Forklift Safety Best Practices for Warehouse Teams
Forklifts are the backbone of warehouse operations—but they can also be one of the biggest safety risks on your floor. When operated carelessly or without proper training, forklifts can cause severe injuries, property damage, and even fatalities.
Why Forklift Safety Matters More Than Ever
According to recent data from the U.S. Bureau of Labor Statistics, workers in material moving occupations—a category that includes forklift operators—accounted for 4.5% to 5.5% of all workplace fatalities between 2019 and 2023.
In 2021, fatalities in this group peaked at 284 deaths, and while the number declined slightly to 268 in 2023, the risk remains high. Forklift operators specifically had a fatal injury rate of 8.8 per 100,000 workers in 2022—more than double the national average.
These numbers are a sobering reminder that forklift-related incidents aren't rare—they're a persistent risk in the warehouse world. That's why every operator, manager, and facility needs to treat forklift safety not just as a compliance issue, but a core part of daily operations.
Forklift Safety Best Practices for Warehouse Teams
1. Start with Certified Forklift Training
No one should operate a forklift without proper OSHA-approved training—and that means certification.
Training should include:
Classroom instruction (rules, hazards, procedures)
Hands-on evaluation (operating in real or simulated conditions)
Refresher courses after incidents or every 3 years
Make it a rule: if they’re not certified, they’re not driving.
Tip: Create a forklift operator checklist during onboarding and re-certify proactively, not just reactively.
2. Inspect Before Every Shift
Daily pre-operation inspections are not just a recommendation—they’re required by OSHA.
Here’s a quick checklist operators should review before each shift:
Fluid levels (oil, water, hydraulic)
Tire condition and pressure
Brakes, horn, lights, and steering
Forks and mast (check for cracks, bends, or warping)
Safety devices (seatbelt, backup alarm, overhead guard)
If something’s not right—report it immediately and tag out the vehicle. Never “just ride it out.”
Bonus: Hang a laminated inspection checklist near the charging station or fuel area.
3. Know Your Load Capacity—and Respect It
Every forklift has a rated load capacity. Exceeding it, even by a little, can lead to:
Tip-overs
Falling loads
Damaged forks or hydraulic systems
Make sure each operator:
Knows where to find the forklift's load capacity (usually on the data plate)
Checks the center of gravity when stacking heavy or oddly shaped items
Uses pallet wrapping and securement to stabilize loads
Never guess. Always check.
4. Stick to Safe Speeds
Speed is one of the most common contributors to forklift accidents—especially in high-traffic warehouse environments.
Operators should:
Drive at walking speed (5 mph or less)
Slow down at intersections, corners, and blind spots
Never tailgate or engage in “horseplay” with forklifts
Post visible speed limit signs in aisles and loading docks as a constant reminder. And make it clear: speeding is a safety violation, not just a policy issue.
5. Watch for Pedestrians—Always
Warehouse workers often assume operators can see them—but forklifts have blind spots. That’s why pedestrian awareness must be drilled into every operator.
Best practices include:
Sounding the horn at intersections and entry points
Making eye contact with pedestrians before moving
Avoiding reversing unless necessary (use spotters if you must)
Never driving with an obstructed view—raise or lower forks as needed
For pedestrians:
Use marked walkways
Wear high-visibility vests
Stay alert and never assume the driver sees you
6. Maintain Clear Visibility
Operators must have a clear line of sight in the direction of travel.
If a load obstructs the view:
Drive in reverse if it's safe to do so
Use spotters when maneuvering in tight areas
Use convex mirrors at intersections or blind corners
Avoid stacking items too high on pallets and secure loads to prevent shifting during transport.
7. Avoid Hazard Zones
Certain warehouse areas are more accident-prone than others:
Loading docks
Ramps and inclines
Wet or oily floors
Narrow aisles
Post warning signs and train operators to:
Approach ramps head-on (never sideways)
Avoid sudden movements or sharp turns on inclines
Reduce speed on slick surfaces and report spills immediately
Bonus points for installing anti-slip mats and guardrails where needed.
8. Never Allow Extra Riders
This one should go without saying—but it still happens. Forklifts are designed for one person only: the operator.
Carrying passengers or using forks to lift people is extremely dangerous and a major OSHA violation.
If your team needs to elevate a worker for inventory or maintenance, use a properly secured and rated man-basket attachment—and ensure the person is wearing a fall harness.
9. Secure Forklift Parking and Shutdown
When a forklift isn’t in use, it still poses a hazard—especially if it’s left running or parked improperly.
At the end of each shift (or when stepping away), operators should:
Lower the forks to the ground
Set the parking brake
Turn off the engine
Remove the key
Bonus: If parking near pedestrian areas, angle the forks down slightly to prevent tripping injuries.
10. Create a Safety-First Culture
Even with all the rules in place, safety won’t stick unless it becomes part of your warehouse culture.
How to reinforce forklift safety daily:
Hold monthly safety meetings
Recognize and reward safe behavior
Encourage peer reporting of unsafe practices
Display posters or signage in key traffic zones
Make safety part of every team huddle
Remember: a strong safety culture isn’t just about compliance—it protects your people, productivity, and reputation.
Go Further: Enhancements to Future-Proof Your Approach
Once your basics are locked in, these modern upgrades can take your warehouse safety from solid to standout:
Forklift safety isn’t just about compliance—it’s about people. By following these best practices and keeping a close eye on data trends, you can reduce risk, improve performance, and send your team home safely every day.
Want more ways to build a culture of safety? Check out these related reads:
Ready to Build a Safer Warehouse?
At Timpl, we specialize in staffing light industrial teams who are safety-trained and warehouse-ready. Whether you're looking for certified forklift operators or support staff who understand the importance of warehouse safety, we're here to help.
Contact us today to find safety-first talent for your team.
