Forklifts are indispensable in warehouses, construction sites, and distribution centers worldwide. These powerful vehicles streamline material handling and improve productivity. However, with power comes risk. Forklift-related incidents are one of the leading causes of workplace injuries and fatalities among industrial equipment.
While forklifts are designed for efficiency, they demand strict adherence to safety protocols due to their size, weight, and function. Understanding what not to do on a forklift is critical for protecting not only the operator but also coworkers and the surrounding environment.
In this article, we’ll explore common mistakes operators make and outline best practices for safe forklift operation. By learning from real-world errors and expert advice, you can help prevent preventable accidents and ensure safer operations.
1. Never Operate Without Proper Training
The Cost of Skipping Forklift Certification
One of the most significant mistakes a person can make is operating a forklift without the proper certification or training. According to Occupational Safety and Health Administration (OSHA) standards, all forklift operators must be trained and evaluated to ensure they can safely handle these vehicles.
Forklifts are complex machines with different controls, tipping risks, and load-handling dynamics. An untrained individual might misinterpret the vehicle’s center of gravity or react incorrectly in an emergency situation.
Key OSHA Requirements for Training
- Formal instruction (e.g., lecture, video, written materials)
- Practical training (e.g., demonstrations and exercises)
- Performance evaluation at least once every three years
- Refresher training when an operator is observed operating unsafely or after an incident
Skipping this process or assigning forklift tasks to partially trained employees can lead to costly violations, legal consequences, and workplace injuries.
2. Do Not Ignore Pre-Operation Inspections
Why Skipping a Quick Safety Check Is a Big Mistake
Forklift inspections are not just a routine—they’re a vital part of equipment safety. Pre-operational checks are designed to identify mechanical issues, fluid leaks, tire damage, brake failures, and other safety risks before they result in accidents or equipment failure.
In many industrial environments, pressures to “get started quickly” can lead some operators to bypass inspection. However, OSHA requires a daily check before the forklift is used. This is not optional.
What a Pre-Operational Inspection Should Include
| Component | Recommended Check | Potential Problem |
|---|---|---|
| Tires | Check for wear, damage, and pressure | Uneven stability leading to tip-over |
| Hydraulic system | Check for leaks or unusual noise | Load drop or mast failure |
| Brakes | Test operation and response | Loss of stopping power, collisions |
| Seat belts | Confirm working order and functionality | Injury risk in case of tip-over |
| Lights and horn | Test for function and visibility | Reduced visibility in low light or inability to warn others |
Neglecting this step can compromise safety for everyone on site. Your few minutes upfront can prevent hours of downtime later.
3. Never Carry Unbalanced or Overloaded Loads
Understanding Forklift Load Capacity
All forklifts are rated for a specific load capacity, usually listed on a data plate that includes weight limits and load center distances. This information is crucial. Exceeding weight limits or failing to balance the load can result in dangerous tipping events, dropped loads, or mechanical failures.
Many operators underestimate the effect of a slight imbalance, which can seriously shift a forklift’s center of gravity. When that happens, especially during turns or while ascending ramps, even experienced operators may not be able to regain control quickly.
Best Practices for Load Handling
- Ensure loads are centered on the forks
- Keep loads low (approximately 4 to 6 inches from the ground) when moving
- Check weight against forklift specifications before lifting
- Never lift a load that blocks forward vision unless using a spotter
Additionally, operators must understand how the load center affects lift capacity. For instance, increasing the load’s center distance from the forks can significantly decrease the forklift’s lifting ability.
4. Do Not Distract or Allow Distractions While Operating a Forklift
Why Focus Is Essential Behind the Wheel
Distracted driving is not unique to cars—forklifts demand the same level of concentration. Whether it’s using a handheld phone, texting, or even excessive conversation with nearby workers, distractions can lead to major accidents.
According to the National Safety Council, distractions can extend reaction times, reduce situational awareness, and prevent timely responses to hazards. Since forklifts often operate in tight, crowded environments, any loss of focus can result in collisions with objects or pedestrians.
Common Distractions in the Workplace
- Talking with coworkers instead of focusing on the driving path
- Using smartphones for messages or non-operational tasks
- Adjusting settings without coming to a complete stop
Operators must avoid multitasking and ensure they keep one hand or hand and foot ready for action at all times.
5. Do Not Use a Forklift to Lift or Transport People
Understanding the Risk of Man-Riding
Although there are specialized forklifts designed for personnel lifting (e.g., man baskets attached to forklift masts), standard forklifts are not meant to carry people on the forks or pallets. Yet, many unauthorized incidents occur when workers or operators attempt to use forklifts as makeshift elevators.
