Forklift Safety: Policy and Training Requirements For Small Business Owners

18 min read
Forklift Safety: Policy and Training Requirements For Small Business Owners

Your forklift operator took a corner too fast. The 9,000-pound machine tipped. He jumped. He wasn’t wearing his seatbelt. He was never trained to stay within the operator’s protection cage. It would have saved his life.

Age 32. Two kids. Mortgage.

Your workers’ comp pays $850,000 in death benefits. OSHA cites you $165,000 for willful violations—no forklift safety training, no certification, no daily inspections.

Your experience modifier rate skyrockets. Your insurance carrier drops you.

Don’t think for a second this is an exaggeration. All of this because putting a policy in place and training staff was just too much.

Don’t let this be your company.

The Bureau of Labor Statistics reports 67 forklift fatalities in 2023 alone. Over 7,000 workers are seriously injured every year—injuries severe enough to miss work. The average forklift injury results in 13 days away from work, nearly double the 8-day average for other workplace injuries.

And every single one impacts your workers compensation costs for years.

If your business operates forklifts—even one forklift—you need a written forklift safety program. Not verbal reminders. Not “common sense.” A documented program with forklift safety training, operator certification, and daily inspections.

Here’s why this matters for your business—and how to get up and running with your new Forklift Safety Program.

Table of Contents

Forklift Accidents Happen Fast

Forklifts weigh up to 9,000 pounds—three times heavier than most cars. They can travel up to 18 mph. They’re rear-heavy to counterbalance front loads. They lift loads 20+ feet in the air while blocking the operator’s view.

When something goes wrong, it happens in seconds. A load shift. An uneven surface. A sharp turn. The machine tips. The operator has little time to react.

The Human Cost

What happens to your employees:

  • Crushed by tipping forklifts (42% of fatalities)
  • Struck by forklifts as pedestrians (36% of fatalities)
  • Crushed between forklift and fixed objects
  • Struck by falling loads
  • Falls from elevated positions
  • Amputations from pinch points
  • Severe lacerations and fractures

OSHA’s finding: 42% of forklift fatalities occur when operators jump from a tipping forklift and are crushed by the overhead guard. The natural instinct—to jump—is exactly what kills them.

These injuries don’t just end careers. They end lives.

The Business Cost

What happens to your company:

Workers Compensation Claims:

  • Emergency medical treatment
  • Surgery and hospitalization
  • Long-term rehabilitation
  • Wage replacement during recovery
  • Permanent partial disability benefits
  • Permanent total disability if unable to return to work
  • Death benefits (average $850,000+ depending on state)
  • Average forklift injury claim: $41,003

Experience Mod Impact:

  • Forklift injuries = severe, high-cost claims
  • EMR stays elevated for 3 years minimum
  • 25-40% premium increase per serious claim
  • Fatal accidents can make you uninsurable

See our post on how your experience modification rate works.

OSHA Penalties:

  • $16,550 per serious violation
  • $165,514 per willful/repeated violation
  • Common citations: no forklift safety training, no certification, no daily inspections, no seat belts
  • Multi-employer worksites = everybody gets cited

Operational Costs:

  • Emergency response
  • Production shutdown
  • Equipment replacement
  • Investigation time
  • Employee replacement and training
  • Project delays
  • Reputation damage

One preventable forklift accident can cost your business $200,000-$500,000 when you factor in medical costs, death benefits, OSHA fines, EMR impact, and lost productivity.

Use our Safety ROI calculator to see the real cost of an injury. Use the second tab, “Injury Cost,” and fill out a few fields. The total will shock you. We also show how much revenue you need to generate to cover that loss. Spoiler: It’s massive.

Compare that to the cost of a safety program: forklift safety training, certification, daily inspections, and a written program. Maybe $2,000-$3,000 total. Far less if using Smarter Risk, as we can provide everything but the hands-on certification.

