Creating a Safe Workplace: Forklift and Pedestrian Safety

Forklifts are involved in nearly 100 fatalities each year, according to a recent Wall Street Journal article. This alarming statistic underscores the urgent need to implement effective solutions to keep workers safe.

Operating forklifts in environments like warehouses, construction sites, and manufacturing facilities presents unique safety challenges. When these challenges are overlooked, the consequences can be severe — often resulting in serious injuries or fatalities.

Key Forklift Accident Statistics

OSHA estimates between 35,000 and 62,000 forklift-related injuries occur annually.
About 11% of the 855,900 forklifts in the U.S. are involved in accidents each year (Industrial Truck Association).
The average cost of an OSHA safety violation is $13,494.

41,003

Average cost of a workers’ compensation claim.

36

Percentage of forklift fatalities that involve pedestrians.

Technology plays a vital role in reducing risks. By integrating smart safety solutions, businesses can significantly decrease the likelihood of forklift-related injuries.

Key Risks Associated with Forklift Operations in Shared Workspaces

Limited Visibility

Forklift design and heavy loads can obstruct the operator’s view.
Pedestrians may not see or hear approaching forklifts, especially in crowded or dimly lit areas.
Blind spots, high shelving, and narrow aisles further increase the risk of collisions.

Speed and Maneuverability

Forklifts can accelerate quickly and are unable to stop suddenly
Sharp turns taken without care can lead to tip-overs or collisions
Uneven flooring, ramps, and slippery surfaces can contribute to instability and crashes.

Creating a Safer Work Environment

A safer environment for forklifts and pedestrians begins with a proactive safety planning and strategic hazard prevention strategy that includes:

Signage

Use clear floor markings and signs to define standard forklift routes.
Implement flashing warning lights and auditory signals in high-traffic areas.

Warehouse Pedestrian Walkway Floor Markings

Walkways

Designate specific pedestrian paths to help avoid cross-traffic with forklifts.
Install physical barriers or guardrails where feasible to prevent unauthorized crossing.
Laser lines offer an adjustable solution when tape or paint isn’t feasible.

Lighting

Well-lit areas improve visibility for both operators and pedestrians.
Motion-sensing lights can automatically illuminate pathways when forklifts or pedestrians’ approach.

Housekeeping

Keeping areas free of clutter, blind spots and obstacles helps to prevent accidents.
Regularly inspect and maintain warehouse floors to reduce slip, trip and fall hazards

Embracing Technology to Improve Safety

Technology plays a vital role in reducing risks. By integrating smart safety solutions, businesses can significantly decrease the likelihood of forklift-related injuries. TruSense Forklift is a proactive safety solution designed to reduce collisions and increase awareness in busy industrial settings.

Here’s how it helps:

Advanced Proximity Alerts

Pedestrians wear a small device on a waistband, inside a vest, on an armband, or on a lanyard.
TruSense detects foot traffic within six feet of a forklift and issues vibrating alerts, allowing pedestrians to react instantly.

Smart Sensing

The system distinguishes between pedestrian and forklift movements and sends alerts based on proximity and speed.

Flexible Deployment

Devices can be shared among shifts or assigned to individuals—ideal for both small teams and large-scale facilities.

Whether you’re enhancing an existing program or starting from scratch, TruSense adds a critical layer of protection that helps reduce injuries, downtime, and costs—while promoting a strong safety culture.

Training and Awareness

Ongoing training is essential to create a workplace where safety comes first. Both operators and pedestrians must be fully informed about the risks and proper safety procedures.

Despite efforts to track workplace incidents, studies suggest that one-third to two-thirds of injuries and illnesses go unreported in the BLS Survey. This makes awareness and training even more critical.

Reinforce safety with daily tips, signage, and team reminders.
Encourage employees to prioritize safety over speed or convenience.
Consider using virtual reality or simulation tools for realistic, hands-on learning.
Promote open communication. Create a non-punitive reporting system to ensure employees feel safe reporting hazards and near-misses.

Compliance and Best Practices

Keep operators up to date with regular training and certification.
Document all procedures, incidents, and training to spot trends and identify areas for improvement.
Hold regular safety meetings to review incidents, share updates, and reinforce protocols.
Engage employees at all levels to build a shared sense of responsibility.
Perform routine audits and risk assessments to identify and correct hazards.
Encourage feedback—those on the floor often provide the most valuable safety insights.

Partner with Arbill to Build a Safer Workplace

Investing in the right safety solution—like TruSense Forklift—can significantly reduce risk and help protect your team. With real-time alerts, smart motion detection, and scalable deployment options, TruSense Forklift makes safer operations possible.