From makeshift platforms to riding on pallets, these actions are highly dangerous. Falling from even a few feet can result in serious injury or death. OSHA strictly prohibits using forklifts to lift people unless certain safety precautions are followed and appropriate attachments are used.
Guidelines for Approved Personnel Tasks
- Ensure man basket or work platform is OSHA compliant
- Secure personnel with harnesses and lanyards
- Only lift people when necessary and under direct supervision
There is never a good reason to risk someone’s life just for convenience. Follow regulations and use proper equipment for elevated tasks.
6. Avoid Speeding or Reckless Driving with a Forklift
Why Maintaining a Safe Speed Is Non-Negotiable
Despite their size, forklifts are often driven forcefully in an attempt to keep pace with fast warehouse operations. However, speed is a critical factor in many forklift accidents, particularly those involving tipping over or colliding with pedestrians or structures.
Forklifts are slower to stop than typical vehicles. Add heavy loads into the equation, and stopping distances can double. Poor judgment of speed in tight corridors, around blind turns, or in poorly lit areas can be catastrophic.
Key Speed Safety Reminders
- Never exceed posted speed limits in the facility
- Reduce speed when turning, moving on slopes, or navigating corners
- Always slow down in high-traffic zones or areas with reduced visibility
Remember: forklifts prioritize lifting over mobility. They should always be driven safely, not quickly.
7. Do Not Drive on Ramps, Slopes, or Uneven Surfaces Without Proper Technique
How Slopes Can Become Slippery Slopes to Safety
Operators often treat driving a forklift uphill or downhill as routine—but it’s not. In fact, improper slope management is one of the top causes of forklift tip-overs.
Whether it’s an internal ramp, loading dock incline, or outdoor terrain, the direction in which you position the forklift—and the load—can mean the difference between safe passage and tipping disaster.
Best Practices for Navigating Slopes
- When ascending or descending ramps: Keep the load facing uphill to maintain stability.
- Reduce speed and ensure full traction when driving on slopes.
- Avoid turning on inclines whenever possible.
Additionally, surfaces should be regularly inspected for oil, debris, or ice that can reduce traction or visibility.
8. Never Modify or Overload a Forklift Beyond Manufacturer Design
Understanding the Dangers of Unauthorized Changes
Sometimes, in an effort to improve efficiency or handle larger loads, operators or maintenance teams may attempt to modify forklifts without manufacturer authorization. These modifications can include extended forks, added attachments, or tampering with the power system.
Such changes can invalidate warranties, compromise safety systems, and dramatically affect the vehicle’s load capacity or balance. Even slight changes in weight distribution or hydraulic pressure can create risks that aren’t immediately noticeable but can lead to severe accidents in the long run.
Steps to Stay Compliant
- Consult the manufacturer or authorized dealer before installing any attachments.
- Have the forklift re-rated (with updated data plates) if modifications affect capacity.
- Update operator training to include use of new accessories or modifications.
Remember: just because you can lift it doesn’t mean you should. Always follow the manufacturer’s safety guidelines.
9. Avoid Parking on Ramps or Inclines Without Safety Precautions
How a Parked Forklift Can Become a Hazard
When parking a forklift, it’s not enough to turn it off and walk away. Especially on inclines, parking requires the correct procedure to prevent the vehicle from rolling or shifting unexpectedly.
Unsecured forklifts can roll away and injure people or damage equipment, even when unattended for just a few seconds. This is particularly dangerous in busy environments where distractions are common.
Best Practices for Parking
- Always set the parking brake when shutting down
- Place transmission in neutral
- Lift forks to approximately 4–6 inches off the ground
- Turn off the engine and remove the key
- Point forks downhill when parked on an incline
Safety during parking isn’t an afterthought—it’s part of safe operation.
10. Do Not Neglect Surrounding Environments and Blind Spots
Situational Awareness Keeps Everyone Protected
Forklifts have significant blind spots both in front of and behind the operator. Failure to maintain situational awareness leads to pedestrian injuries, wall and equipment damage, and collisions with stationary objects.
Operators must make a habit of checking their surroundings before moving, especially in tight or congested areas. Use of mirrors, lights, horns, and spotters can greatly reduce the risk in complex environments.
Environmental Hazards to Watch For
- Slippery surfaces (oil spills, water, frost)
- Narrow aisles
- Overhead obstructions (low beams, lights, cables)
- Poor lighting
- Obstructed views due to tall or bulky loads
Forklifts must always be aware of pedestrians. One common mistake is failing to use audible signals before backing up or while entering intersecting aisles.
