Common Causes of Forklift Accidents

Whether they are used to load trucks or stack merchandise on shelves, forklifts play an important role in business operations. Unfortunately, they are also a leading cause of workplace injuries in various industries. Common causes of forklift accidents can originate with poor training, unsafe premises, machine failures, and misuse. Many of these scenarios are preventable. 

When you get hurt in a forklift accident, you can seek compensation through various legal processes, including workers’ compensation and third-party lawsuits. A Chicago forklift injury lawyer from our team can guide you through the claims process to receive the compensation you deserve for losses like lost wages, medical expenses, future medical bills, and more. 

Across the United States, nearly 25,000 workplace injury cases resulted in missed work time, new job duties, or employee transfers from 2021 to 2022. These forklift injury statistics demonstrate the extent of the issue in the American workforce. Let’s examine some of the most common forklift accidents and explore why they frequently result in workplace injuries. 

Operator-Related Causes of Forklift Accidents

The most common cause of forklift injuries is operator error. Whether the person is improperly trained or not paying attention, their actions can put others at risk of harm. 

Lack of Proper Employee Training or Evaluation

If someone engages in forklift operation without proper training, they are in violation of 29 CFR 1910.178(l). This standard requires all operators to be at least 18 years old, have completed adequate training, and have been recertified at least every three years. An individual with improper training puts themselves and others at risk when they operate heavy equipment.

The employer may also be liable for failing to comply with training regulations. Under state law 820 ILCS 219 (Illinois Occupational Safety and Health Act), companies are required to provide a safe environment for their employees, which includes mandatory training. 

If the person using a forklift has not been properly trained or evaluated for certification, this could open the door to third-party injury claims or negligence lawsuits. For example, if a staffing agency failed to train an employee properly, that agency could be liable for injuries caused by the operator. 

Reckless or Careless Operation

Even if the operator is trained sufficiently, their behaviors when using the forklift could be reckless or careless. Speeding in narrow aisles, taking sharp turns, riding with passengers, and failing to use horns when rounding corners are all examples of reckless operation. 

These circumstances would violate OSHA code 1910.178(n), which regulates the safe operation and handling of powered industrial trucks. If you are hurt in this type of accident, an expert legal team can investigate the event to determine if the driver’s reckless actions violated certain OSHA standards. 

Operating Under the Influence

Using a forklift while under the influence of drugs or alcohol is a very serious violation of safety regulations. You would not get behind the wheel of a motor vehicle on the road when affected by these substances, and a forklift should be no different. 

If an accident is caused by an operator who is impaired by drugs or alcohol, this could constitute gross negligence, which would increase the potential payout in a lawsuit due to punitive damages. 

Improper Loading or Overloading

The primary purpose of a forklift is to move cargo loads from one place to another. The fork lifts the burden, often on a pallet, to transport it somewhere else. Load handling is essential when using a forklift, as you must secure the items well. Improper loading procedures or overloading can cause a tip-over accident or a dropped load. 

OSHA code 1910.178(o) provides safety guidelines for properly secured loads on a forklift. Failing to adhere to these requirements could lead to a forklift accident lawsuit if someone gets hurt. You can pursue a settlement if the operator was unable to safely lift and secure the materials, causing them to fall off and hit you. 

Faulty Equipment as a Cause of Forklift Incidents

Some lift truck accidents are caused by faulty equipment, whether these issues result from poor maintenance, ineffective design, or misuse. 

Mechanical Failures

Mechanical failures often occur due to deferred maintenance or inadequate inspection and maintenance. Brake failure, hydraulic leaks, steering problems, and lift fork malfunctions could all be the result of a poorly designed or maintained machine. 

If such failures cause forklift-related accidents, a product liability lawsuit or a claim for negligent maintenance may follow. Proving liability in these cases can be challenging, so it is crucial to work with the best attorneys in the state during the claims process. 

Inadequate Maintenance

Adhering to OSHA forklift regulations can help prevent accidents. For example, code 1910.178(q) establishes guidelines for daily inspections of forklifts. These evaluations consider everything from forklift masts to the hydraulic features. 

