Forklift tip-overs are among some of the most serious hazards in material handling operations, and according to The British Safety Council, over 1,300 people are involved in forklift-related accidents every year. Understanding what causes these incidents and implementing proper prevention strategies can save lives and protect your business from costly downtime.
In the UK, forklift accidents contribute to multiple fatalities each year, with most deaths involving the driver being crushed during a tip-over. While the exact number varies annually, the Health and Safety Executive (HSE) consistently lists forklift incidents among the top workplace transport risks.
What makes this even more concerning is that 70% of forklift accidents are preventable with standard safety measures. This means most tip-over incidents don’t have to happen if we understand the causes and take appropriate action.
One of the primary causes of forward tip-overs is carrying loads that exceed the forklift’s rated capacity. Every forklift has a capacity plate that shows the maximum weight it can safely handle at specific load centres. When you overload the machine, the centre of gravity shifts beyond the stability triangle, making a tip-over almost inevitable.
Prevention: Always check the capacity plate before lifting any load. If you’re unsure about a load’s weight, don’t take chances – weigh it first or use a forklift with higher capacity.
HSE statistics revealed turning with elevated loads as being the biggest single cause of fatalities in forklift accidents in the UK. When you turn corners with the mast raised, the combined centre of gravity shifts dramatically, increasing the risk of tipping over, especially if you’re moving too quickly.
Prevention: Lower your load to the ground before making any turns. If you must turn with a load, keep it as low as possible and take corners extremely slowly.
Driving on slopes, uneven ground, potholes, or damaged surfaces can quickly destabilise a forklift. The shifting weight distribution can cause the centre of gravity to move outside the stability zone, leading to a sideways tip-over.
Prevention: Inspect your operating area regularly and avoid damaged surfaces. When working on slopes, keep loads low and travel slowly. Consider investing in surface repairs as part of your safety programme.
The most common causes of rollover or tip-over accidents involve dangerous speeds, abrupt movements, and poorly balanced loads. High speeds combined with sharp turns create a dangerous situation where momentum overcomes stability.
Prevention: Establish and enforce speed limits in your facility. Train operators to accelerate, brake, and turn gradually. Remember: smooth operation is safe operation.
According to recent BITA analysis of 2016–2018 RIDDOR reports, the most common contributory factor in lift truck tip-over events was the handling of live loads, or those suspended below the forks. These types of loads, such as bulk bags or items hanging from attachments, create unpredictable weight distribution.
Prevention: Whenever possible, use palletised alternatives instead of suspended loads. If you must handle live loads, drive in reverse to maintain visibility, reduce transport distance, and move extremely slowly.
Loads that aren’t properly positioned or secured can shift during transport, changing the forklift’s centre of gravity unexpectedly. This is particularly dangerous when the load shifts suddenly during movement or turning.
Prevention: Ensure loads are properly centred on the forks and secured with appropriate restraints. Both forks should be positioned fully under the load, with weight evenly distributed.
Many tip-overs result from operators who don’t fully understand their forklift’s stability principles or haven’t received comprehensive training on safe operating procedures.
Prevention: Invest in thorough operator training that covers stability principles, load handling, and emergency procedures. Regular refresher training helps reinforce safe practices.
Despite your best prevention efforts, if you find yourself in a tip-over situation, knowing the correct response can save your life. The most important thing to remember is never jump from the forklift.
For sit-down forklifts:
For stand-up forklifts:
The natural instinct to jump can be deadly because you can’t escape fast enough, and the overhead guard can crush vital areas like your head, neck, or shoulders.
Preventing forklift tip-overs is about creating a workplace culture where safety comes first. This means:
At Acclaim Handling, we understand that keeping your operation running safely and smoothly is your top priority. That’s why we provide comprehensive support beyond just equipment – from operator training to essential forklift safety tips that help prevent accidents before they happen.
Our experienced team can assess your current safety procedures and recommend improvements tailored to your specific operation. We also offer regular servicing for handling equipment to ensure your forklifts maintain optimal safety performance throughout their service life.
Forklift tip-overs are serious incidents that can result in fatalities, injuries, and significant business disruption. However, they’re largely preventable when you understand the causes and implement proper safety measures. By focusing on operator training, equipment maintenance, and creating a strong safety culture, you can protect your team and keep your operation running smoothly.
Remember, investing in safety is about protecting the people who make your business successful. Every tip-over prevented is a life potentially saved and a family kept whole.
Need expert guidance on improving forklift safety in your operation? Our team at Acclaim Handling is here to help with trusted material handling solutions that put safety first. Contact us today to discuss how we can support your business.
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