Forklifts are essential to warehouse and industrial operations, but when used improperly, they can become dangerous—and even deadly. The main causes of forklift-related injuries include overturns, collisions with pedestrians, and crushing incidents. These accidents are not only life-threatening, but also incredibly costly for businesses in terms of downtime, liability, and OSHA violations.
Fortunately, many of these risks are 100% preventable with the right training, awareness, and equipment.
Below, we break down the top three causes of forklift injuries and offer practical ways to avoid them, including how modern forklifts from Noblelift, Ekko, and Tailift are built with safety-first features t
o help protect your team and your bottom line.
1. Forklift Overturns: Stay Stable, Stay Safe
Why it happens:
Forklift tip-overs are the leading cause of operator fatalities. This usually occurs when turning corners too fast, driving on uneven surfaces, lifting loads improperly, or exceeding weight limits.
How to prevent it:
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Always check the load center and keep heavy loads low to the ground while moving.
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Reduce speed, especially when turning or operating on ramps.
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Ensure operators are trained to understand the forklift’s stability triangle.
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Avoid sharp or sudden movements.
Safety features to look for:
Modern forklifts from Noblelift, Ekko, and Tailift offer enhanced stability control systems, ergonomic operator cabins, and low center-of-gravity designs to reduce the risk of tipping.
2. Pedestrian Collisions: Keep Eyes on the Floor
Why it happens:
Warehouses are busy environments. Poor visibility, blind spots, and distractions can cause forklift operators to accidentally strike coworkers walking nearby.
How to prevent it:
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Install pedestrian walkways and enforce “no-go” zones for f
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oot traffic.
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Use spotters or mirrors in high-traffic areas.
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Equip forklifts with backup alarms, LED warning lights, and 360° cameras.
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Train both operators and pedestrians on shared space etiquette.
Safety features to look for:
Forklifts from brands like Ekko and Tailift now come standard or optional with proximity sensors, blue safety lights, and audible motion alerts, making it easier to avoid pedestrian collisions.
3. Crush Injuries: Know Your Surroundings
Why it happens:
Crushing injuries often occur when operators or bystanders get caught between the forklift and a wall, or when loads fall unexpectedly.
How to prevent it:
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Never walk or stand between a forklift and a fixed surface.
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Always secure loads before lifting and moving.
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Keep clear of lift mechanisms and ensure proper stacking.
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Wear seatbelts to prevent being ejected or pinned during an overturn.
Safety features to look for:
Tailift and Noblelift forklifts offer operator presence detection systems and automatic braking features that stop movement if the operator leaves the seat—helping to prevent unintended motion that could cause a crush injury.
Invest in Equipment That Prioritizes Safety
At Coastal Material Handling, we understand that forklift safety isn’t just about training—it’s also about the tools you trust on your floor.
We sell brand new forklifts from Noblelift, Ekko, and Tailift—three of the most reputable names in the industry—offering equipment that’s built with advanced safety features designed to help your team avoid costly mistakes.
Whether you’re upgrading your fleet or buying your first forklift, we’re here to help you choose models that are not only efficient but engineered to protect.
Final Thoughts
Forklift accidents are serious—but avoidable. By focusing on operator training, maintaining awareness, and investing in modern forklifts with smart safety features, you can significantly reduce risk and create a safer, more productive work environment.
Looking to upgrade your warehouse with safer, more reliable forklifts?
Contact us today to learn more about our lineup of Noblelift, Ekko, and Tailift forklifts and get a free consultation.
Ph: 757-465-8338
Email: info@coastalmhe.com
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