.
The driver failed to engage the handbrake, causing the forklift to roll and fatally strike someone.
✅ Solution: Always apply parking brake and shut off engine before leaving the seat.
25.
On uneven ground, a single-fork lift of a ton bag caused the forklift to tip, killing three people.
✅ Solution: Never use a single fork for heavy loads. Ensure level surfaces and balanced forks.
26.
While loading logs, the operator made an error and a log fell, killing a worker
✅ Solution: Use log clamps or secure loads properly before transport. Maintain safe distance from stacked logs.
27.
A forklift being towed by a truck swerved during braking, ejecting the driver to death.
✅ Solution: Never tow forklifts in an unsafe manner. Transport them using appropriate flatbeds.
28.
A forklift operator’s view was blocked while moving a container and crushed another worker.
✅ Solution: Use spotters when handling large or obstructive loads.
29.
A worker fell from a forklift pallet and died.
✅ Solution: Strictly ban standing on pallets. Use forklift safety cages designed for lifts.
30.
While using the forklift as a ladder to replace a light, a worker triggered the lift function and crushed his leg.
✅ Solution: Do not use forklifts as access platforms. Use certified lifts or forklift safety cage for maintenance.
31.
A person fell from the forklift top and accidentally activated the tilt lever, getting crushed by the mast.
✅ Solution: No one should stand or sit atop the forklift. Only trained operators should handle controls.
32.
A worker stepped down from stairs and was crushed by cargo falling from a braking forklift.
✅ Solution: Maintain awareness of surroundings and avoid working below active forklift routes.
33.
A novice operator caused a stacker to slide off the platform during operation
✅ Solution: Restrict use of stackers to trained personnel. Guard platform edges and use anti-slip protection.
34.
The driver answered a phone call and left the seat without turning off the forklift, which overturned and fatally crushed him.
✅ Solution: Enforce a zero-tolerance policy for phone use during operation. Always power down and secure equipment before leaving it unattended.
✅ General Safety Recommendations
- Training: Mandatory operator training and certification.
- Load Management: Never overload. Secure and center all loads.
- People Safety: Prohibit standing on forks or pallets. Keep pedestrians clear.
- Vehicle Maintenance: Regularly inspect brakes, hydraulics, and tires.
- Work Area Management: Clearly mark pedestrian zones and install warning systems.
- Use Forklift Safety Technology: Forklift camera, forklift pedestrians detection system etc.
- No Phone Rule: No use of mobile devices during forklift operation.
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