The Official Numbers: Bureau of Labor Statistics Data

Fatalities and Serious Injuries (BLS and OSHA Data)

According to the U.S. Bureau of Labor Statistics and OSHA:

Annual Fatalities:

  • 67 workers killed in forklift accidents in 2023 (National Safety Council citing BLS)
  • 74 fatalities in 2017
  • 614 workers died from 2011-2017 (7-year period)
  • 96 fatalities in 2015 (OSHA data)

Annual Injuries:

  • 35,000 serious injuries annually (OSHA estimate)
  • 62,000 non-serious injuries annually
  • 9,050 nonfatal injuries with days away from work in 2017
  • Over 7,000 serious injuries requiring time off work each year
  • 24,960 DART cases (Days Away, Restricted, or Transferred) in 2021-2022

Injury Severity:

  • Median 13 days away from work per forklift injury
  • Compare to 8 days median for all other workplace injuries
  • Nearly double the recovery time

Sources: U.S. Bureau of Labor Statistics (BLS); OSHA Directive CPL 04-00-023F; National Safety Council Injury Facts 2025

Primary Causes (OSHA Investigation Data)

  • 42% of fatalities: Operator crushed by tipping forklift
  • 36% of fatalities: Pedestrians struck by forklifts
  • 25% of accidents: Forklift tip-overs
  • 20-25% of accidents: Inadequate forklift safety training

Most vulnerable workers:

  • 42% of accidents occur in workers with less than 1 year of experience
  • Operators aged 25-34 suffer the most injuries

Critical finding from OSHA: An estimated 70% of forklift injuries could be prevented with proper training.

Workers Compensation Costs

  • Average forklift injury claim: $41,003
  • Average OSHA penalty: $13,494 per violation
  • Death benefits: $850,000+ (varies by state)
  • Equipment replacement: $15,000-$50,000 per damaged forklift
  • Lost productivity: Hundreds of thousands in downtime

What Is a Forklift Safety Policy?

A forklift safety policy is your comprehensive program for training operators, certifying competence, inspecting equipment, and maintaining safe operating procedures for powered industrial trucks (PITs).

OSHA mandates written programs and operator certification (29 CFR 1910.178).

What OSHA Calls Forklifts

OSHA refers to forklifts as “powered industrial trucks” (PITs) and regulates all variants:

  • Sit-down counterbalanced forklifts
  • Stand-up reach trucks
  • Order pickers
  • Pallet jacks (powered)
  • Narrow aisle trucks
  • Rough terrain forklifts
  • Telehandlers

If it’s powered and moves loads, OSHA’s forklift safety requirements apply.

OSHA Requirements: What You Must Do

OSHA’s Powered Industrial Truck standard (29 CFR 1910.178) has specific requirements. Miss any of them, and you’re in violation.

1. Forklift Safety Training (OSHA-Compliant)

You must provide formal forklift safety training that includes:

  • Classroom instruction (formal instruction)
  • Practical training (hands-on demonstration)
  • Performance evaluation (operator assessment)

Forklift safety training must cover:

  • Operating instructions and controls
  • Differences between forklifts and cars (rear-wheel steering, counterbalancing)
  • Load capacity and stability
  • Hazard recognition
  • Refueling procedures
  • Daily inspection requirements
  • Workplace-specific hazards
  • Surface conditions and ramps

Training required:

  • Before operators use forklifts for the first time
  • Before operating a different type of forklift
  • When operators demonstrate unsafe behavior
  • When workplace conditions change
  • Every 3 years minimum (refresher forklift safety training)

OSHA does NOT accept generic online-only training unless combined with hands-on practical evaluation at your worksite.

2. Forklift Operator Certification

Every forklift operator must be certified, which means:

  • Completing OSHA-compliant forklift safety training
  • Passing a practical evaluation by a qualified trainer
  • Receiving written certification from the employer
  • Being at least 18 years old

Forklift operator certification documentation must include:

  • Operator’s name
  • Date of training
  • Date of evaluation
  • Identity of person conducting training/evaluation
  • Type of equipment operator is certified to use

This is not a “forklift license.” It’s employer-issued certification proving the operator completed required forklift safety training and demonstrated competence.

Certification must be renewed:

  • Every 3 years minimum
  • When unsafe operation observed
  • After an accident or near-miss
  • When assigned to a different type of forklift

3. Daily Forklift Inspection Checklist

Operators must conduct pre-shift inspections using a forklift inspection checklist before each shift.

Daily inspection must check:

  • Tires (inflation, damage, wear)
  • Brakes (service brake and parking brake)
  • Steering mechanism (responsiveness)
  • Hydraulic systems (leaks, damage)
  • Forks (cracks, bends, locking mechanisms)
  • Overhead guard (damage, integrity)
  • Lights and warning devices (horn, lights, backup alarm)
  • Seat belt (function, damage)
  • Fluid levels (oil, coolant, fuel)
  • Controls (all functions operate correctly)

If defects found:

  • Remove forklift from service immediately
  • Tag “DO NOT OPERATE”
  • Report to supervisor
  • Document defects
  • Do not operate until repaired and re-inspected

Missing or incomplete daily inspections are one of the most common OSHA violations.

