Forklift Accidents: Expert Witness Insights on Causes and Prevention

Article By Nathan Macdonald

As a forklift expert witness and engineering investigation firm, Alpine Engineering & Design has analyzed forklift-related incidents throughout the United States over the last 30 years, uncovering critical patterns that show how these accidents occur and how they can be prevented.

In our experience, most, if not all, forklift accidents are preventable. While each incident is unique and requires specialized analysis, the underlying causes consistently trace to identifiable failures in training, communication, maintenance, operational protocols, workplace design, or in some cases, equipment design defects.

This article shares insights from our engineering investigations to help industry professionals understand the root causes of forklift accidents and implement effective safety measures through improved design, training, and operational protocols.

Some of the most common types of forklift accidents are:

• Tip-overs and rollovers when operating on slopes or making sharp turns with elevated loads
• Struck-by incidents where forklifts collide with pedestrians or other equipment
• Falling loads due to improper stacking, overloading, or sudden stops
• Crushing incidents when workers are caught between the forklift and fixed objects

Looking at the numbers, forklift accidents are not rare isolated events. The good news is that this all-too-common workforce safety problem can be prevented through proper training, safety feature implementation, and/or design improvements.

During typical warehouse operations (loading and unloading trailers, stacking pallets, or repositioning materials), operators and ground workers often occupy the same space simultaneously.

Accidents frequently occur when:

• Operators cannot see nearby personnel during critical maneuvers
• Verbal communication breaks down between operators and spotters
• Multiple workers move within the same operational zone without coordination

Prevention through design: Modern engineering solutions include rear-view camera systems, proximity sensors (including ultrasonic, radar, and LiDAR technologies), and improved mast design for better sightlines. However, the most effective safeguard combines technology with operational discipline.

This familiarity leads to carelessness in several ways:

• Skipping daily pre-operation inspections
• Failing to set parking brakes before dismounting
• Allowing unauthorized personnel into the work zone
• Taking shortcuts on safety procedures to save time

The engineering solution: Rather than relying solely on operator discipline, effective forklift design incorporates safety features that compensate for human error. Automatic parking brakes, seat interlocks that disable motion when the operator leaves the seat, motion alarms, wireless IMU (inertial measurement unit) sensors for impact detection, and proximity warning systems create multiple layers of protection against lapses in judgment.

Forklifts operate under demanding conditions: constant vibration, heavy loads, and continuous use create wear on critical parts and safety systems. When maintenance schedules slip or inspections become cursory, small mechanical issues can escalate into serious hazards.

Without rigorous, documented maintenance and inspection protocol, critical components like brakes, hydraulics, steering systems, and warning devices can degrade to the point of failure. These mechanical issues not only create direct safety risks but can also compound operator errors or environmental hazards.

Prevention through maintenance: Properly documented routine maintenance ensures safety-critical components (brakes, hydraulics, steering systems, and warning devices) function as designed. Daily pre-operation inspections catch developing issues before they become hazards, while scheduled preventive maintenance by qualified technicians addresses wear before failure occurs.

Effective forklift operator training must include:

• Classroom training and a written test
• Hands-on skill evaluation
• Periodic refresher training that address changing workplace conditions
• Ongoing operator evaluation and timely response to any unsafe practices observed

Many forklift accidents occur not because operators don’t know safety rules, but because they fail to apply that knowledge under real-world pressure. Training programs need to prepare operators for real-world situations, not just classroom tests.

• Mechanical condition of the forklift (brakes, hydraulics, steering, controls)
• Operator actions and decision-making at the time of the incident
• Environmental conditions and workplace layout
• Maintenance records and inspection history
• Training documentation and operational procedures
• Design features that may have contributed to or could have prevented the accident

This comprehensive approach identifies not just what happened, but why. The analysis reveals whether incidents stem from operator error, equipment failure, inadequate training, poor maintenance, or design deficiencies. These findings inform systemic improvements that improve workplace safety.

Critical evidence preservation: Equipment involved in any incident should never be altered, repaired, or returned to service until a qualified engineering investigation is complete. In one case Alpine Engineering & Design reviewed, the condition of a forklift’s parking brake couldn’t be properly evaluated because it had been adjusted after the incident, destroying critical evidence about its original state.

This shows why preserving equipment exactly as it was immediately post-accident is essential for accurate forensic analysis.