If known hazards are revealed and then ignored, a lawsuit may be filed against the employer or a third-party maintenance contractor for negligence. 

Site-Related Causes

The surrounding workplace environment may have an impact on serious forklift accidents. Both employers and employees are responsible for maintaining safe premises to reduce the risk of forklift accidents. 

Poor Floor Conditions

Unclean floors can cause forklifts to skid or tip over. Spilled liquids, debris, and uneven surfaces may all contribute to a dangerous accident involving a forklift.

Under the Premises Liability Act (740 ILCS 130/), property owners and business owners can be held liable if they fail to maintain safe premises by clearing away potential hazards. 

Obstructed Visibility

Forklift safety is also influenced by the level of organization in a space. For example, if there are cluttered aisles or materials stacked high, this can obstruct the operator’s view, increasing the risk of collisions. Another concern could be accessories on the vehicle that hang down and block the operator’s view of their surroundings. 

Faulty Elevated Load Dock or Ramp Design

Many forklift-related injuries occur in loading docks or near ramps. A broken dock plate can easily trigger a rollback or a driver ejection, especially if they are not wearing a seatbelt. Some loading ramps may be poorly designed and collapse, or they may be placed at too steep an angle. If the forklift operator loses control of the vehicle, the machine could seriously injure them or a nearby individual. 

Faulty loading docks and ramps can lead to lawsuits against property managers or construction site contractors. 

External Human Factors

External human factors can also cause forklift-related accidents. It is not always the driver’s fault that injuries occur. Let’s examine some scenarios where the human element can introduce additional risks. 

Forklift Accidents Involving Pedestrians

Pedestrians can be unpredictable when it comes to workplace safety. Employees may not be on the lookout for customers or other passersby, especially if most of the workers in that space are familiar with the forklift’s operation. 

If a forklift strikes a pedestrian, it could be the result of insufficient floor markings and poor communication in heavy equipment zones. A forklift accident involving a pedestrian will typically involve multiple parties in a lawsuit, including the site supervisor, staffing agency, or third-party logistics team. 

Lack of Supervision

If a work site is poorly supervised, it could allow employees to use forklifts improperly. Workplace mishaps can often be attributed to foremen or supervisors who fail to enforce safety regulations.

For example, if one area of the warehouse lacks adequate lighting, a forklift accident could be the supervisor’s fault because they failed to notice or address the safety concerns. 

Environmental Hazards

Even the natural environment can play a role in causing some of the most common forklift accidents. Weather conditions, especially in Illinois, can be unpredictable. If snow, ice, or rain has impacted a working surface, it may not be safe for forklift operators. This is especially true in outdoor settings. 

Some OSHA standards address general safety guidelines that prevent slippery surfaces caused by the weather. Therefore, an employer that fails to adjust to these conditions could be at fault for a victim’s severe injuries. 

Common Forklift Accidents Leading to Injuries

Forklift Tip-Overs

This type of accident occurs when a forklift loses balance and either falls forward, backward, or sideways. In many tip-over accidents, the operator is crushed underneath the weight of the machine and its elevated load. 

These accidents are most frequently caused by uneven surfaces, faulty ramps, or very elevated loads. 

Forklift Rollovers

A rollover is when the forklift overturns completely. This situation can occur if the operator takes a sharp turn or goes up a ramp at high speed. 

Rollover crashes are more likely to happen in outdoor work sites and loading dock areas. Slippery conditions caused by inclement weather, which is common in Illinois, can cause the operator to lose control of the vehicle and flip over if they are driving too fast. 

Caught-In or Caught-Between Accidents

Inattention and improper operation can lead to a caught-in or caught-between accident. A caught-in accident usually involves someone getting stuck in the forklift components, which can lead to an amputation in serious cases. A caught-between accident is when a worker is pinned between the forklift and a wall, pallet rack, or other object.

Crush injuries and amputations are the most common injuries in forklift accidents. Often, these situations occur due to the operator’s or another employee’s inattention. 