4. Safe Operating Procedures

Your forklift safety program must include:

Load Handling:

  • Never exceed rated capacity
  • Keep loads low during travel (4-6 inches off ground)
  • Tilt mast back when traveling with load
  • Travel in reverse if load blocks forward view
  • Use spotter when visibility limited

Travel Safety:

  • Observe speed limits (typically 5 mph in facilities)
  • Slow down at intersections, blind corners, doorways
  • Sound horn at intersections and when approaching pedestrians
  • Never drive with elevated forks empty
  • Watch for pedestrians constantly
  • Maintain 3-forklift-length distance from other forklifts

Stability and Tip-Over Prevention:

  • Keep load low—elevated loads cause tip-overs
  • Never turn with elevated load
  • Watch for uneven surfaces, ramps, dock plates
  • Drive straight up/down ramps—never across
  • Slow down before turning
  • WEAR SEAT BELT ALWAYS
  • If forklift tips, DO NOT JUMP—stay in seat, hold on, brace yourself

Loading Docks:

  • Verify trailer secured (wheel chocks, dock locks)
  • Check dock plate properly positioned
  • Ensure trailer floor can support forklift weight
  • Verify trailer won’t roll or separate during loading

Parking:

  • Lower forks flat to ground
  • Tilt mast forward
  • Set parking brake
  • Turn off ignition and remove key
  • Never park on incline
  • Block wheels if parking on slope unavoidable

5. Pedestrian Safety

36% of forklift fatalities involve pedestrians struck by forklifts.

Required pedestrian safety measures:

  • Designated pedestrian walkways
  • Physical barriers separating forklifts from foot traffic
  • Floor markings (yellow lines, crosswalks)
  • Mirrors at blind corners
  • Warning signs and lights
  • Pedestrian right-of-way rules
  • Spotters for high-traffic areas

Operators must:

  • Always look in direction of travel
  • Sound horn at intersections and near pedestrians
  • Stop and yield to pedestrians
  • Never assume pedestrians see or hear the forklift
  • Maintain visual contact with spotters

6. Seat Belts Required

OSHA requires seat belts on all forklifts equipped with them.

Critical fact: 42% of forklift fatalities occur when operators jump from tipping forklifts. The overhead guard then crushes them.

If the forklift tips:

  • DO NOT JUMP
  • Stay in the seat
  • Hold on firmly
  • Brace yourself
  • Lean away from the point of impact

Seat belts keep operators in the protective zone of the overhead guard during tip-overs.

7. Fuel Handling and Battery Charging

Propane Forklifts:

  • Change tanks in well-ventilated areas
  • Turn off ignition before changing
  • Store cylinders upright and secured
  • Keep fire extinguisher within 25 feet

Electric Forklifts:

  • Charge batteries in designated areas
  • Provide ventilation (hydrogen gas release)
  • Wear PPE (face shield, rubber apron, gloves)
  • Eyewash station required in charging areas

Gasoline/Diesel Forklifts:

  • Refuel outdoors or in well-ventilated areas
  • Turn off engine before refueling
  • No smoking within 50 feet
  • Use approved containers only

Common Mistakes That Cause Fatalities

Mistake #1: No Forklift Safety Training
“He’s driven forklifts before” doesn’t count. OSHA requires formal training, practical evaluation, and written certification.

Mistake #2: Generic Online-Only Training
Online forklift safety courses satisfy classroom requirements but NOT practical evaluation. You must conduct hands-on assessment at your worksite.

Mistake #3: No Daily Inspections
“It worked yesterday” isn’t an inspection. Pre-shift forklift inspection checklists are mandatory every shift.

Mistake #4: Not Wearing Seat Belts
Operators who jump from tipping forklifts get crushed by overhead guards. Seat belts save lives during tip-overs.

Mistake #5: Elevated Loads While Traveling
Driving with elevated loads causes tip-overs. Keep loads 4-6 inches off the ground.

Mistake #6: Letting Untrained Employees “Just Move It Quick”
One quick move by an untrained person can result in a fatality. No exceptions.

