Common Causes of Forklift and Facility Damage

Forklifts are essential pieces of material handling equipment, supporting everything from warehouse operations to manufacturing environments. While forklifts themselves aren’t inherently dangerous, they can become hazardous when operated improperly, leading to costly facility damage, equipment downtime, and workplace injuries. Understanding the most common causes of forklift damage is a critical part of any successful forklift safety program.

Below are four of the top causes of forklift‑related facility damage—and how you can help prevent them.

1. Poor Floor Conditions

Unsafe floor conditions are one of the most overlooked contributors to forklift damage.

Common hazards include:

• Debris such as wood, plastic wrap, twine, or banding
• Loose materials that can get caught under tires
• Obstacles that disrupt travel paths

Running a forklift over debris can cause:

• Radiator or axle damage
• Damage to the cooling system
• Engine overheating or engine failure if debris enters the engine compartment

Maintaining clean aisles and debris‑free floors is crucial for reducing equipment wear and preventing facility damage.

2. Improper Operating Practices

Unsafe or careless forklift operating practices frequently result in product loss, forklift damage, and workplace accidents.

Examples include:

Congested Work Areas

Tight or cluttered spaces increase the likelihood of collisions with:

• Racking
• Inventory
• Other forklifts
• Facility structures

“Bulldozing” Pallets

Using the forklift to push pallets causes:

• Premature tire wear
• Transmission damage
• Excessive strain on hydraulic components

Loss of Vehicle Control

Impacts can damage:

• Forklift body panels
• Frame components
• Forks and attachments
• Load backrests and masts

Proper training, clear aisle organization, and effective traffic management are essential to preventing these costly issues.

3. Unsafe Lifting and Speed

Excessive speed is one of the leading contributors to forklift accidents and facility damage. High lift and travel speeds increase the risk of:

• Tip‑overs
• Collisions
• Dropped or unstable loads
• Injuries involving pedestrians and operators

What Is a Safe Forklift Speed?

• In pedestrian areas: no more than 3 mph
• General operations: 8–10 mph maximum

At 10 mph, a forklift typically needs 40 feet to stop completely, which is why enforcing speed limits is a key element of every forklift safety plan.

Raising heavy loads while traveling too fast can also cause tip‑overs—one of the most dangerous types of forklift accidents.

4. Incorrect Equipment or Options

Using the wrong equipment for the job creates safety hazards, reduces productivity, and increases maintenance costs.

Common issues include:

• Using a forklift without the proper capacity
• Operating with worn or incorrect tires
• Using equipment not designed for the application
• Lacking necessary attachments

Proper equipment selection helps ensure:

• Efficient forklift operation
• Reduced component wear
• Lower ongoing maintenance costs

Always match the forklift to your load type, environment, and application requirements.

What Are the Most Common Types of Forklift Accidents?

While many types of accidents can occur in a warehouse or facility, three of the most common forklift‑related incidents include:

1. Forklift tip‑overs
2. Workers struck by forklifts
3. Falls from forklifts

A strong forklift safety training program, along with proper maintenance and equipment selection, can dramatically reduce the likelihood of these incidents.