Conclusion: Prioritize Safety Over Convenience
Understanding what not to do on a forklift is more than following safety rules—it’s cultivating a mindset of risk awareness and responsibility. Many forklift accidents could be prevented through proper training, regular maintenance, and strict adherence to safe operating procedures.
Whether you’re an operator, safety supervisor, or warehouse manager, it’s your collective duty to ensure that every forklift is used with the respect and caution it demands. By avoiding the common mistakes outlined in this article, you can create a culture of safety that protects everyone on site and helps operations run more efficiently in the long term.
Forklift safety isn’t optional. It’s essential. Stay compliant, stay alert, and avoid preventable accidents at all costs.
1. Why should you never raise or lower loads while traveling on a forklift?
Raising or lowering loads while moving can significantly compromise the stability of the forklift and increase the risk of tipping over. The shifting weight during motion can cause the center of gravity to move outside the forklift’s stability triangle, especially when combined with sudden stops or turns.
Additionally, lifting or lowering while traveling may lead to loss of visibility, as the operator’s line of sight can be obstructed by the load. This increases the chance of collisions with objects, structures, or pedestrians. For safety, operators should always stop the forklift and ensure it is stable before adjusting the height of the load.
2. What are the dangers of driving a forklift with the forks elevated?
Driving a forklift with the forks elevated is extremely hazardous because it raises the center of gravity, making the truck more prone to tip over, particularly when turning or navigating ramps. This can lead to serious injury or even fatalities if the forklift overturns.
Moreover, elevated forks can obstruct the operator’s view and prevent proper control of the vehicle, potentially resulting in damage to racking, ceilings, or other overhead structures. To reduce these risks, operators should keep the forks as low as possible—ideally 6 to 10 inches above the ground—while driving and only raise them once the truck has come to a complete stop at the intended location.
3. Why is it unsafe to allow additional people to ride on a forklift?
A forklift is designed to accommodate only the operator and should never be used to transport additional riders. There is no safe place for a second person to stand or sit during operation, and doing so exposes them to serious injury from falling loads, accidental bumps, or lack of protection during sudden stops or collisions.
Even attempting to hold onto the truck for stability can be dangerous as there are no designated handholds or restraints. If an additional person needs to be lifted for work purposes, a properly secured platform specifically designed for such use and meeting OSHA standards should be utilized. Otherwise, extra riders should not be permitted under any circumstances.
4. What risks are associated with turning a forklift on a ramp or slope?
Turning a forklift on a ramp or slope can cause the vehicle to tip over due to the shift in weight distribution and the raised center of gravity during the turn. Forklifts are more unstable on inclines, and the lateral forces generated during a turn can exceed the vehicle’s tipping capacity.
To avoid this, operators should avoid making sharp turns when going up or down a slope and ensure the load is always carried uphill when moving on an incline. Ideally, all turns should be made on level ground with the forklift fully stopped before changing direction, especially when dealing with heavy or uneven loads.
5. Why shouldn’t you use a forklift to lift people unless it has a proper platform?
A forklift is not designed to carry personnel unless it is equipped with a lifting platform specifically manufactured and approved for that purpose. Attempting to lift individuals without such equipment increases the risk of falls, crushing injuries, or entanglement in the mast or carriage.
Using makeshift platforms or allowing workers to stand on the forks is a violation of safety standards and significantly increases liability in the event of an accident. If lifting personnel is necessary, only a work platform that complies with OSHA regulations and is secured to the forklift according to the manufacturer’s instructions should be used.
6. What are the dangers of traveling with a load that exceeds the forklift’s capacity?
Exceeding the forklift’s load capacity can lead to loss of control, reduced maneuverability, and an increased risk of overturning the vehicle. Overloading also puts excessive stress on the forklift’s components—such as the mast, hydraulics, and tires—potentially causing mechanical failure or sudden breakdowns.
Moreover, carrying a load that is too heavy can impair braking ability and cause the front wheels to lift, increasing the chance of tipping, especially when going up an incline or making turns. Operators must always check the forklift’s data plate to verify weight limits and never attempt to lift loads beyond the stated capacity, even for a short distance.
7. Why should you never jump from a forklift in case of a tip-over?
In the event of a tip-over, operators may instinctively attempt to jump off the forklift to escape, but this action significantly increases the risk of being crushed or seriously injured. Modern forklifts are equipped with rollover protective structures (ROPS) and seat belts designed to protect the operator inside the operator’s compartment if these safety devices are used correctly.
Operators should instead stay firmly seated with their seat belt fastened, hold onto the steering wheel, brace their feet, and lean in the opposite direction of the tip. Following these procedures helps maintain distance from the overhead guard and reduces the likelihood of injury. Jumping should never be considered as a means of escape during a forklift tip-over.