Mistake #7: No Pedestrian Separation
Forklifts and pedestrians don’t mix. 36% of fatalities are struck-by incidents.

Mistake #8: Expired Certifications
Training from 5 years ago doesn’t count. Forklift operator certification expires after 3 years.

How Smarter Risk Makes Forklift Safety Simple

Building an OSHA-compliant forklift safety program used to mean months of work—finding forklift safety policy templates, creating documentation and certificates.

Not anymore.

Build Your Program in Minutes

Smarter Risk’s Policy Builder generates a complete, OSHA-compliant forklift safety program based on your risk assessment.

What you get:

  • Complete written forklift safety program (29 CFR 1910.178 compliant)
  • Daily forklift inspection checklist forms
  • Forklift operator certification records
  • Training documentation templates
  • Accident investigation forms
  • Forklift Safety Rules Acknowledgement forms

Download in Word format. Customize for your operation. Implement immediately.

What’s Included with Smarter Risk

Intelligent Plan ($500/year):

150+ Safety Forms

  • Daily forklift inspection checklists
  • Operator certification records
  • Incident investigation forms
  • Annual Evaluation Report

50+ Training Courses

  • Forklift Safety Training (OSHA-compliant classroom instruction)
  • 50+ additional courses

Important: Our forklift safety course satisfies OSHA’s classroom/formal instruction requirement. You must still conduct hands-on practical training and evaluation at your worksite. We provide evaluation forms and guidance.

View the complete course catalog at smarterrisk.com/training.

No safety expertise required. RISK-B, our AI assistant, guides you through everything.

Implementation: Your 30-Day Plan

Don’t let this sit on a shelf. Here’s how to implement fast:

Week 1: Assessment and Documentation

  • Complete your risk assessment with Smarter Risk
  • Generate your forklift safety program
  • Identify which operators need forklift safety training
  • Determine which operators need refresher training

Week 2: Training (Classroom/Formal Instruction)

  • Have operators take the Smarter Risk forklift safety course
  • Ensure all operators complete OSHA-required classroom instruction
  • Document training completion
  • Prepare for hands-on practical training

Week 3: Practical Training and Certification

  • Conduct hands-on forklift operator training at your worksite
  • Evaluate each operator on each forklift type they’ll use
  • Issue forklift operator certification to qualified operators
  • Document all certifications (name, date, evaluator, equipment type)
  • Set up 3-year renewal reminders

Week 4: Inspections and Procedures

  • Implement daily forklift inspection checklist requirement
  • Post forklift safety rules and have all operators sign the acknowledgement form
  • Establish pedestrian traffic patterns
  • Install floor markings and barriers
  • Post speed limits
  • Conduct supervisor training on enforcement

Ongoing

  • Daily pre-shift inspections required every shift
  • Document all inspections
  • Remove defective forklifts from service immediately
  • Monthly forklift safety audits
  • Annual training reviews
  • Refresher forklift safety training every 3 years minimum
  • Immediate training after any accident or unsafe behavior

The Bottom Line

Forklift accidents are immediate and devastating. Unlike repetitive strain injuries, one tip-over can kill someone in seconds.

A forklift safety program prevents these tragedies. It’s required by OSHA. It protects your workers. It protects your business from fatal accidents that raise your experience mod for years—or make you uninsurable.

With Smarter Risk, implementation takes minutes instead of months. For $500/year, you get complete forklift safety programs, training, inspection checklists, and certification tracking.

One prevented fatality is priceless.

Build Your Forklift Safety Program Today

Start your free risk assessment and generate your complete forklift safety program in minutes →

Or explore our Safety Made Simple approach to building comprehensive safety programs from scratch.

Frequently Asked Questions

What is forklift safety training?
Forklift safety training is OSHA-required training that includes formal classroom instruction, hands-on practical training, and operator evaluation. It covers forklift operation, load handling, hazard recognition, inspection procedures, and workplace-specific conditions. Training must be documented and renewed every 3 years minimum.

Do I need forklift operator certification?
Yes. OSHA requires all forklift operators to be trained and certified before operating powered industrial trucks. Forklift operator certification means completing OSHA-compliant training, passing a practical evaluation, and receiving written documentation from your employer. Operators must be at least 18 years old.

