FORKLIFT ACCIDENTS
Forklifts, also known as powered industrial trucks, are used in numerous work settings, primarily to move materials. Each year in the United States, nearly 100 workers are killed and another 20,000 are seriously injured in forklift-related incidents [BLS 1997, 1998].
Forklift overturns are the leading cause of fatalities involving forklifts; they represent about 25% of all forklift-related deaths. National fatality data indicate that the three most common forklift-related fatalities involve forklift overturns, workers on foot being struck by forklifts, and workers falling from forklifts. The case studies indicate that the forklift, the factory environment, and actions of the operator can all contribute to fatal incidents involving forklifts. In addition, these fatalities indicate that many workers and employers are not using or may be unaware of safety procedures and the proper use of forklifts to reduce the risk of injury and death.

FATALITY DATA
The following paragraphs summarize information about fatalities involving forklifts. The information is from databases that identify work-related fatalities in the United States.
National Traumatic Occupational Fatalities (NTOF) Surveillance System
In the United States, 1,021 workers died from traumatic injuries suffered in forklift-related incidents from 1980 to 1994. The NTOF Surveillance System uses death certificates to identify work-related deaths. These fatalities resulted from the following types of incidents:

        Type of Incident                    % total victims
        Forklift overturns                            22
        Worker on foot struck by forklift       20
        Victim crushed by forklift                 16
        Fall from forklift                              9

Source: Census of Fatal Occupational Injuries (CFOI)

The Bureau of Labor Statistics CFOI identified 94 fatal injuries associated with forklifts in 1995 [BLS 1997].     OSHA has developed standards for powered industrial trucks (such as low- and high-lift trucks and forklift trucks) [29 CFR 1910.178] and for forklifts used in the construction industry [29 CFR 1926.600; 1926.602]. 
 
Forklift Training
OSHA has promulgated the Final Rule for Powered Industrial Truck Operator Training [29 CFR 1910.178(l)], which became effective March 1, 1999. The standard requires operator training and licensing as well as periodic evaluations of operator performance. The standard also addresses specific training requirements for truck operation, loading, seat belts, overhead protective structures, alarms, and maintenance of industrial trucks. Refresher training is required if the operator is observed operating the truck in an unsafe manner, is involved in an accident or near miss, or is assigned a different type of truck.

Forklift Maintenance
OSHA requires that industrial trucks be examined before being placed in service. They shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily. When industrial trucks are used around the clock, they shall be examined after each shift. When defects are found, they shall be immediately reported and corrected [29 CFR 1910.178(q)(7)].

Forklift Operation
OSHA requirements for forklift operation are as follows:

• On all grades, the load and loadengaging means shall be tilted back, if applicable, and raised only as far as needed to clear the road surface. The forks shall not be raised or lowered while the forklift is moving [29 CFR 1910.178 (n)(7)(iii)].
• Under all travel conditions, the truck shall be operated at a speed that will permit it to be brought safely to a stop [29 CFR 1910.178 (n)(8)].
• The operator shall slow down and sound the horn at cross aisles and other locations where vision is obstructed [29 CFR 1910.178 (n)(4)].
• The operator is required to look toward and keep a clear view of the travel path [29 CFR 1910.178(n)(6)].
• Unauthorized personnel shall not be permitted to ride on powered industrial trucks. A safe place to ride shall be provided where the riding of trucks is authorized [29 CFR 1910.178 (m)(3)].
• Forklift trucks shall not be driven up to anyone standing in front of a bench or other fixed object [29 1910.178 (m)(1)].

Fair Labor Standards Act (FLSA) and Youth Employment

• The FLSA [29 USC† 201 et seq.] (the primary law governing the employment of youth under age 18) includes work declared hazardous for youth by the Secretary of Labor. Hazardous Order No. 7, Power-Driven Hoisting Apparatus Occupations, prohibits workers under age 18 from using forklifts and similar equipment in nonagricultural industries [29 CFR 570.58]. In agricultural industries, minors under age 16 are prohibited from using forklifts [29 CFR 570.71 (a)(3)(ii)]. 
  † United States Code..
   

