Illinois Forklift Accident Statistics

According to national forklift accident statistics, thousands of workers suffer injuries every year, many of them severe enough to require hospitalization or long-term recovery. 

In Illinois, these risks are heightened in busy industrial areas where forklift operators are often under pressure to meet tight deadlines, increasing the chances of common forklift accidents such as tip-overs, falling loads, or pedestrian collisions.

Our forklift accident lawyers represent injured workers for anything from serious injuries like broken bones to fatal cases. We fight to hold employers accountable when poor training, inadequate safety measures, or violations of occupational safety standards lead to preventable accidents. 

By understanding the most common forklift accidents and the numbers behind them, you can better recognize the risks, demand safer workplaces, and know your rights if you or a loved one is hurt. Consult our Illinois work injury lawyers today.

Forklift Safety Statistics by the Occupational Safety and Health Administration

National data shows that forklift accidents remain a serious threat in the workplace, with around 75 to 100 workers killed annually, an average of 87 deaths each year. Alarmingly, this number has increased by nearly 30% over the past decade. 

According to the Occupational Safety and Health Administration (OSHA), between 35,000 and 62,000 injuries occur every year involving forklifts, ranging from serious physical injuries such as broken bones and head trauma to non-serious injuries related to forklifts, like sprains and bruises.

Among the most common forklift accidents, tip-overs are the leading cause, accounting for about 25% of all forklift-related incidents. OSHA has also found that a rough average of 70% of forklift accidents in the United States could be prevented through more stringent training, adherence to standard safety measures, and improved oversight of forklift operators. 

On average, 95 people suffer serious injuries in a forklift accident each day, and one person dies in a forklift incident every four days. Tragically, about 36% of forklift-related deaths involve pedestrian collisions, underscoring the risks for both operators and those working nearby.

The scope of the problem becomes even clearer when considering that roughly 11% of all forklifts in the United States will be involved in an accident in any given year. These statistics highlight the urgent need for employers to prioritize forklift safety, ensure adequate forklift training, and enforce preventive measures that protect workers and reduce the devastating toll of injuries and deaths.

Statistics on Accidents Involving Forklifts in Illinois

Illinois forklift accident statistics, compiled through OSHA investigation summaries between 2020 and 2024, provide a detailed look at workplace incidents involving forklifts across the state. These reports, created after inspections following fatalities, serious injuries, or employer-reported incidents, reveal patterns in causes, injury types, and industry risks.

The Chicago North Area Office investigated six forklift-related workplace accidents across its jurisdiction, which includes Cook County and Lake County. 

One worker was killed in a fall from height in 2021, while other cases involved severe physical harm, including broken legs from being struck by forklifts, a crushed leg from a falling pallet, and a heel fracture after being pinned between pallets. Additional injuries included a fingertip amputation caused by contact with equipment. 

The Chicago South Area Office—which covers Kankakee County, Cook County, and Will County—investigated 26 forklift-related workplace accidents, including 6 fatalities. 

The Fairview Heights Area Office—which covers the following counties: Alexander, Bond, Calhoun, Clay, Clinton, Crawford, Edwards, Effingham, Fayette, Franklin, Gallatin, Greene, Hamilton, Hardin, Jackson, Jasper, Jefferson, Jersey, Johnson, Lawrence, Macoupin, Madison, Marion, Massac, Monroe, Montgomery, Perry, Pope, Pulaski, Randolph, Richland, Saline, St. Clair, Union, Wabash, Washington, Wayne, White, and Williamson—investigated four forklift-related accidents. 

The Fairview Heights Area Office—which covers the following counties: Alexander, Bond, Calhoun, Clay, Clinton, Crawford, Edwards, Effingham, Fayette, Franklin, Gallatin, Greene, Hamilton, Hardin, Jackson, Jasper, Jefferson, Jersey, Johnson, Lawrence, Macoupin, Madison, Marion, Massac, Monroe, Montgomery, Perry, Pope, Pulaski, Randolph, Richland, Saline, St. Clair, Union, Wabash, Washington, Wayne, White, and Williamson—investigated four forklift-related accidents.

These incidents resulted in serious injuries, including leg fractures from falls, multiple leg fractures from being struck and pinned by powered industrial vehicles (PIVs) while loading cargo, leg fractures sustained during operation, and a toe being run over, requiring surgical amputation. 

While no fatalities were recorded in these cases, the injuries highlight the significant hazards of forklift use in this region.

The Naperville Area Office covers the following counties: Boone, Bureau, Carroll, DeKalb, DuPage, Grundy, Jo Daviess, Kane, Kendall, LaSalle, Lee, McHenry, Ogle, Putnam, Stephenson, Whiteside, and Winnebago. 

It recorded eight forklift accidents. Two of them were fatal; one in April 2022, where an employee was crushed by a powered industrial vehicle, and another in June 2021, where an employee was killed when crushed between a forklift and a basket. 

Other reported cases included multiple fractures, amputations, lacerations, dislocations, and crush injuries, often caused by employees being struck by forklifts, pinned between equipment, or injured while handling rigging and heavy materials.

