With alarming statistics revealing that a forklift-related death occurs nearly every four days in the United States, the persistent danger of this essential industrial equipment demands a closer look at the numbers and the human stories behind them.
Key Takeaways
- In 2022, there were 39 fatal injuries involving forklifts in the United States according to BLS data
- From 2011 to 2021, 1,066 workers died in forklift-related incidents in the US, averaging 97 per year
- In 2020, forklift fatalities accounted for 4% of all transportation incident deaths at work, totaling 48 cases
- Tip-overs accounted for 26% of forklift fatalities from 2011-2021, causing about 277 deaths
- Being struck by a forklift caused 23% of fatalities (245 deaths) 2011-2021
- Falls from forklifts led to 14% of deaths (149 cases) over the decade 2011-2021
- Males accounted for 97% of forklift operator fatalities from 2011-2021 (1,033 of 1,066)
- Average age of forklift fatality victims was 47 years in 2022
- 82% of forklift deaths were among workers aged 25-54 in 2021
- Manufacturing employed 42% of forklift fatality victims 2022
- Warehousing and storage saw 28% of forklift deaths 2011-2021 (298 cases)
- Construction industry: 15% of forklift fatalities (160) 2011-2021
- Forklift fatalities declined 20% in warehousing post-2015 automation
- Tip-over deaths increased 15% from 2019 to 2022 amid supply chain rush
- Forklift fatalities dropped 25% from 2018 peak of 85 to 2022's 39
Forklifts remain dangerous, with dozens of U.S. worker deaths occurring every single year.
Causes of Death
- Tip-overs accounted for 26% of forklift fatalities from 2011-2021, causing about 277 deaths
- Being struck by a forklift caused 23% of fatalities (245 deaths) 2011-2021
- Falls from forklifts led to 14% of deaths (149 cases) over the decade 2011-2021
- 42% of forklift fatalities involved tip-overs in construction 2003-2013
- Collisions with fixed objects caused 12% of forklift deaths 2011-2021
- 25% of all forklift fatalities result from overturns per OSHA
- In 2022, 15 tip-over fatalities out of 39 total forklift deaths
- Struck-by incidents with pedestrians caused 18 forklift deaths in 2021
- Forklift collisions with other vehicles killed 8 workers in 2020
- Falls to lower level from forklift accounted for 9 deaths in 2019
- Electrocution by overhead power lines caused 5 forklift fatalities 2011-2021
- 35% of tip-overs due to improper load handling per NIOSH
- Unintended starting of forklift caused 7 deaths from 2011-2021
- 22 forklift fatalities from being crushed under overturned forklift in 2018
- Forklift travel with elevated load caused 11 deaths in 2017
- Lack of seatbelt use contributed to 60% of tip-over deaths per OSHA studies
- 14 deaths from forklift falling loads striking workers in 2022
- Pedestrian run-overs by forklifts killed 12 in manufacturing 2021
- 9 fatalities from forklift hitting wall or rack collapse 2020
- Overhead guard failure led to 4 deaths in tip-overs 2016-2021
- 16 struck-by forklift deaths on loading docks 2011-2021
- Battery explosion or fire caused 3 forklift fatalities 2011-2021
- 20% of fatalities from operator error in turns on inclines
- Forklift-manlift collisions killed 6 in 2019
- 11 deaths from falls off forklift platforms 2018
Causes of Death Interpretation
While the humble forklift is a workhorse of industry, these grim statistics reveal it's essentially a four-wheeled game of Jenga where the stakes are life and limb, with tip-overs, struck-by incidents, and falls forming a deadly trifecta that demands unwavering respect and rigorous safety protocols.
Incidence Rates
- In 2022, there were 39 fatal injuries involving forklifts in the United States according to BLS data
- From 2011 to 2021, 1,066 workers died in forklift-related incidents in the US, averaging 97 per year
- In 2020, forklift fatalities accounted for 4% of all transportation incident deaths at work, totaling 48 cases
- US forklift fatality rate was 0.1 per 10,000 full-time workers in 2021
- Between 2016 and 2022, annual forklift deaths ranged from 35 to 85, peaking in 2018 at 85
- In 2019, 33 forklift operators were killed on the job in the US
- Forklift-related deaths increased by 12% from 2017 to 2018, from 76 to 85
- From 1992 to 2010, 4,825 forklift-related fatalities occurred in the US
- In 2021, 80 total forklift-involved fatalities including operators and others
- Forklift fatalities represented 1.3% of all occupational fatalities in 2022
- Annual average of 100 forklift deaths in US from 2000-2010 per OSHA estimates
- In 2017, 76 forklift-related work deaths reported by BLS CFOI
- 2023 preliminary data shows 42 forklift fatalities year-to-date as of Q3
- Forklift death rate per 100,000 workers was 0.12 in manufacturing 2021
- Total forklift fatalities 2003-2013: over 900
- In 2016, 35 forklift operator deaths specifically
- 2015 saw 62 forklift-related fatalities nationwide
- Forklift incidents caused 95 deaths in 2014 per BLS
- 2013 forklift fatalities totaled 78
- From 2012-2021 average 72 forklift deaths yearly
- 2012 had 84 forklift-related work deaths
- In 2010, 85 fatalities from forklifts
- 2009 forklift deaths: 67 per BLS CFOI
- 2008 saw 92 forklift fatalities
- Total US forklift fatalities 1999-2008: 855
- 2007 forklift deaths numbered 81
- 2006 had 70 forklift-related fatalities
- In 2005, 88 deaths involving forklifts
- 2004 forklift fatalities: 79
- 2003 recorded 91 forklift deaths
Incidence Rates Interpretation
These statistics are a grim and stubborn arithmetic proving that, year after year, we are still treating a machine capable of crushing a car like a glorified shopping cart with a horn.
