Forklift Accident Reconstruction

Forklift accidents pose certain challenges during accident reconstruction due to their relatively small size, but heavy weight. Typically forklift accidents occur when the operator misjudges the handling of the forklift, or when the forklift contacts another object, such as pallet racking. Rough terrain forklifts and telehandlers (telescoping material handler) are typically used in challenging environments or in areas of uneven terrain. These machines are designed with wide track widths to aid in lateral stability and with multiple degrees of freedom to allow them to tilt from side to side when used off-road. The complexity of the machine along with uneven terrain can be challenging to an operator which can result in a variety of accidents.

Forklifts are designed to be operated in many different environments. Their ease of use makes them invaluable in factory work settings as well as in outdoor loading areas alike. Most of the time, forklifts are designed to lift loads that have been “palletized” with a wooden pallet underneath the payload. Pallets position the load at a small distance above the ground, allowing the forks of the forklift to slide underneath the load, within the spacing that the pallet provides, and lift the pallet and load together off of the ground.

Accident Reconstruction Services

Common Forklift Accidents and Safety Hazards

Forklifts and material handling equipment are essential in warehouses, distribution centers, construction sites, and industrial settings. However, despite their utility, forklifts present significant safety risks. Understanding the common types of forklift accidents is critical for accident prevention, workplace safety, and forensic investigation in cases of injury or litigation.

Forklift Tip-Overs Due to Overloading

One of the most frequent and dangerous forklift accidents involves tip-over events, often caused by overloaded or improperly positioned loads. Forklift stability depends on keeping the load close to the mast and within the rated weight capacity. If a palletized load is positioned too far forward on the forks, the forklift becomes unbalanced, increasing the risk of tipping forward.

Key factors contributing to tip-over accidents include:

Exceeding the forklift’s rated load capacity
Incorrect load placement or uneven weight distribution
Lifting heavy loads at elevated heights without proper stabilization
Navigating uneven surfaces while carrying an unstable load

Proper training in load handling, fork placement, and vehicle balance is critical to minimizing tip-over incidents and ensuring operator safety.

Loading Dock and Elevated Surface Accidents

Forklifts are commonly used in loading dock areas, where the dock surface is typically aligned with the deck height of commercial trailers (around four feet). Accidents often occur when operators misjudge the distance between the forklift and the edge of the dock.

Common scenarios include:

Driving a forklift off the dock edge
Falling with the forklift from elevated surfaces
Partial or full entrapment of the operator beneath the forklift

These accidents often result in crushing injuries, fractures, or even fatalities. Forensic investigation often examines operator positioning, dock design, and safety procedures to determine the cause of the accident.

Off-Road and Construction Site Hazards

Telehandlers and rough-terrain forklifts are widely used on construction sites due to their load-carrying capacity and off-road capabilities. Unlike standard forklifts, telehandlers feature forks mounted on extendable booms, allowing operators to lift and position loads at significant heights. While versatile, these vehicles are prone to tip-over accidents, particularly on soft, uneven, or sloped terrain.

Factors influencing off-road forklift accidents include:

Load weight and placement relative to the boom
Ground stability and terrain conditions
Operator handling of elevated loads
External conditions, such as weather or site obstacles

Accident reconstruction in these cases requires a detailed analysis of the forklift’s center of gravity, load distribution, and operating environment.

Mechanical Failures and Equipment Malfunctions

Forklifts contain numerous moving parts, including hydraulic systems, brakes, steering mechanisms, and lifting components. Proper inspection, maintenance, and operation are crucial because mechanical failures can result in catastrophic accidents.

Examples include:

Hydraulic system failure causing uncontrolled platform or fork movement
Brake or steering malfunction leading to collisions or tip-overs
Structural failures in forks, masts, or booms

Forensic engineers assess whether equipment malfunctions or maintenance deficiencies contributed to the accident or the severity of injuries.

Forklift Safety and Forensic Investigation

In addition to understanding operator error and environmental hazards, forensic engineers evaluate the mechanical, hydraulic, pneumatic, and electrical systems of forklifts during accident reconstruction.

Veritech engineers analyze:

Load handling procedures and operator positioning
Vehicle design, weight distribution, and stability
Maintenance records and mechanical integrity
Site conditions and environmental influences

Veritech’s trial-experienced Professional Engineers are well-qualified to investigate complex forklift incidents and provide detailed technical analysis for litigation or insurance purposes.

Forklift accidents occur in a variety of ways, including tip-overs, falls from loading docks, off-road mishaps, and equipment failures. Proper operator training, routine equipment maintenance, and adherence to safety protocols are essential to prevent injuries. For workplace safety, litigation support, or forensic analysis, Veritech engineers provide expert evaluation of forklift accidents, analyzing all contributing factors to determine root causes. Contact us today to discuss your case and receive professional guidance on forklift accident investigation and reconstruction.