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Introduction
We recently analyzed seven years’ worth of forklift-related fatality reports provided by OSHA, covering incidents across the U.S. from 2017 to 2024. You can find this data on OSHA’s website here. We studied all incidents where the words “forklift”, “pallet jack” or “industrial truck” were included. The results were eye-opening and underline just how important it is to stay vigilant when operating or working near forklifts.
Here’s what we uncovered—and what your operation can learn from it.
What the Data Shows
Our analysis included hundreds of incidents, each one involving a forklift or pallet jack in some capacity. There were a total of 317 incidents on OSHA’s website. Here’s what stood out:
– Texas leads the nation in forklift-related fatalities with 48 recorded deaths during the period. California followed with 26, and Georgia came in third with 18.
– Across all states, certain types of incidents repeated themselves—pointing to preventable patterns.
Most Common Fatal Incident Types
From reviewing detailed hazard descriptions, we grouped the incidents into key categories:
| Incident Type | Number of Cases |
| Crushed/Pinning | 132 |
| Struck by Forklift | 108 |
| Falls from Height | 40 |
| Forklift Overturned | 21 |
| Other/Unclear | 14 |
Real-World Lessons from the Field
Reading through these reports is sobering. In many cases, the root cause wasn’t complicated equipment failure—it was a lack of training, poor visibility, or failure to follow basic safety protocols.
It’s a reminder that safety doesn’t have to be complex, but it does have to be consistent.
How to Prevent These Incidents
If you operate forklifts or work around them, here are a few simple steps that could save lives:
– Reinforce operator training. OSHA certification is a great start, but refresher training makes sure safe habits stick.
– Separate pedestrian and forklift traffic. Clear walkways, signage, and floor markings help everyone stay in their lane.
– Inspect equipment regularly. A daily walkaround can catch mechanical issues before they become deadly.
– Use seat belts. They’re not optional—and they work.
Final Thoughts
The takeaway? Forklifts are powerful tools, but they demand respect. These real-world fatalities from 2017 to 2024 show that small missteps can have tragic consequences. But with the right training, processes, and awareness, nearly all of these incidents could have been prevented.
At Intella, we’re here to help keep your team safe—not just with the right parts, but with the right information too. Our safety items are affordable and easy to add to any forklift that has missing safety items. Learn more here: https://intellaparts.com/c/Safety/forklift-safety.html