Hidden Hazards: Forklift Dangers You Might Be Overlooking in the Workplace
When it comes to forklift safety, most people focus on the obvious risks: overloading, speeding, or operating without proper training. But what about the hazards that aren’t so easy to spot? These hidden dangers can be just as deadly if left unchecked. Whether you’re a seasoned operator or new to the warehouse environment, it’s crucial to recognise and address these less obvious risks to maintain a safe workplace.
1. Floor Gradients and Uneven Surfaces
Why It’s a Hidden Hazard:
Most warehouse floors look flat at first glance, but even slight slopes or uneven surfaces can affect a forklift’s stability.
The Risks:
- Tip-overs: A gradient as small as 5% can increase the risk of a forklift tipping, especially when carrying heavy loads.
- Load Shifts: Going downhill can cause loads to shift forward, while uphill movement stresses the engine and braking system.
How to Mitigate:
- Conduct regular floor inspections for dips, cracks, and uneven surfaces.
- Post clear signage indicating gradient areas.
- Reduce speed when operating on slopes and always keep the load uphill.
2. Large Loads & Limited Visibility
Why It’s a Hidden Hazard:
Forklift design naturally creates problems when driving, especially when carrying large loads. Operators may think they have clear visibility when, in reality, pedestrians or objects could be hidden.
The Risks:
- Pedestrian Accidents: Collisions with co-workers walking through blind spots.
- Property Damage: Striking shelving units, walls, or equipment.
How to Mitigate:
- Look over both shoulders, use your mirrors and make sure the reverse beeper is working, before going backwards.
- Consider using another person to guide & direct you
- Repack the load, for clearer visibility.
- Implement designated pedestrian walkways with high-visibility markings.
- Encourage operators to drive in reverse when carrying large loads that obstruct the front view.
3. Poor Pedestrian Traffic Flow
Why It’s a Hidden Hazard:
Many workplaces lack clearly defined pedestrian routes, leading to dangerous intersections where forklifts and foot traffic overlap.
The Risks:
- High Collision Risk: Unpredictable pedestrian movement increases the chance of accidents.
- Distraction: Operators may become distracted trying to monitor people instead of focusing on safe driving.
How to Mitigate:
- Designate separate pedestrian and forklift zones.
- Install physical barriers where possible.
- Use floor markings, warning lights, and pedestrian crossing signs to guide safe movement.
4. Inadequate Lighting
Why It’s a Hidden Hazard:
Dim or inconsistent lighting can make it hard to spot obstacles, changes in floor elevation, or other hazards.
The Risks:
- Reduced Reaction Time: Operators may not see hazards until it’s too late.
- Increased Accident Rates: Poor visibility contributes to collisions, especially in storage areas with high shelving.
How to Mitigate:
- Conduct regular lighting audits to ensure all areas are well-lit.
- Use additional forklift-mounted lights, especially in darker areas.
- Encourage reporting of burnt-out bulbs or poorly lit zones.
5. Load Instability Due to Improper Stacking
Why It’s a Hidden Hazard:
Operators often focus on lifting heavy loads safely but may overlook how poorly stacked items can shift during transport.
The Risks:
- Falling Loads: Items can slide off pallets if not secured properly.
- Forklift Tip-Over: Uneven weight distribution affects the forklift’s centre of gravity.
How to Mitigate:
- Train staff on proper load stacking techniques.
- Use shrink wrap, straps, or load binders to secure items.
- Perform regular checks to ensure loads are balanced and stable before moving.
6. Fatigue and Operator Distraction
Why It’s a Hidden Hazard:
Fatigue isn’t as visible as a cracked floor or an overloaded pallet, but it significantly impacts operator performance.
The Risks:
- Slow Reaction Times: Fatigued operators are less alert, increasing the likelihood of accidents.
- Poor Decision-Making: Tired individuals are more prone to errors in judgment.
How to Mitigate:
- Implement regular break schedules.
- Encourage operators to report fatigue without fear of repercussions.
- Rotate tasks to prevent monotony and maintain focus.
7. Unsecured Dock Plates and Loading Ramps
These are used for the gaps between trucks and loading docks.
Why It’s a Hidden Hazard:
Dock plates and ramps can shift if not properly secured, creating unstable surfaces for forklifts.
The Risks:
- Sudden Drops: A loose dock plate can cause the forklift to tip or the load to shift unexpectedly.
- Operator Injury: Falls or jolts from unstable ramps can injure operators.
How to Mitigate:
- Ensure all dock plates are properly secured before use.
- Regularly inspect ramps for wear and tear.
- Use anti-slip coatings and proper securing mechanisms.
Keep In Mind
Forklift safety isn’t just about avoiding the obvious hazards—it’s about recognising the hidden dangers lurking in your workplace. By addressing risks like floor gradients, blind spots, and poor pedestrian flow, you can create a safer environment for everyone.
Stay alert, stay informed, and never underestimate the hidden hazards around you. After all, it’s the dangers you don’t see coming that pose the greatest risks.