The Peoria Area Office, covering Adams, Brown, Bureau, Cass, Champaign, Christian, Clark, Coles, Cumberland, De Witt, Douglas, Edgar, Ford, Fulton, Hancock, Henderson, Henry, Iroquois, Knox, Livingston, Logan, Macon, Marshall, Mason, McDonough, McLean, Menard, Mercer, Morgan, Moultrie, Peoria, Piatt, Pike, Rock Island, Sangamon, Schuyler, Scott, Shelby, Stark, Tazewell, Vermilion, Warren, and Woodford, reported 17 forklift accidents.

Three of these cases resulted in fatalities, including workers killed after being run over and crushed by a forklift, pinned between equipment, and suffering internal injuries when a forklift overturned. Non-fatal incidents involved severe injuries such as multiple leg fractures, crushed hands, amputated fingers, rib fractures, compound leg fractures, and brain bleeds from falls. 

Many accidents were caused by struck-by incidents, tip-overs, or workers being pinned between a forklift and other objects.

Forklift Accidents and Lost Productivity

Per recent data from the U.S. Bureau of Labor Statistics (BLS), in 2023 alone, forklifts were linked to 67 work-related deaths. For non-fatal cases, BLS recorded 24,960 DART cases (Days Away from Work, Job Restriction, or Transfer) in 2021–2022, including 15,480 DAFW cases (Days Away from Work only). Forklift injuries tend to result in a median of 22 DART days and 18 days away from work.

When breaking down the causes of forklift accidents, transportation incidents were the most common, making up 53% of cases. Other causes included being struck by an object (13%), falls, slips, or trips (11%), being struck against an object (9%), being caught in equipment or materials (9%), and overexertion or bodily reaction (4%). 

In terms of industry impact, service-providing industries accounted for 65% of forklift DART cases, with transportation and warehousing (31%), wholesale trade (17%), retail trade (11%), and professional/business services (3%) being the most affected. Goods-producing industries represented 35% of cases, led by manufacturing (28%) and construction(4%). 

Forklift Injuries 

The nature of injuries varied, with bruises and contusions leading at 22%, followed by soreness or pain (19%), sprains, strains, or tears (19%), fractures (17%), cuts or lacerations (7%), and other injuries (11%). Less frequent but still serious events included multiple traumatic injuries (4%) and amputations (1%).

The Most Common Forklift Accidents

Below are the most common types of forklift accidents, their statistical impact, and how they can be avoided.

Rollover and Tip‑Over Crashes

Rollover and/or tip‑over is the most common incident. About 24% of all forklift accidents and approximately 42% of recorded forklift injuries trace back to rollovers. Speeding through tight turns, abrupt steering inputs, uneven weight distribution, and heavy loads are the usual culprits.

To reduce risk, workers should slow down before turns, keep forks low while traveling, center and secure loads, respect capacity plates, and avoid uneven surfaces that shift a truck’s center of gravity.

Pedestrian Collisions

Pedestrian events make up about 20% of forklift accidents, but a disproportionate 36% of forklift deaths. Within those events, the breakdown looks like this:

• 25% involve a pedestrian crushed against a stationary object.

• 11% involve a pedestrian being struck or run over.

• 11% involve a pedestrian crushed between two vehicles.

• 8% involve the truck or its load falling onto a pedestrian standing.

To reduce risk, employers should install wall‑mounted mirrors to eliminate blind spots; add warning lights/backup alarms to alert pedestrians; paint or tape dedicated walkways; use physical barriers where feasible; post speed limits and enforce them; eliminate distracted driving; and stage loads to minimize on‑foot traffic near travel lanes.

Falling Loads

Unsecured or poorly balanced cargo leads to severe injuries when loads slip, tilt, or topple, often during abrupt turns, hard braking, or mast tilts. To reduce risk, workers should secure and center every load, use a load backrest to shield the operator compartment, avoid damaged forks or bent masts, and move smoothly without sudden starts or stops.

Falls from Forks or Improvised Lifts

Forklifts aren’t people‑lifts. “Riding the forks” or using a pallet as a platform turns a minor task into a high‑consequence fall. To reduce risk, never lift personnel without an approved work platform/man‑basket and use aerial lifts designed for the task when the job involves personnel elevation.

Emissions Poisoning

Combustion forklifts used indoors can build up carbon monoxide quickly, leading to headaches, dizziness, and, in severe cases, fatal poisoning. Charging lead‑acid batteries can also release harmful fumes.

To reduce risk, employers should opt for electric trucks indoors; ensure robust ventilation and carbon‑monoxide monitoring; isolate charging stations; and keep regular maintenance to limit emissions.

Safe and Efficient Forklift Operation to Reduce Risks and Costs

Forklift operators must maintain standards critical for workplace safety and preventing serious factory accidents. Recent estimates show that forklift incidents can lead to significant property damage and lost productivity, highlighting ongoing safety concerns. 

Operators should exercise extreme caution, especially when navigating near rear wheels, around many cars, or in tight spaces where the risk of personnel falling is higher. Inadequate training remains a major factor in avoidable accidents, so consistent education and visual reminders—such as floor tape—can support safer practices. 

By addressing these hazards proactively, companies can reduce costs, protect workers, and ensure forklifts account for productivity gains rather than preventable injuries.