What’s the difference between forklift safety training and forklift operator certification?
Forklift safety training is the instruction and practical training process. Forklift operator certification is the written documentation your employer provides after you complete training and pass the evaluation. You need both—training first, then certification proving you completed it.

Can I take a forklift safety course online?
Partially. Online forklift safety courses satisfy OSHA’s classroom/formal instruction requirement. However, you must also complete hands-on practical training and evaluation at your actual worksite. Online-only training without practical evaluation does not meet OSHA requirements.

How long is forklift operator certification good for?
Forklift operator certification must be renewed every 3 years minimum. However, you must provide refresher training immediately if an operator: (1) operates unsafely, (2) is involved in an accident, (3) is assigned to a different type of forklift, or (4) workplace conditions change.

What should be on a forklift inspection checklist?
A daily forklift inspection checklist must include: tires, brakes, steering, hydraulics, forks, overhead guard, lights/horn/backup alarm, seat belt, fluid levels, and all controls. Any defects require immediate removal from service until repaired. Inspections must be documented every shift.

How often should forklifts be inspected?
Forklifts must be inspected before every shift using a forklift inspection checklist. Additionally, conduct formal maintenance inspections according to manufacturer recommendations (typically monthly or quarterly depending on usage). Document all inspections.

Do forklift operators need to wear seat belts?
Yes. OSHA requires seat belts when forklifts are equipped with them. This is critical—42% of forklift fatalities occur when operators jump from tipping forklifts and are crushed by the overhead guard. Seat belts keep operators in the protective zone during tip-overs.

What should I do if my forklift tips over?
DO NOT JUMP. Stay in the seat, hold on firmly, brace yourself, and lean away from the point of impact. The overhead guard protects you if you stay in the seat. Jumping puts you directly in the path of the falling overhead guard, which causes most forklift fatalities.

What are the most common OSHA forklift violations?
The most common violations are: (1) no forklift safety training or certification, (2) allowing uncertified operators to use forklifts, (3) no daily forklift inspection checklists, (4) operators not wearing seat belts, (5) inadequate pedestrian safety measures, and (6) expired operator certifications (over 3 years old).

How much does a forklift accident cost?
The average forklift workers compensation claim costs $41,003. Fatal accidents result in death benefits averaging $850,000+. Add OSHA penalties ($16,550-$165,514), equipment replacement ($15,000-$50,000), lost productivity, and increased insurance premiums. Total costs easily exceed $200,000-$500,000 per serious accident.

What happens if OSHA finds untrained forklift operators?
OSHA can issue serious citations ($16,550 each) or willful citations ($165,514 each) for allowing untrained operators to use forklifts. If an accident occurs involving an untrained operator, penalties increase significantly and may include criminal charges if the accident is fatal.

Can temporary workers operate forklifts?
Only if they complete full OSHA-required forklift safety training, practical evaluation, and receive forklift operator certification from your company. You cannot rely on training from previous employers—you must ensure they’re trained on your specific equipment and workplace hazards.

Do I need different certifications for different forklift types?
Yes. Operators must be trained and certified on each specific type of powered industrial truck they’ll operate. Training on a sit-down counterbalance forklift doesn’t certify someone to operate a reach truck or order picker. Document certification for each equipment type separately.

What is the number one cause of forklift fatalities?
According to OSHA, 42% of forklift fatalities are caused by operators being crushed by tipping forklifts—specifically when operators jump from the tipping forklift and the overhead guard crushes them. This is why wearing seat belts and staying in the seat during tip-overs is critical.

Internal Resources

  • Safety ROI Calculator
    Calculate your specific savings from implementing safety programs. Use the “Injury Cost” tab to see the real financial impact of forklift accidents.

  • Free Risk Assessment
    Take a 15-minute assessment and get your customized forklift safety program instantly.

  • Smarter Risk Training Library
    Access 52 OSHA-compliant safety training courses including Forklift Safety Training and Powered Industrial Truck Safety.

  • OSHA Recordable App
    Determine if workplace injuries need to be recorded on OSHA 300 logs.

External Resources

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About the Author

John Morlan - Founder of Smarter Risk

John Morlan

Founder & CEO, Smarter Risk

John Morlan is the founder of Smarter Risk, a platform helping small businesses implement practical safety and risk control programs. With years of experience in workers' compensation and risk management, John has helped businesses reduce their risk and save on insurance costs through proactive risk control and safety strategies.