Not all working minors are covered by the FLSA. The regulations in agriculture do not apply to minors working on their parents' farms. Also exempted are youths aged 14 and 15 who are working under carefully regulated conditions in a bona fide vocational agriculture program.
American Society of Mechanical Engineers (ASME)/American National Standards Institute (ANSI)

Maintenance and Safety Equipment
Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, lift overload devices, guard and safety devices, lift and tilt mechanisms, articulating axle stops, and frame members shall be carefully and regularly inspected and maintained in a safe condition (ASME/ANSI B56.1–1993m 6.2.7) [ASME 1993].

• When work is being performed from an elevated platform, a restraining means such as rails, chains, etc., shall be in place, or a body belt with lanyard or deceleration device shall be worn by the person(s) on the platform (ASME/ANSI B56.1, §4.17.1[b]) [ASME 1993].

Safe Operation
An operator should avoid turning, if possible, and should use extreme caution on grades, ramps, or inclines. Normally the operator should travel straight up and down (ASME/ANSI B56.1, §5.3.8[d]) [ASME 1993]. The operator of a sit-down type forklift should stay with the truck if lateral or longitudinal tipover occurs. The operator should hold on firmly and lean away from the point of impact (ASME/ANSI B56.1, §5.3.18[d]) [ASME 1993].  In addition to the above regulations, employers and workers should follow operator's manuals, which are supplied by all equipment manufacturers and describe the safe operation and maintenance of forklifts. 

Reducing the risk of forklift incidents requires a safe work environment, a safe forklift, comprehensive worker training, safe work practices, and systematic traffic management.
NIOSH recommends that employers and workers comply with OSHA regulations and consensus standards, maintain equipment, and take the following measures to prevent injury when operating or working near forklifts.

Employers
Worker Training
Make sure that workers do not operate a forklift unless they have been trained and licensed.
Develop, implement, and enforce a comprehensive written safety program that includes worker training, operator licensure, and a timetable for reviewing and revising the program. A comprehensive training program is important for preventing injury and death. Operator training should address factors that affect the stability of a forklift—such as the weight and symmetry of the load, the speed at which the forklift is traveling, operating surface, tire pressure, and driving behavior.

Inform operators of sit-down type forklifts that they can be crushed by the overhead guard or another part of the truck after jumping from the overturning forklift. The operator of a sit-down type forklift should stay with the truck if lateral or longitudinal tipover occurs. The operator should hold on firmly and lean away from the point of impact.

Train operators of stand-up type forklifts with rear-entry access to exit from the truck by stepping backward if a lateral tipover occurs.

Ensure that operator restraint systems are being used on sit-down type forklifts. Since 1992, forklift manufacturers have been required to equip new sit-down type forklifts with operator restraint systems. Many manufacturers of these forklifts offer restraint systems that can be retrofitted on older forklifts. Many of the fatalities resulting from overturns of sit-down type forklifts might have been prevented if the operator had been restrained. The overhead guard of the forklift is generally the part that crushes the operator's head or torso after he or she falls or jumps outside of the operator's compartment. The risk of being crushed by the overhead guard or another rigid part of the forklift is greatly reduced if the operator of a sit-down type forklift remains inside the operator's compartment. Because many forklifts are not equipped with a restraint system and operator compliance is less than 100% on forklifts equipped with a restraint system, operators of sit-down type forklifts should be instructed not to jump from the operator's compartment but to stay inside by leaning in the opposite direction of the overturn.
Train operators to handle asymmetrical loads when their work includes this activity.

Forklift Inspection and Maintenance
Establish a vehicle inspection and maintenance program.
Retrofit old sit-down type forklifts with an operator restraint system if possible.

Lifting
Ensure that operators use only an approved lifting cage and adhere to general safety practices for elevating personnel with a forklift. Also, secure the platform to the lifting carriage or forks.
Provide means for personnel on the platform to shut off power to the truck whenever the truck is equipped with vertical only or vertical and horizontal controls for lifting personnel.

