Forklift Safety: Protecting Property and Preventing Damage

When we think about forklift safety, the focus is often on protecting people—and rightly so. However, forklifts can also cause significant property damage in warehouses and other facilities, affecting everything from storage racks to doorways. This guide covers the main causes of property damage involving forklifts and the best ways to minimize these incidents, keeping both people and property safe.

The Impact of Forklift Damage on Property

While accidents that lead to serious injury or death are well-documented, forklift-related property damage is often unreported, making it easy to overlook. However, for those in material handling, it’s well-known that forklift mishaps can result in costly repairs and downtime. Common accidents include forklift rollovers and falling loads, which frequently damage goods, racking systems, and the forklifts themselves. 

Key Causes of Forklift-Related Property Damage

1. Driver Error

Many incidents stem from driver mistakes. For example, overloading a forklift can lead to tip-overs, and failing to check height clearances can cause damage to ceilings or doorways. Simple oversights like not properly positioning loads are also frequent culprits.

2. Poor Visibility and Tight Spaces

Limited visibility and maneuvering space can make it challenging for operators to navigate, especially in narrow aisles or busy areas, increasing the risk of accidents. 

3. Insufficient Clearance

Doorways, roller shutters, and other structures often suffer damage when forklifts try to pass through tight spaces with raised masts or long loads. 

Solutions to Minimize Forklift Accidents and Property Damage

Fortunately, various technologies and strategies can help reduce forklift-related property damage:

 

• 360° Camera Systems

Systems like the addedVIEW 360° camera from Jungheinrich give operators a complete view around their forklift, helping them avoid obstacles and safely maneuver in confined spaces.

• Speed Control for Corners

Jungheinrich’s curveCONTROL automatically slows forklifts down when turning corners, minimizing the risk of tipping or collisions.

• Zone-Controlled Speed Reduction

Systems like zoneCONTROL place digital anchors at high-risk areas in a facility, automatically slowing forklifts when they enter, ensuring they move at a safe speed.

These tools are available on newer forklift models, and some, like pedestrian detection systems, can even be retrofitted to older forklifts.

• Anti-Crash Technology

With their size and weight, forklifts can easily become “battering rams” if mishandled. Weston Handling offers safety solutions like the ACKBelt (Anti-Crush Kick-Pad) and CrashPad, which mount on forklifts to detect and warn operators of nearby obstacles. These systems activate alarms to alert both the driver and those nearby, preventing further damage and accidents. 

Enhanced Safety Through Telematics and AI

Safety doesn’t stop with just physical equipment; data can play a huge role. Systems like GemOne’s telematics monitor forklift use in real-time, allowing managers to track performance, monitor driver habits, and maintain compliance. AI-based tools, such as Panacea’s Smart Vision AI, improve visibility in blind spots, giving drivers real-time alerts to avoid potential accidents.

Maintenance Matters

According to Transmon Engineering, poor maintenance is another common cause of forklift-related accidents. Worn brakes, tires, or faulty warning horns can create hazards. Transmon’s proximity warning systems and AI cameras enhance safety by helping operators maintain awareness and avoid obstacles.

Choosing the Right Forklift for the Job

Using the appropriate forklift for the specific load is essential. For example, handling long or bulky loads with a traditional counterbalance forklift can be risky. Combilift’s multidirectional C-series offers a flexible solution, acting as a counterbalance, side loader, and reach truck in one, allowing operators to navigate tight spaces safely without compromising stability.

The Growing Role of AI

AI has become increasingly valuable in forklift safety. AI-based detection systems, like those from Panacea Aftermarket Co., give operators proactive warnings and real-time feedback, allowing them to avoid obstacles and reducing the risk of collisions with racks or other structures.

Assistance for Narrow Aisles

In narrow-aisle warehouses, where maneuverability is limited, assistance systems are particularly useful. Hubtex’s Aisle Entry Assist, for example, guides forklifts into narrow racks safely, minimizing the chance of accidental collisions. 

Using Telematics for Safer Operations

Telematics systems, like Hyster’s Hyster Tracker, track operator performance, manage certifications, and even restrict forklift access to certified drivers. These systems provide real-time data on forklift impacts, idle times, and other usage patterns, allowing managers to make informed decisions on training and fleet management.

A Proactive Approach to Safety

Preventing forklift damage isn’t just about avoiding accidents—it’s about creating a culture of safety and efficiency. From technology investments to regular training, taking proactive steps ensures a safer work environment, reduces costs, and improves productivity. Investing in safety systems and maintenance is a smart move for any business looking to protect its people and property.