Forklifts play a crucial role in material handling, warehouse operations, and heavy‑duty outdoor applications. However, without the proper precautions, forklifts can become dangerous and cause costly facility damage or serious workplace injuries. A strong forklift safety program is essential for protecting operators, pedestrians, and equipment.

Below are key safety rules, best practices, and answers to common forklift safety questions to help keep your operation productive and compliant.

What Are the Keys to Forklift Safety?

Safety and health must be top priorities whenever operating a forklift. Ensuring that operators understand safe operating procedures—and that your facility enforces them—is critical for preventing forklift accidents.

The tips below serve as general guidance. Always refer to your forklift’s operator manual for specific instructions.

BEFORE YOU START

1. Certification and Training

Forklift safety begins with proper operator training. Anyone operating a lift truck must be certified according to OSHA standards. Properly trained operators are more aware of hazards and can make safer decisions.

2. Wear Proper Protective Gear

Operators must wear appropriate PPE, including:

• Hard hats
• Steel‑toed shoes
• High‑visibility safety vests

Drivers should also check hands and feet for grease or oil before entering the forklift to prevent slipping.

3. Conduct a Pre‑Shift Inspection

Before each shift, operators should complete a forklift inspection checklist to ensure the truck is in safe working condition. This includes checking brakes, steering, tires, warning devices, hydraulics, and battery or fuel levels.

STARTUP

4. Use Available Safety Features

When entering the forklift:

• Use steps and handgrips
• Apply the three‑point contact method
• Avoid using the steering wheel to pull yourself in

Once seated, adjust mirrors and ensure all controls are within comfortable reach. Always wear the seat belt or restraint system.

WHEN YOU’RE UP AND RUNNING

5. Stay Inside the Operator Compartment

Operators should never reach outside the frame or into moving parts of the lift truck.

6. Pay Attention to Surroundings

Be aware of:

• Speed limits
• Maximum permitted loads
• Overhead clearances
• Loading dock edges
• Wet, uneven, or hazardous surfaces

Always account for the height of the mast, load, and overhead guard when entering buildings or passing under structures.

7. Move Cautiously

Safe forklift operation includes:

• Obeying posted speed limits
• Avoiding sudden stops or sharp turns
• Driving slowly, especially with heavy loads
• Keeping forks low while traveling
• Sounding the horn at intersections, blind corners, and pedestrian walkways

When using ramps:

• Drive forward up the ramp
• Drive in reverse down the ramp

These practices help prevent forklift tip‑overs, one of the most common causes of forklift fatalities.

8. Manage Loads Properly

Operators should:

• Ensure each load is stable and secure
• Tilt the load back before moving
• Use straps or ropes when necessary
• Never exceed the forklift’s rated capacity

Overloading can lead to loss of control, dropped loads, or tip‑overs.

9. Maintain Visibility

Operators must have a clear view of their travel path at all times. This may require:

• Driving in reverse with bulky loads
• Asking a spotter for assistance
• Pausing operation if visibility becomes obstructed

10. Keep Others Clear of the Mast

No one should walk or stand under a raised mast or near moving parts. Keep hands, feet, and limbs away from mast cross‑members to avoid serious injury.

11. Refuel and Recharge Safely

When refueling or recharging:

• Turn the forklift off
• Park in designated fueling or charging areas
• Keep flames, sparks, and smoking materials away

This is especially important for electric forklifts and LP forklifts.

END OF SHIFT

12. Park Properly

Park forklifts only in designated areas. Once parked:

• Fully lower the forks
• Turn off the forklift
• Apply the parking brake

This ensures a safe work environment for the next shift.

FORKLIFT SAFETY FAQ

What is the number one cause of forklift accidents?

The leading cause of forklift accidents is inadequate operator training. OSHA estimates that 25% of forklift accidents could be prevented with proper training and certification.

How many forklift accidents occur each year?

According to OSHA, forklifts cause:

• 35,000 serious injuries
• 62,000 non‑serious injuries
• And in 2015, 96 fatalities

Can you drive a forklift on the street?

Under certain conditions, a forklift may be driven on a public road, but only if:

• The forklift meets state licensing and registration requirements
• The operator has proper certification and insurance

Always check local regulations before operating a forklift on public streets.