Common forklift mistakes made by operators…and how to avoid them
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- Common forklift mistakes made by operators…and how to avoid them
In the UK, figures show that forklifts account for more workplace accidents than any other machine. Forklift accidents result in 300 hospital visits a year, which, according to the British Safety Council, is five British workers a day or 1,300 forklift-related accidents every year in the UK.
For experienced operators, using a forklift is a straightforward task, that they have done thousands of times before. But, even experienced operators can make costly mistakes. These errors not only pose serious safety risks but can also lead to damage, downtime, and inefficiencies in the workplace.
In this article we explore the most common mistakes made forklift operators and what can be done to avoid them.
1. Failing to perform pre-operational checks
One of the biggest mistakes forklift operators make is skipping pre-use inspections. A thorough check of the forklift, including brakes, tyres, lights, and hydraulic systems, helps prevent breakdowns and accidents.
- Solution: Operators should always follow a structured daily checklist before starting work. Our forklift training courses teach drivers the importance of these checks, ensuring compliance with safety regulations.
2. Miscommunication
Clear communication between forklift operators and ground staff is critical for a safe working environment. Misunderstandings can lead to collisions, dropped loads, or injuries.
- Solution: Operators should use standard hand signals, radio communication, and visual checks to confirm instructions. Our training courses emphasise clear communication techniques to avoid confusion in busy workplaces.
3. Overloading the forklift
Every forklift has a weight limit, and exceeding it can cause instability, tipping, or mechanical failure. Many accidents occur when operators fail to check the load capacity before lifting heavy goods.
- Solution: Training is key. During our counterbalance training, we educate operators on load distribution, weight limits, and safe lifting techniques to prevent accidents and damage.
4. Trying to complete a task alone
Many forklift tasks require a second pair of eyes for spotting hazards, guiding loads, or directing movement. Operators who attempt to work alone risk accidents, especially in tight spaces or when handling oversized loads.
- Solution: Teamwork is essential. Operators should always ask for assistance when handling complex tasks.
5. Ignoring safe manoeuvring practices
Sharp turns, excessive speed, and poor visibility can lead to collisions. Forklift operators must be aware of their surroundings at all times to avoid injuring pedestrians and damaging goods or infrastructure.
- Solution: Our forklift operator certification courses cover speed control, visibility techniques, and safe cornering to help operators stay in control in busy warehouse environments.
6. Driving too fast
Speeding on a forklift increases the risk of tipping over, losing control, or colliding with objects or pedestrians. Unlike cars, forklifts are top-heavy, making them unstable at high speeds.
- Solution: Operators must always follow site speed limits and adjust their speed depending on load weight and surface conditions. Our training teaches controlled driving techniques to reduce accident risks.
7. Improper fork positioning
Incorrect fork height or angling can result in unstable loads and potential tip-overs. Many new operators also forget to lower the forks when parking, creating a tripping hazard for pedestrians.
- Solution: Our training ensures that operators learn the correct fork positioning for loading, unloading, and parking, reducing the risk of workplace injuries.
8. Ignoring blind spots
Forklifts have restricted visibility, especially when carrying large loads. Operators who fail to check blind spots risk colliding with workers, shelves, or other vehicles.
- Solution: Operators should lean forward, use mirrors, and signal turns before moving. Our courses train drivers in effective blind spot awareness techniques to prevent accidents.
9. Not wearing proper PPE
Even though forklifts have safety features, personal protective equipment (PPE) is essential. Failing to wear high-vis vests, safety boots, and helmets increases the risk of serious injuries.
- Solution: HGVC emphasises the importance of PPE in all our forklift training sessions, helping businesses reinforce a safety-first culture.
10. Ignoring pedestrian right-of-way
Pedestrians always have priority in shared workspaces, but some operators fail to yield, leading to dangerous near-misses or collisions.
- Solution: Operators must slow down, sound the horn at intersections, and respect pedestrian walkways. HGVC forklift training reinforces pedestrian safety awareness in every course.
11. Lack of proper training & certification
Untrained or uncertified operators pose a significant risk to workplace safety. Not only is it illegal for unqualified staff to operate forklifts, but it also leads to costly accidents and non-compliance fines.
- Solution: Investing in forklift operator certification ensures that your team is properly trained, reducing accidents and improving efficiency. HGVC offers fully managed training solutions, handling everything from bookings to certification, so you don’t have to worry about compliance.
12. Inadequate Mast Tilt control
Tilting the mast incorrectly can make loads unstable, causing items to fall or the forklift to tip. This is especially dangerous when operating on slopes or ramps.
- Solution: Operators must tilt back slightly when lifting and adjust the angle carefully when placing loads. Our training teaches correct mast control techniques for various load types and surfaces.
13. Driving in reverse unnecessarily
Reversing is sometimes necessary, but constantly driving backwards without proper visibility increases the risk of accidents.
- Solution: Operators should drive forwards whenever possible, using reverse only when necessary. Our training emphasises correct reversing techniques and the use of mirrors, cameras, or a spotter to stay safe.
14. Driver not wearing seatbelt
Some operators skip wearing their seatbelt, assuming that forklifts move too slowly to be a risk. However, in the event of a tip-over, not wearing a seatbelt can be fatal.
- Solution: Seatbelts must always be worn to prevent the driver from being thrown from the seat. HGVC forklift training highlights real-world accident cases to reinforce the importance of seatbelt use.
15. Not reporting a fault
Operators sometimes ignore minor faults, thinking they can still complete their shift. However, small issues (like low hydraulic fluid or worn-out brakes) can quickly escalate into dangerous failures.
- Solution: Any faults must be reported immediately to prevent breakdowns and accidents. Our courses teach operators to recognise warning signs and follow proper reporting procedures.
16. Checking the forklift battery improperly
Electric forklifts rely on properly maintained batteries. Operators who fail to check water levels, clean terminals, or charge correctly reduce battery lifespan and risk power failures during operations.
- Solution: Our training covers battery maintenance best practices, including charging schedules, electrolyte level checks, and safe handling to extend battery life and ensure forklift reliability.
Why choose HGVC for forklift training?
At HGVC, we provide businesses with fully managed, high-quality forklift training that meets all legal and industry standards. Our training includes:
- Counterbalance & Reach training & certification
- Comprehensive safety & compliance education
- Flexible training options across 400+ locations in the UK
- The highest pass rates in the industry