Workers on Foot

• Separate forklift traffic and other workers where possible.
• Limit some aisles to workers on foot only or forklifts only.
• Restrict the use of forklifts near time clocks, break rooms, cafeterias, and main exits, particularly when the flow of workers on foot is at a peak (such as at the end of a shift or during breaks).
• Install physical barriers where practical to ensure that workstations are isolated from aisles traveled by forklifts.
• Evaluate intersections and other blind corners to determine whether overhead dome mirrors could improve the visibility of forklift operators or workers on foot.
• Make every effort to alert workers when a forklift is nearby. Use horns, audible backup alarms, and flashing lights to warn workers and other forklift operators in the area. Flashing lights are especially important in areas where the ambient noise level is high.

Work Environment
Ensure that workplace safety inspections are routinely conducted by a person who can identify hazards and conditions that are dangerous to workers. Hazards include obstructions in the aisle, blind corners and intersections, and forklifts that come too close to workers on foot. The person who conducts the inspections should have the authority to implement prompt corrective measures.

• Install the workstations, control panel, and equipment away from the aisle when possible. Do not store bins, racks, or other materials at corners, intersections, or other locations that obstruct the view of operators or workers at workstations.
• Enforce safe driving practices such as obeying speed limits, stopping at stop signs, and slowing down and blowing the horn at intersections.
• Repair and maintain cracks, crumbling edges, and other defects on loading docks, aisles, and other operating surfaces.

Workers

• Do not operate a forklift unless you have been trained and licensed.
  Use seatbelts if they are available.
• Report to your supervisor any damage or problems that occur with a forklift during your shift.
• Do not jump from an overturning, sit-down type forklift. Stay with the truck if lateral or longitudinal tipover occurs. Hold on firmly and lean in the opposite direction of the overturn.
• Exit from a stand-up type forklift with rear-entry access by stepping backward if a lateral tipover occurs.
• Use extreme caution on grades, ramps, or inclines. Normally you should travel only straight up and down.
• On all grades, tilt the load back if applicable, and raise it only as far as needed to clear the road surface.
• Do not raise or lower the forks while the forklift is moving.
• Do not handle loads that are heavier than the rated weight capacity of the forklift.
• Operate the forklift at a speed that will permit it to be stopped safely.
• Slow down and sound the horn at intersections and other locations where vision is obstructed.
• Look toward the path of travel and keep a clear view of it.
• Do not allow passengers to ride on forklift trucks unless a seat is provided.
• When dismounting from a forklift, always set the parking brake, lower the forks, and neutralize the controls.
• Do not drive up to anyone standing in front of a bench or other fixed object.
  Do not use a forklift to elevate workers who are standing on the forks.
• Do not elevate a worker on a platform unless the vehicle is directly below the work area.
• Whenever a truck is used to elevate personnel, secure the elevating platform to the lifting carriage or forks of the forklift.
• Use a restraining means such as rails, chains, or a body belt with a lanyard or deceleration device for the person(s) on the platform.
• Do not drive to another location with the work platform elevated.

Serious accidents can occur even when trained professionals are involved. In the aftermath of a tragic forklift accident, hiring a personal injury lawyer may not be your top priority.  Your health and families well being, should be your main concern. However, while the injured party is receiving initial medical treatment, chances are, the negligent parties have notified their lawyers or insurance company of the accident. Every insurance company has a team of adjusters, investigators and attorneys whose primary responsibility is to limit the liability of the insurance company and minimize the amount of money to be paid to injured parties. Often, victims are bombarded with paperwork and critical evidence is destroyed immediately following an accident. If you have been injured as a result of the carelessness or negligence of another, you may be entitled to monetary compensation. For a free review of your "forklift accident" claim please fill out the form below.  An experienced personal injury lawyer will review your claim and may contact you to discuss your legal rights. There is no charge or obligation for this free evaluation.

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