lift truck accident

What Is the Most Common Type of Lift Truck Accident and How to Prevent It

Lift trucks, also known as forklifts, are extremely common machines in warehouses, construction sites, and manufacturing facilities. Unfortunately, they can be extremely dangerous when not operated properly. If you were injured in a forklift accident, determining who’s at fault in a truck accident can help you determine if you’re eligible for compensation. 

Speaking with an experienced attorney can help you fight for the compensation you are entitled to.

Common Types of Lift Truck Accidents

Many workers wonder: What is the most common type of lift truck accident? The unfortunate answer is that they are all very common events anywhere in their presence. Understanding the most common types of lift truck accidents can help employers and workers implement safety measures more effectively to protect the safety of everyone involved. 

These are the most common forklift accidents:

  • Forklift rollovers: This is the most common type of forklift accident in the United States. According to OSHA, 25% of all forklift accidents happen because of an overturned forklift. These accidents happen when operators take turns too quickly, drive on uneven surfaces, or carry loads that exceed the forklift’s capacity. The physics of a forklift makes it particularly susceptible to rollovers because of its high center of gravity.
  • Pedestrian impacts: These accidents can be especially devastating in warehouses where workers on foot must share the space with lift trucks. Limited visibility, blind spots, and the frequent need to drive in reverse when operating a forklift make it difficult for operators to stay aware of their surroundings.
  • Falling loads: Accidents like these happen when items are improperly loaded or secured on the forklift, causing them to fall from its forks or storage racks. These accidents happen from overloading the forks or incorrectly positioning the mast while lifting or lowering the forks. The consequences largely depend on the size, weight, and shape of the falling objects and can cause severe trauma and fractures.
  • Tip-overs: While similar to rollovers, tip-over accidents specifically occur when a lift truck becomes unstable front-to-back rather than side-to-side. They happen when operators attempt to lift loads that are way too heavy for the forklift’s rated capacity or when operators load incorrectly. Trying to load while on an incline or when the mast is tilted forward can significantly increase the chances of these accidents due to the shifted weight distribution.
  • Dock accidents: These happen when lift trucks run off loading docks or when the truck being loaded pulls away prematurely. Poor communication between the truck driver and forklift operator usually causes these accidents, especially when the warehouse lacks proper signaling systems. These accidents can be especially devastating for the lift truck operator, as they may fall several feet to the ground and could even be crushed by this heavy machine.
  • Collisions with fixed objects: Many lift truck accidents involve collisions with stationary objects like rack systems, walls, or stored materials. This can happen when the operator isn’t paying attention, although poor visibility can also influence this. While these accidents may sound less severe than others, they can still cause serious injuries and significant property damage. Especially if the rack collapses or the impact causes structural damage to a building. 

Primary Causes of Lift Truck Accidents

Understanding the major causes of truck accidents can help prevent future incidents and establishing liability in accident cases. While lift truck accidents can be devastating, the reality is that many of them can be easily preventable. 

Some of the most common reasons of these types of lift truck accidents are: 

Operator Training Deficiencies

While OSHA requires comprehensive training and certifications for all forklift operators, many facilities don’t offer thorough training or fail to provide adequate ongoing education. This lack of training makes it difficult for inexperienced operators to react properly to unsafe conditions to avoid an accident. 

For example, an improperly trained forklift operator may not fully understand the complex physics involved in lift truck operation, causing them to make unsafe maneuvers. Understanding the principles of center of gravity and load capacity is extremely important, as the forklift’s stability changes dramatically based on load weight, lift height, and mast angle. 

Without this knowledge, operators may unknowingly create dangerous situations by exceeding their vehicle’s operational limits.

Improper Loading Techniques

The way cargo is loaded onto a lift truck can dramatically affect its stability and safety. Many accidents happen when the operator fails to properly assess load weight distribution or secure the load accurately. The risk of tip-overs and falling material increases significantly when the loads are improperly balanced or exceed the forklift’s rated capacity. 

Lack of Maintenance

Regular maintenance is extremely important for preventing lift truck accidents. Yet many facilities fail to complete proper maintenance schedules or respond quickly to mechanical issues. Worn tires, faulty brakes, hydraulic system problems, and steering mechanism failures can all easily cause serious accidents. 

Companies must implement preventative maintenance schedules to regularly inspect and replace parts before they fail. This includes:

  • Checking fluid levels
  • Inspecting chains and cables for wear
  • Testing safety systems 
  • Making sure all controls are working smoothly 

The risk of catastrophic mechanical failure increases dramatically when companies ignore or defer preventative maintenance.

Environmental Factors

Workplace environmental conditions also play a huge role in lift truck safety. Poor lighting, cluttered aisles, uneven surfaces, and inadequate signage can all contribute to accidents. Wet or slippery floors, in particular, can very easily cause accidents due to skidding or losing control. 

Narrow aisles or blind corners create dangerous situations where operators don’t have enough room to safely maneuver the forklift.

Poor Communication Protocols

Ineffective communication systems and protocols are another significant cause of lift truck accidents. Manufacturing facilities can get very busy, which means that potentially dozens or even hundreds of lift trucks operate in close proximity to each other and to pedestrian workers. This can increase the risk of collisions significantly without clear communication procedures and established right-of-way rules. 

The absence of standardized hand signals, warning systems, or traffic management procedures can create confusion and lead to dangerous situations. This is especially true during shift changes or in areas with limited visibility.

Time Pressure and Production Demands

Production pressures and unrealistic time constraints can also contribute to lift truck accidents by encouraging operators to take shortcuts or rush through tasks. 