• The forklift design included adequate safety features for its intended use
• Manufacturing defects compromised safety systems
• Maintenance failures masked underlying design issues
• Operators were expected to compensate for foreseeable hazards that should have been engineered out

Even when accidents don’t stem from design defects, investigation can potentially reveal opportunities for enhanced safety features that would make operator errors less likely or less harmful.

The Safety by Design Philosophy

Human error is predictable. Workers will get tired, distracted, or confident enough to take small risks. The best engineering designs anticipate that reality and make unsafe actions less dangerous.

The best forklift engineering designs acknowledge these realities and make unsafe actions more difficult or less dangerous.

Key safety-by-design principles include:

Passive safety systems: Features that work automatically without operator action

• Automatic parking brakes that engage when the operator leaves the seat
• Deadman switches that halt movement if the operator becomes incapacitated
• Load backrests that prevent materials from shifting toward the operator
• Overhead guards that protect against falling objects
• Seat belt interlocks that prevent operation unless restraints are fastened

Active warning systems: Technology that alerts operators to hazards

• Backup alarms and visual warning lights
• Proximity sensors (including ultrasonic, radar, and LiDAR technologies) to detect pedestrians and obstacles
• Load weight indicators that warn of overloading
• Wireless IMU sensors that detect and log impacts for incident analysis

Improved visibility: Design features that reduce blind spots

• Multi-angle camera systems with in-cab displays
• Enhanced mast design minimizing obstructed sightlines
• Strategically positioned mirrors covering all approach angles
• Transparent overhead guard sections where structurally feasible

Operator controls: Ergonomic design that encourages safe operation

• Intuitive control placement that reduces operator error
• Motion interlocks that prevent unsafe combinations of actions (such as driving with elevated load)
• Clear instrumentation and warning indicators
• Comfortable seating that reduces operator fatigue during long shifts

Diagnostic and maintenance features: Systems that support proper upkeep

• Built-in diagnostic sensors monitoring brake condition, hydraulic pressure, and structural integrity
• Automated maintenance logging systems
• Easy-access inspection points encouraging thorough checks
• Warning systems that alert supervisors when maintenance schedules are overdue

Further still, unique hazards can be created when autonomous forklifts are not handled properly, including during maintenance activities. If an autonomous forklift fleet is not shut down for facility or equipment maintenance, injuries and even fatalities can occur.

Industry standards for industrial equipment safety continue to change based on accident data and engineering research. Manufacturers, operators, and safety professionals must stay current with OSHA regulations, ANSI standards, and industry best practices for forklift design, maintenance, and operation.

Alpine Engineering & Design works with clients to ensure their equipment and operations meet or exceed current safety standards, and we provide expert analysis when determining whether standards were followed in accident cases.

Creating safer workplaces requires commitment on multiple fronts:

• Manufacturers must continue advancing safety by design, building protection into equipment
• Operators must maintain vigilance and follow safety protocols consistently
• Supervisors must enforce standards and create cultures where safety comes first

Organizations must invest in quality equipment, thorough training, and proper maintenance

By understanding how and why forklift accidents occur, we can implement engineering solutions and operational practices that protect workers and prevent incidents. Safety isn’t just a matter of training people to do better. It’s about designing machines and systems that make safe operation the natural, default choice.

The statistics are clear: tens of thousands of workers are injured in forklift-related incidents every year. But with systematic application of engineering principles, comprehensive training, and commitment to safety as a core operational value, these numbers can be dramatically reduced.

Alpine Engineering & Design remains committed to this goal through our investigation work, expert testimony, and continuous pursuit of safety improvements across the material handling industry.

Alpine Engineering & Design provides comprehensive services including equipment engineering and design, forensic investigation, forklift accident investigation, equipment failure analysis, and expert witness testimony. Over the last 30 years, our team of experienced engineers has analyzed industrial equipment incidents across the United States while also designing safer equipment solutions, helping organizations improve safety and providing authoritative expertise in legal proceedings. Contact us to learn how our engineering analysis and design capabilities can support your safety initiatives or legal case.

Alpine Engineering & Design is an engineering company that specializes in trailer design engineering services and equipment safety analysis. Our engineers evaluate mechanical systems and equipment to determine causes of failure, assess safety compliance, and identify practical design improvements. Alpine Engineering also provides unbiased trailer expert witness testimony in legal disputes involving product liability and accident investigation.