Struck-by Forklift Accidents

Struck-by incidents are often associated with pedestrian accidents. Passersby may not be aware of the dangers of a work site that includes forklifts. However, the collision could also be someone else’s fault because of poor visibility or a lack of warning signs. 

Struck-by forklift accidents are most common in tight warehouse aisles and loading bays. 

Falling Load Accidents

When materials fall off the load fork, it can lead to serious injuries for anyone standing nearby. This type of forklift accident can affect consumers or spotters. 

Many falling load accidents are entirely preventable if forklift operators are willing to follow standard loading procedures. Overloading a forklift increases the risk of falling objects striking nearby individuals, which could open the company up to potential lawsuits. 

Ejection from the Forklift

A sudden movement, collision, or tip-over can dislodge the operator from the vehicle. This is called an ejection. Forklifts often include seatbelts that can prevent this issue, but many operators avoid wearing them. 

If someone is suddenly ejected from a forklift, they could also be struck by falling materials that were dislodged by the same movement. Although forklifts are usually not operated at speeds that cause forceful ejections, small sudden movements can still dislodge a worker if they are not buckled in. 

Forklift Collisions and Crushing Accidents

Improper forklift operator training or reckless behavior may cause a driver to crash into other vehicles or objects. Walls, machinery, and shelving may be involved in a forklift collision if someone isn’t paying attention to their surroundings. 

The result of these collisions typically involves injuries to forklift operators, but it can also lead to falling merchandise from the shelves.

Forklift Falls from Loading Docks or Trailers

Forklifts often drive up ramps and into trucks for loading purposes. However, if there is a collapsed edge or an unsecured ramp, the forklift could fall from a significant height and crash. The operator may be ejected and suffer blunt force trauma. 

Fires or Explosions Involving Forklifts

Although this type of accident is rare, it could cause the most damage to bystanders and other equipment. Gas-powered forklifts could ignite flammable materials or leak fuel, creating a burn hazard in the workplace. Severe burns can result in substantial medical expenses, particularly for skin grafts and other surgical procedures. 

This is why OSHA enforces fuel-handling practices and regular maintenance. 

How Our Forklift Injury Lawyers Use Cause Analysis to Build Strong Cases

Whether your injury was caused by a careless lift truck operator, improper turning practices, faulty backup alarms, or a collision with other vehicles, you have the right to seek compensation for eligible legal damages. IL Work Injury Lawyer can guide you through the legal process if you are pursuing a forklift accident workers’ compensation claim or a personal injury lawsuit.

Our law firm can help you build a strong case with our range of legal services, including:

• Investigating and documenting OSHA violations by researching maintenance logs and training records
• Working with forensic experts, engineers, and other specialists to determine the root cause of the accident
• Using the cause to identify liable parties, including property owners, equipment manufacturers, staffing companies, and construction contractors
• Gathering additional evidence in the form of incident reports, witness statements, surveillance footage, and medical expert testimony
• Filing third-party lawsuits on behalf of workers beyond what workers’ compensation covers
• Negotiating with insurance companies for fair compensation
• Pushing for full disability benefits for injured workers
• Holding at-fault parties accountable to enact positive changes

In a personal injury lawsuit, you may be eligible for both economic and non-economic damages. Economic losses can include lost income, medical expenses, future medical costs, and property damage. Non-economic losses include emotional distress, pain and suffering, disfigurement, disability, and loss of enjoyment of life. 

Secure Expert Legal Counsel

Our legal team is prepared to hold Illinois business owners, contractors, property owners, and other parties accountable for causing your suffering. Proving negligence can be a difficult task, but our work injury law firm in Chicago has decades of experience securing compensation for injured clients, including those who suffered severe injuries in forklift accidents. 

At IL Work Injury Lawyer, we work on a contingency fee basis. This means there are no upfront costs for our services and you owe nothing unless we win. Payment is then deducted from the final settlement amount. You will also receive a free consultation with an expert attorney, allowing you to ask questions about the claims process before committing to legal action. 

Contact our top-rated personal injury lawyers today to schedule your free case evaluation.