Workers may feel pressured to skip safety checks, exceed speed limits, or attempt to move loads that exceed their truck’s capacity when they feel the need to meet quotas. This pressure can lead to fatigue and decreased attention to safety protocols, particularly during extended shifts or busy periods.

Common Injuries Resulting From Lift Truck Accidents

The National Safety Council reports that almost 25,000 injuries per year are related to forklift accidents in the United States alone. Many of these injuries cause severe damage that require extensive medical treatment and long-term rehabilitation. 

Some of the most common types of forklift injuries include:

  • Fractures and broken bones: The tremendous force involved in lift truck accidents can easily result in multiple or compound fractures, especially in the legs, arms, and pelvis. These injuries often happen when workers are caught between the lift truck and a fixed object, or during a rollover accident where operators are ejected from the cab. Recovery from these injuries may require extensive surgery and long-term physical therapy. They may even lead to permanent mobility limitations.
  • Head injuries: Traumatic brain injuries (TBIs) and other head trauma are particularly common in forklift accidents. This is especially true when operators or pedestrians are struck by falling objects or during rollover accidents. These injuries can range from mild concussions to severe brain damage. They could potentially cause permanent cognitive impairment, memory loss, and personality changes. Keep in mind that the long-term effects of head injuries may not be immediately apparent and can develop or worsen over time.
  • Crush injuries: The forklift’s massive weight makes crush injuries particularly devastating when they occur. These injuries can happen when workers become pinned between the forklift and another object or during tip-over accidents. Crush injuries can cause severe internal organ damage, massive tissue death, and in many cases require amputation. The psychological trauma from these injuries can also be intense, especially as amputations can affect a person’s self-esteem and ability to work.
  • Soft tissue injuries: Although these might be considered less intense than other types of injuries, soft tissue damage can lead to chronic pain and long-term disabilities. These injuries include sprains, strains, and tears to muscles, ligaments, and tendons. The recovery process can take many years. Some victims may experience chronic pain or reduced motion even after extensive physical rehabilitation.

Responsibilities of Operators and Employers

Operating lift trucks safely requires a collaborative effort between operators and their employees. Understanding what these responsibilities are can help you identify negligence in accidents caused by the wrongful actions of a third party. 

Generally, operators and employers have the following responsibilities:

  • Operator responsibilities: Licensed forklift operators must conduct thorough pre-shift equipment inspections and report any mechanical issues to supervisors before starting work. They are required to maintain continuous education certifications, follow all safety protocols, and wear appropriate safety equipment at all times. Failing to comply with any of these regulations may count as a violation of their duty of care, which means that they may be responsible for all damages associated with any accident.
  • Employer responsibilities: Employers must provide comprehensive initial and refresher training programs to meet OSHA standards and maintain detailed records of all operator certifications. They are responsible for implementing and enforcing all safety protocols, maintaining equipment in working condition, and verifying that the work environment meets all safety standards.

Legal Rights of Injured Individuals

If you were injured in a lift truck accident, whether as a worker or as a patron, you may have several avenues for obtaining compensation. The legal process begins with establishing negligence. This involves showing that a third party owed you a duty of care and then breached said duty of care. You must also demonstrate that your injuries were caused by this duty of care. 

Next, you must document all economic and non-economic damages that you may have suffered from the accident. For example, employers have a duty to provide safe working conditions and proper training to their customers. If they fail to do so and an accident occurs as a result, then you can sue the trucking company if their driver caused an accident.

In general, the process involves gathering evidence, documenting injuries and expenses, and working with insurance companies and legal representatives to secure a settlement. This can include collecting witness statements, accident reports, maintenance records, and medical documentation to build a strong case for compensation. 

You may be able to pursue one or more of the following compensation avenues for a lift truck accident case:

  • Workers’ compensation: Most employees injured in lift truck accidents qualify for workers’ compensation benefits. These cover medical expenses and a portion of lost wages regardless of fault. These benefits begin immediately after the injury and continue throughout the recovery process. Workers’ compensation also provides disability benefits to those who are unable to return to their previous job duties. 
  • Personal injury claims: In situations where the accident resulted from negligence outside the scope of workers’ compensation, victims may be able to pursue a personal injury claim. These claims can provide compensation for additional damages not covered by workers’ compensation, including full lost wages, pain and suffering, and loss of quality of life. Personal injury settlements typically end up with larger settlement amounts, but they require proving fault.
  • Third-party liability: You may be able to pursue a third-party personal injury lawsuit when a party other than the employee or employer was responsible for the accident. For example, you may be able to pursue compensation if the accident occurred due to equipment malfunction, defective parts, or the actions of non-employer third parties. These claims allow for broader compensation than workers’ compensation alone, as you may be able to pursue economic and non-economic damages to the fullest extent.

Final Recommendations for Preventing Lift Truck Accidents

The key to preventing lift truck accidents lies in implementing a comprehensive safety program that addresses their training, maintenance, equipment, and protocols. Organizations must prioritize ongoing operator training that goes beyond basic certification to include regular skill assessments and updates on new safety procedures. 

Maintaining a strict schedule of equipment inspections and immediate repairs helps prevent mechanical failures, while proper safety gear and equipment provide essential protection. 

If you’ve been injured in a lift truck accident, the experienced legal team at Morris & Dewett can help you understand your rights and pursue the compensation you deserve. Contact us today for a free consultation to discuss your case with our skilled workplace injury attorneys.

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