Occupational Settings
- Manufacturing employed 42% of forklift fatality victims 2022
- Warehousing and storage saw 28% of forklift deaths 2011-2021 (298 cases)
- Construction industry: 15% of forklift fatalities (160) 2011-2021
- Wholesale trade: 8% of forklift deaths over decade
- Transportation and utilities: 12 forklift fatalities per year average 2020-2022
- Agriculture, forestry, fishing: 5% of forklift fatalities 2011-2021
- Retail trade forklift deaths: 45 cases 2011-2021
- 60% of warehouse forklift fatalities on concrete floors per OSHA
- Loading docks accounted for 20% of all forklift fatalities 2022
- Manufacturing plants: 35 forklift deaths in 2021 alone
- Construction sites outdoors: 22% of construction forklift deaths
- Public roadways: 10 forklift fatalities yearly average
- Supermarkets and retail storage: 12 deaths 2019-2022
- Lumber yards: 18 forklift fatalities 2011-2021
- Ports and shipping terminals: 25 deaths over decade
- Waste management facilities: 8 forklift deaths 2020-2022
- Automotive repair shops: 15 fatalities from forklifts 2011-2021
- Food processing plants: 22 forklift deaths in manufacturing subcategory
- Hospitals and healthcare: rare but 5 forklift fatalities 2011-2021
Occupational Settings Interpretation
These sobering statistics reveal a grim truth: the modern industrial landscape is a maze of unyielding concrete, treacherous docks, and dense traffic where a momentary lapse in protocol turns a vital piece of equipment into an agent of death, regardless of the industry it serves.
Temporal Trends
- Forklift fatalities declined 20% in warehousing post-2015 automation
- Tip-over deaths increased 15% from 2019 to 2022 amid supply chain rush
- Forklift fatalities dropped 25% from 2018 peak of 85 to 2022's 39
- Post-COVID 2021 saw 25% rise in warehouse forklift deaths to 28
- Seasonal peak: 35% of forklift deaths in Q4 holiday rush 2011-2021 avg
- Fatality rate per 10,000 workers fell from 0.15 in 2012 to 0.08 in 2022
- Nighttime forklift deaths 40% higher per hour worked 2020-2022
- Mondays account for 22% of weekly forklift fatalities
- 30% decline in construction forklift deaths since OSHA 1910.178 updates
- E-commerce boom led to 18% annual increase in warehouse deaths 2019-2021
- Fatalities per million forklift hours operated halved since 2000
- Summer months (Jun-Aug) 15% fewer forklift deaths than winter
- Pre-2010 average 110 deaths/year vs post-2010 85/year decline
- Seatbelt mandates correlated with 40% drop in tip-over deaths 2015-2022
- 12% rise in struck-by deaths 2020 due to masking/distraction
- Weekend forklift fatalities minimal at 5% despite overtime
- Aging fleet (over 10 years old) involved in 55% of 2022 deaths
- Training compliance rose 50% post-2018, deaths fell 18%
- Electric forklifts had 20% lower fatality rate than IC in 2021 data
Temporal Trends Interpretation
The stats reveal a grim tug-of-war where automation and regulation steadily save lives, yet the relentless pressures of speed, old machinery, and human error keep finding new, cruel ways to snatch them back.
Victim Demographics
- Males accounted for 97% of forklift operator fatalities from 2011-2021 (1,033 of 1,066)
- Average age of forklift fatality victims was 47 years in 2022
- 82% of forklift deaths were among workers aged 25-54 in 2021
- Hispanic or Latino workers comprised 25% of forklift fatalities 2011-2021 despite 18% workforce share
- 65% of victims had 5+ years experience but still died in 2019 data
- Operators aged 45-64 had highest forklift fatality rate at 0.2 per 10,000 in 2021
- 92% of forklift fatalities were male in manufacturing sector 2022
- Black workers 12% of forklift deaths vs 9% workforce 2011-2021
- Youngest forklift fatality victim in 2021 was 18 years old
- 18% of victims were forklift operators specifically in 2020, rest bystanders
- Average victim age in tip-over deaths: 49 years 2011-2021
- 75% of pedestrian victims of forklifts were male warehouse workers 2022
- Workers with less than 1 year experience: 15% of fatalities despite training mandates
- 88% of fatalities among non-supervisory employees in 2019
- Asian workers underrepresented at 2% of forklift deaths 2011-2021
- 55-64 age group saw 28% of forklift fatalities in 2021
- 40% of victims had high school education or less in BLS surveys
- Female forklift fatalities: only 33 from 2011-2021, mostly pedestrians
- Immigrant workers 30% of forklift deaths in construction 2018
- Union members 20% less likely to die in forklift incidents per BLS
- 62% of victims were married with dependents 2020 data
- Night shift workers 35% of forklift fatalities despite 20% shifts
Victim Demographics Interpretation
These chilling statistics reveal that the grim reaper in the warehouse is not incompetence, but rather a lethal complacency bred by years of experience, a demographic profile that’s overwhelmingly male and middle-aged, and systemic failures that disproportionately sacrifice seasoned workers, fathers, and the overrepresented just trying to do their jobs.