Avoiding Struck-By Hazards When Operating Forklifts
The Problem
Forklifts are an essential part of many workplaces, but they also present significant struck-by hazards. Each year, workers are seriously injured or killed in forklift-related incidents. Most of these accidents occur due to poor visibility, unsafe operation, or failure to follow site safety protocols. Today, we’ll focus on identifying these hazards and discuss how to operate forklifts safely to prevent struck-by incidents.
Identify the Hazards
- Blind Spots: Limited visibility can prevent operators from seeing pedestrians or other obstructions.
- Unsecured Loads: Incorrectly loaded or unstable cargo can shift or fall, striking nearby workers.
- Excessive Speed: Driving too fast reduces reaction time and increases the likelihood of collisions.
- Pedestrian Proximity: People working or walking near forklifts are at risk of being struck, especially in tight or busy areas.
- Improper Reversing: Operators reversing without checking surroundings can hit other workers or structures.
Safety Practices and Preventative Measures
Maintain Clear Visibility
- Always ensure the area ahead and around the forklift is free from obstructions.
- Use mirrors and spotters in areas with blind spots.
- Avoid carrying loads that block your line of sight; reverse if necessary.
Secure and Balance Loads
- Ensure loads are stable and evenly distributed before moving.
- Do not exceed the forklift’s rated lifting capacity.
- Use straps or load restraints where appropriate for loose or irregular loads.
Control Speed
- Drive at safe speeds, especially in shared or confined areas.
- Slow down when cornering, and avoid sudden stops to prevent load displacement.
Warn and Communicate
- Use horns, flashing lights, and alarms to alert others of your presence.
- Make eye contact with pedestrians before proceeding.
Create Safe Pedestrian Zones
- Where possible, separate forklift routes from pedestrian paths.
- Use cones, barriers, painted walkways, or signage to clearly define exclusion zones.
- Restrict forklift use in high foot-traffic areas when possible.
Safe Reversing Procedures
- Always check surroundings before reversing.
- Use a spotter in tight or blind spots.
- Never assume the area behind you is clear—always confirm visually.
Training and Certification
- Only certified operators should use forklifts.
- Operators must be trained in accordance with WorkSafe NZ requirements and site-specific procedures.
Real-Life Case or Scenario
A worker was seriously injured when struck by a forklift carrying a high load that blocked the operator’s view. The pedestrian did not see the forklift, and the operator did not have a spotter. This incident could have been prevented by using a spotter and ensuring clear communication.
Employee Responsibilities
- Follow forklift safety procedures including speed limits and load checks.
- Remain alert and aware of forklift activity around you.
- Communicate with operators before crossing or working in their area.
- Report any damaged forklifts or unclear pedestrian areas to your supervisor.
Employer Responsibilities
- Ensure operators are properly trained and certified.
- Maintain forklifts to ensure all safety systems are working (e.g. alarms, mirrors, lights).
- Create and maintain clear pedestrian and vehicle zones.
- Conduct routine site safety checks to identify and address risks.
Discussion & Questions
- “What struck-by hazards have you observed with forklifts on our site?”
- “How can we improve operator-pedestrian communication here?”
Encourage workers to share experiences or suggestions.
Commitment/Action Plan
Let’s commit to improving forklift safety starting today. All operators should inspect their forklifts before use, drive safely, and ensure good communication with others. Pedestrians should stay alert, stay in marked walkways, and avoid cutting across active forklift zones.
Wrap-Up
Struck-by incidents involving forklifts are preventable. By remaining vigilant, using proper communication, and following safety protocols, we can protect ourselves and our workmates. Thank you for your commitment to site safety.
Standards Overview
WorkSafe New Zealand requires all forklift operators to hold a current operator certificate and be trained in accordance with the Approved Code of Practice for Operator Protective Structures and Training. Employers must:
- Maintain forklifts in safe working condition.
- Implement traffic management plans separating pedestrians and mobile plant.
- Ensure forklifts are only operated by trained, competent workers.
- Provide high-visibility PPE and ensure signage and warnings are clearly displayed.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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