Forklift Safety Tips & Rules for 2025

Those who work in warehouses and industrial settings heavily rely on forklifts to carry out their day-to-day responsibilities, yet they remain a significant cause of workplace injuries.

According to NSC Injury Facts, in 2023 forklifts were responsible for 67 work-related deaths. Additionally, during 2021 and 2022, there were 24,960 cases where workers had to take time off or be assigned different duties due to forklift-related injuries. Out of these, 15,480 cases involved workers missing days from work.

Forklift safety today is more than just following a daily checklist. Modern solutions combine human vigilance with innovative technology such as Powerfleet’s forklift telematics solutions which can detect hazards in real time.

Train and Certify Operators for Safer Forklift Use

A robust forklift safety program starts with properly trained and certified operators. Any untrained individuals are not legally allowed to operate a forklift – alongside those under 18 according to OSHA regulations.

Comprehensive Curriculum

Effective training includes learning about load capacity limits, safe maneuvering, daily inspections, and procedures such as seat belt use, PPE requirements, and hazard recognition.

Trainees should learn how a forklift’s center of gravity shifts with raised or unbalanced loads and how steering differs from driving a car. They must understand why tip-overs occur and how to avoid them by never exceeding the forklift’s rated load capacity.

Regular Evaluations and Refreshers

Per OSHA’s Powered Industrial Truck standard (29 CFR 1910.178), operators should be evaluated at least once every three years. Refresher training must also occur following:

• An accident or near-miss
• A new forklift model introduced
• Unsafe behaviors (such as speeding, improper load handling)
• Changes in workplace conditions

Safety-First Culture

In addition to formal training, frequent safety briefings or toolbox talks keep crucial points top of mind. Operators and supervisors should openly discuss near-misses or potential hazards to learn from real-world situations. Ensuring that employees always wear seat belts, adhere to forklift capacity limits, and remain alert creates a proactive culture of safety.

Conduct Thorough Pre-Operation Equipment Inspections

Even an expertly trained operator can’t compensate for a faulty forklift. That’s why daily or pre-shift inspections are vital. A simple checklist helps detect flaws before they cause accidents or expensive downtime. Common inspection points include:

Controls, Brakes, and Steering

Check that the steering wheel turns easily, brakes engage properly, and warning devices (lights, horn, backup alarm) function. Malfunctioning controls frequently lead to collisions.

Mast, Chains, and Forks

Examine the mast assembly and forks for cracks, bends, or warping. Damaged components may fail under load, causing dropped cargo and serious injuries.

Fluid Levels and Leaks

Inspect hydraulic, brake, and engine fluids, as well as fuel lines. Leaks can undermine performance and cause sudden brake or lift failures.

Tires and Attachments

Confirm that tires have proper pressure, minimal wear, and no cuts. Loose or faulty attachments (such as drum clamps) should be repaired or replaced immediately.

Operator Compartment

Ensure seat belts, mirrors, and any protective equipment are in good condition. Adjust mirrors or camera systems so the operator has full visibility before starting a shift.

Any defect that emerges during inspection must be documented, and the forklift must be taken out of service until repaired. These checks are not only legally mandated but help preserve equipment life and avert safety lapses.

Powerfleet’s Forklift Gateway for Monitoring Vehicle Health

While manual inspections remain critical, technology can reinforce adherence to them such as Powerfleet’s Forklift Telematics solutions.

The Forklift Gateway is a specific feature which allows you to monitor vehicle health and performance, allowing you to spot potential issues before they cause disruptions. It requires operators to log in and complete a digital inspection checklist before the forklift will start. Should someone skip the checklist or record a significant fault, the system can lock out operation until corrections are made.

Beyond that, the Gateway collects real-time data about engine hours, impact events, usage patterns – and alerts fleet managers if maintenance is overdue or if an operator drives recklessly. This proactive oversight ensures each forklift meets safety standards at every shift.

Follow Safe Operating Practices to Prevent Accidents

Operator skill and well-maintained equipment form the backbone of safety, but day-to-day driving habits also matter enormously. Most forklift incidents stem from human error: rushing, complacency, or breaking established rules.

1. Respect Load Capacity

Never exceed a forklift’s rated load limit. About 42% of fatal forklift accidents involve tip-overs, often triggered by overloading or unbalanced cargo. Check the weight of each load and ensure it’s centered on the forks.

2. Keep Loads Low

Transporting loads close to the ground with a slight backward tilt helps maintain stability. If the load blocks forward visibility, drive in reverse or enlist a spotter. An elevated load, especially if heavy, raises the center of gravity and increases tip-over risk.

3. Maintain Safe Speeds and Maneuvers

Limit speeds to around 5 mph (roughly walking pace) in congested areas. Forklifts are unable to stop quickly, and swift turns or sudden stops can topple a heavily loaded forklift. Using the horn at intersections or blind corners alerts others of your presence.

