Industrial vehicle and forklift accident statistics

These accident statistics point to many reasons why forklift accidents can have the most serious consequences in industrial facilities. Particularly for facilities in the transportation and storage sector, where forklift numbers are greater and movement near pedestrians more frequent.

The mechanical workings and specifications unique to forklift trucks are another indicator of why forklift accidents have such severe consequences.

• They are deceptively small, but with their essential dense counterweight they weigh considerably more than much larger vehicles such as cars, vans and some lorries.
• In busy facilities with high volume targets, forklift speeds may be de-restricted allowing them to travel up to 18 mph. Even at restricted speeds, their weight and density can generate considerable impact force in an accident.
• Unlike a road vehicle, forklifts have no crumple zone. Their forks and back end are solid steel, so accidents can cause severe crush injuries and huge amounts of damage.
• Forklifts are counterbalanced with heavy weights in the rear to compensate for loads being raised high on the forks. Drivers may need time to adjust to handling this unfamiliar weight distribution.
• Forklift trucks are rear wheel turning, so their turning circle can be a risk as the rear of the vehicle swings outwards. This can result in impact at tight corners, such as the end of racking aisles.
• With their raised sitting position in the cabin, the line of sight for forklift drivers is different to other vehicle types. Their view can also be partly obscured when carrying loads on the front forks.

1. Improve driving standards

Properly trained drivers with certification is a legal requirement for those operating fork lift trucks. Other measures which can improve forklift driving standards are:

Frequent re-training and refresher courses for drivers.

Keeping operator training and development top-of-mind can make a huge difference to facility safety standards.

Warehouse racking monitoring.

Giving forklift drivers visibility of how their vehicle is impacting on rack infrastructure helps them improve their driving standards. Electronic and IoT devices can reveal a picture of where forklift accidents might occur and where more driver training is needed. The A-SAFE RackEye safety system is at the forefront of this technology.

2. Conduct daily inspections

The forklift trucks in your fleet need to be inspected daily. Checks on the following areas will identify potential accident risks.

• Is the volume and function of the horn as it should be?
• Check for any leaking fluids under and around the forklift. This could create a slip hazard or indicate a problem with the vehicle.
• Just as with a car, forklift truck tyres have a recommended PSI. It is important that they remain inflated to the right level to prevent problems with steering and stopping, or further damaging the vehicle.
• All brakes on the forklift should be functioning effectively, inspect them thoroughly before use.
• The forklift steering should also be checked for responsivity and proper operation.

The Forklift Truck Association provide further advice and fact sheets on owning and operating forklift trucks.

3. Conduct a thorough risk assessment in accordance with PAS 13

PAS 13 is the official Code of Practice for safety barriers in the industrial workplace. It was published by the British Standards Institute (BSI) in 2017 and has become hugely influential for health and safety managers worldwide.

It contains traffic management advice to ensure facility layouts minimise forklift and pedestrian interactions. This massively reduces the risk of forklift accidents. It also gives guidance on how to know if safety barrier suppliers are providing are properly tested, fit for purpose equipment.

Misinformation is a problem where safety products are concerned. Ask your barrier supplier if their products are tested to PAS 13, and if they can show independent verification from a reputable certifier, such as TUV Nord.

4. Physical protection with safety barriers

Every facility can avoid forklift accidents by using safety barriers that are properly tested and certified. From a trusted barrier supplier, the right barriers, in the right place, are the best way to minimise operating risk. This provides protection for people and assets from forklift vehicle movements.

Find out more about Pedestrian Protection on the A-SAFE website:

[1] Over the five years to March 2021. RIDDOR

[2] 5 years RIDDOR combined with other data, using the GB level employment by Broad Industry Group data from the ONS

[3] Average over 5 years to March 2021

[4] Ibid.