Forklifts are essential for moving heavy materials efficiently in warehouses, factories, and construction sites—but with that power comes significant risk. According to forklift accident statistics from the U.S. Bureau of Labor Statistics, 614 workers were killed in forklift-related incidents between 2011 and 2017, with over 7,000 nonfatal injuries requiring days away from work each year.
These injuries often lead to extended recovery times and costly downtime, but the majority can be avoided with proper forklift safety training, equipment, and ergonomic practices. Below are the top 10 most common forklift injuries and how to prevent them through smarter practices and safer work environments.
1. Foot Injuries
Foot injuries are among the most frequent and severe forklift injuries. They often occur when a forklift runs over a pedestrian’s or operator’s feet, or when heavy loads fall during transport. Crush injuries, fractures, and even amputations can result.
Prevention tips:
- Operators should always check blind spots and drive at safe speeds.
- Workers must wear steel-toed safety boots and stay within marked pedestrian walkways.
- Employers should keep aisles clear and clearly define pedestrian zones to avoid overlap between walking and driving paths.
2. Back Injuries
Back injuries remain one of the top causes of worker downtime in material handling. They can develop from improper lifting techniques or from sitting for long hours in poorly designed seats.
Prevention tips:
- Train workers on proper lifting mechanics—lifting with the legs, not the back.
- Provide ergonomic seating and ensure forklift cabins encourage good posture.
- Schedule regular breaks and stretching exercises to reduce muscle strain and fatigue.
3. Crush Injuries From Tipping Over
Forklift tip-overs are the leading cause of forklift fatalities. These accidents often happen when loads are unbalanced, turns are taken too sharply, or operators drive on uneven surfaces.
Prevention tips:
- Only trained operators should handle forklifts.
- Secure and balance loads properly before moving.
- Always wear a seat belt—it can prevent being thrown or crushed if a forklift overturns.
- Slow down before turns and avoid sudden stops or starts.
4. Injuries From Falling Loads
Unstable or improperly stacked loads can fall suddenly, causing serious injuries to anyone nearby. These types of forklift injury incidents often result from poor load securing or sudden shifts in motion.
Prevention tips:
- Confirm that loads are stable and correctly positioned before lifting.
- Avoid jerky or abrupt movements while carrying materials.
- Inspect forks and hydraulic systems regularly for wear or damage that could lead to load failure.
5. Collisions With Pedestrians
Collisions are one of the main causes of injuries when using forklifts, especially in shared warehouse spaces. Blind corners, poor visibility, and distraction are common contributing factors.
Prevention tips:
- Separate pedestrian and vehicle traffic with barriers and designated lanes.
- Use mirrors, blue safety lights, and audible alarms on every forklift.
- Train both pedestrians and operators to stay alert and communicate in busy areas.

6. Hand and Arm Injuries
Operators and nearby workers risk serious harm if hands or arms are caught between loads, shelving, or moving machinery.
Prevention tips:
- Keep all limbs inside the operator’s cabin during operation.
- Ensure forklift safety guards and shields are intact and properly fitted.
- Wear gloves and arm protection when handling rough or sharp materials.
7. Head Injuries
Head injuries can result from falling objects, overhead obstructions, or collisions. Even minor bumps can become serious without proper protection.
Prevention tips:
- Always wear a safety helmet in active forklift zones.
- Maintain awareness of low ceilings and stacked materials.
- Use spotters when maneuvering large or unstable loads.
8. Neck and Shoulder Injuries
Repeated turning, twisting, or looking up to stack loads can lead to chronic neck and shoulder strain. Poor ergonomics or unsupportive seats make the problem worse.
Prevention tips:
- Choose forklift seats with adjustable lumbar and neck support.
- Position mirrors to minimize twisting while driving.
- Provide ergonomics training and encourage posture checks during shifts.
9. Leg and Knee Injuries
These injuries often happen when operators slip while climbing on or off the forklift or trip in cluttered workspaces.
Prevention tips:
- Use anti-slip steps and proper footwear with traction.
- Keep loading areas clean and dry.
- Train operators on the “three points of contact” rule when mounting or dismounting.
10. Injuries Caused by Low-Quality Seating
Poorly designed or worn-out seats are a hidden cause of many forklift injuries. Continuous vibration, pressure on the lower spine, and lack of cushioning can lead to chronic back pain, sciatica, and fatigue—reducing focus and increasing accident risk.
Prevention tips:
- Invest in high-quality ergonomic forklift seats with proper lumbar and suspension support.
- Ensure seats are adjustable to accommodate different body types.
- Replace worn cushions and faulty mechanisms during regular equipment maintenance.
Enhance Operator Safety With Ergonomic Forklift Seats
The right seat can make a measurable difference in preventing forklift injuries. At Suburban Seating & Safety, we provide a full range of ergonomic forklift seats designed to support operator comfort and reduce fatigue on every shift. Our options—including models for Toyota, Hyster, and Yale forklifts—offer the support and durability today’s operators need for both safety and productivity.
Protect your operators and strengthen your forklift safety record—explore Suburban Seating & Safety’s forklift seat collection and make injury prevention part of your company’s daily routine.