4. No Unauthorized Passengers

A forklift is designed to move goods, not people. Unless the vehicle includes an approved second seat, never allow anyone to ride. Lifting a person on forks or pallets is extremely dangerous and violates guidelines.

Speed Controls: Powerfleet’s Speed Manager

Controlling vehicle velocity is crucial in order to help reduce forklift incidents.

One feature of Powerfleet’s In warehouse solutions is the Speed Manager. This automatically governs how fast the forklift can travel in specific conditions. Sensors detect high-risk scenarios, like entering a pedestrian area or making a sharp turn, and lower the forklift’s speed accordingly. This safeguard enforces consistent driving standards and prevents operators from exceeding limits even if they’re momentarily distracted or pressed for time.

Maintain a Safe and Organized Warehouse Environment

A clean, well-lit, and properly laid out facility reduces forklift accidents by giving operators and pedestrians predictable travel paths.

Key measures include:

Regular Safety Audits

Perform monthly or quarterly reviews of your warehouse layout. Check aisle widths, stock placement, and signage to confirm everything aligns with forklift dimensions and safety rules. If a particular aisle witnesses repeated collisions, consider widening it or rerouting traffic to ease bottlenecks.

Adequate Lighting

Dimly lit aisles hamper visibility. Ensure overhead lighting is bright, consistent, and repaired promptly. Adding task lights or reflective markers in risk-prone areas, such as loading docks, can prevent accidents.

Floor Condition and Markings

Potholes or cracks can destabilize forklifts. Repair surface damage quickly and keep floors clean of debris or spills. Use colored tape or paint to delineate vehicle lanes, pedestrian walkways, and restricted zones. Even small steps like placing mirrors at intersections can reduce blind-spot incidents.

Pedestrian Awareness

Separate foot traffic from vehicle pathways whenever possible with guardrails or floor markings. Post clear signage – “Forklift Crossing,” “Pedestrians Only” – to alert both drivers and walkers. Encourage employees on foot to establish eye contact with operators before stepping into forklift routes.

Improve Pedestrian Safety Using Technology

Despite best efforts, interactions between forklifts and pedestrians pose one of the highest risks in many facilities. While mirrors, horns and signage help, human error or blind spots can still lead to collisions.

Pathways and Traditional Measures

Start by mapping out forklift lanes and dedicated pedestrian walkways with visible barriers or floor markings. One-way aisles, stop signs, and “blind corner” mirrors can moderate traffic flow.

However, these static measures still rely heavily on humans noticing each other and reacting in time.

Powerfleet’s Pedestrian Proximity Detection

This AI-powered Pedestrian Proximity system monitors the forklift’s surroundings with onboard cameras and sensors, detecting people or other vehicles in real time, with no special tags required.

Once a pedestrian enters a preset caution zone, the operator receives an alert; if the person moves closer, the system can slow or stop the forklift automatically.

Use Real-Time Video Capture for Incident Prevention

While cameras often help with post-accident investigations, they also deter unsafe behavior. Operators aware of active video monitoring are more likely to follow protocols consistently. Real-time footage can also reveal warehouse patterns like a cluttered aisle that keeps forcing sudden forklift maneuvers.

Powerfleet’s Event-Triggered DVR

Paired with the Forklift Gateway, Powerfleet’s Event-Triggered DVR system – powered by Powerfleet starts saving video clips before, during, and after a safety-related event, such as an impact or abrupt stop.

Managers can review clips to understand what went wrong: Was the operator speeding? Did a pedestrian appear unexpectedly? Was the aisle blocked?

Over time, these clips can highlight recurring issues, for example, a tight turn near a busy exit or an overlooked need for additional signage. Video-based insights can shape operator coaching sessions or targeted layout improvements. Sharing anonymized clips during training also makes a strong impression, showing employees exactly how certain behaviors or conditions lead to near-misses.

Integrating People, Process, and Technology for 2025

Forklift safety in 2025 depends on three interlocking components:

• People – Skilled operators who understand the forklift’s mechanics, adhere to daily checklists, and respect speed limits.
• Processes – Structured inspections, routine safety audits, and well-organized warehouses that reduce guesswork and hazards.
• Technology – In warehouse solutions offer real-time oversight and intervention when human vigilance falters.

By combining these pillars, companies can cut accidents, protect workers, and keep workflows on schedule. Technology removes many gray areas such as enforcing digital checklists, limiting speed automatically, detecting pedestrians, and recording incidents, to ensure that everyone abides by essential guidelines.

As you review or expand your forklift fleet, integrating these advancements to improve your safety culture is crucial. From preventing tip-overs to stopping collisions before they happen, modern solutions give you more control than ever.