What Do Illinois Forklift Accident Statistics Reveal About Occupational Injuries?

Statistics About Forklift Fatalities and Accidents From Personal Injury Attorneys

Illinois forklift accident statistics reveal the major risk of serious injuries or death when using these powerful tools. The Industrial Truck Association estimates that 4.5 million people in the United States operate forklifts across over 300 different industries, making them one of the most common industry vehicles in the country. 

Depending on their size, these vehicles can carry thousands of pounds of weight and are easy to maneuver, allowing workers to move everything from hay bales to pallets of merchandise. 

However, with such ubiquity comes a serious risk. There are thousands of accidents every year involving forklifts. The enormous weight and instability of these tools make them highly susceptible to overturning or running over a worker, causing serious injury or death. 

Read on to explore forklift accident statistics and how a Chicago forklift accident attorney can help you recover compensation. 

Why Are Forklift Accidents So Dangerous?

• Forklifts can weigh over 9,000 pounds, compared to the 3,000 pounds of a typical automobile. They also have an average speed of 18 miles per hour. 
• A forklift has an uneven weight distribution to counterbalance elevated forks.
• When operating with a raised mast or tall loads, blocked sight lines can cause the forklift operator to strike a pedestrian.
• When a forklift turns from the rear end, the rear wheels swing outward, which can lead to tipping over during tight turns.
• These vehicles only have brakes on the front wheels, making stopping a forklift difficult. 
• Unlike a scissor lift, which provides a safe and stable platform for elevated work, forklifts are designed to be mobile, meaning they could hit a worker who crosses in front of the path of travel. 

How Common Are Forklift Accidents?

• 90% of all forklift trucks will be involved in an accident over their useful lifespan.
• Forklift accidents resulting in serious injury total around 34,900 annually. 
• There are approximately 61,800 non-serious injuries related to forklifts every year. 
• Between 2021 and 2022, the Bureau of Labor Statistics reported 24,960 DART (Days Away from Work, Restriction, or Transfer) cases related to nonfatal injuries from forklift accidents. 
• In 2022, there were 73 forklift fatalities across the United States. 
• 25% of all transport-related workplace injuries are directly related to forklifts.

Illinois Forklift Accident Statistics 

In 2023, 145 workers died in workplace accidents in Illinois. Of these, 55 were transportation accidents, which can include forklift trucks. 

Chicago has two OSHA offices, one for the north and one for the south. The Chicago North Area Office has reported 15 forklift-related accidents from 2000 to 2025, with one fatality. On the other hand, the Chicago South Area Office has 35 incident reports within this 25-year period, including six deaths. 

Several forklift accident cases in 2024 resulted in serious harm or death. In one, a Woodford County woman was struck and killed by a forklift while working at the Case IH Factory. 

Another accident occurred in February 2024, when a worker was trapped under pallets in an Antioch pallet supply facility. Approximately 12 feet of pallets were being moved by a forklift when they slid off and engulfed the man, who had to be extracted by EMS. The facility had 20 prior safety violations and had been fined over $65,000. 

Illinois Forklift Laws

Illinois companies are governed by the Occupational Safety and Health Act, which requires employers to take any reasonable measures to prevent worker injuries while providing a safe workplace (820 §ILCS 219/1). They are also required to report any occupational injuries or deaths as soon as possible (820 ILCS §305/1).

Any employer that willfully disregards these rules can be charged with a Class 4 felony if it results in a person’s death (820 ILCS §219/120). 

In Chicago, manufacturing plants are subject to regular inspections by the fire department or another department, and they must immediately fix any violations that may endanger worker safety (§4-224-030).

Illinois Supreme Court precedent notes that manufacturers are under a nondelegable responsibility to create safe products, as seen in Anderson v. Hyster Company. In this case, unsafe design was the primary factor in the forklift operator’s injury, and any negligent action was secondary unless it constituted an intentional misuse of the product. 

This verdict means that, in addition to seeking workers’ compensation for injuries, plaintiffs can also pursue a product liability lawsuit if the forklift had a known design flaw or manufacturing defect. 

Most Common Forklift Accidents

• According to the National Safety Council, from 2021-2022, 53% of DART cases related to forklift accidents resulted from a transportation accident, such as forklift operators losing control of the vehicle.
• Approximately 25% of all forklift accidents are due to the forklift overturning. 
• Although forklift overturns account for approximately 25% of all accidents, they account for 42% of fatalities. 
• 17% of forklift accidents involve a worker struck by materials. 
• Workers falling from or being struck by forklifts account for 14% of all accidents. 

Forklift Accidents by Industry

Any workplace that utilizes these vehicles may pose a risk to workers, but the top industries for forklift accidents include the following. 

• Accidents in a warehouse account for 30% of all forklift accidents.
• 42.5% of fatal forklift accidents involve manufacturing. 
• 23.8% of deadly accidents involving a forklift truck are in the construction industry. 
• Fatal workplace accidents in wholesaling account for 12.5% of forklift accidents. 

Causes of Forklift Accidents

Many forklift accidents are a result of these major hazards, including:

• Unclear line of sight
• Mechanical failures
• Emissions intoxication
• Uneven surfaces
• Damaged tires
• Falling loads
• Truck instability
• Failure to follow safety procedures
• Pedestrian impacts
• Trailer personnel falling from forks

The Impact of Training Policies on Forklift Accidents

The Occupational Safety and Health Administration (OSHA) asserts that better training policies could prevent 70% of forklift accidents. Undertrained forklift operators pose serious dangers to themselves and others.

In-person forklift training programs take approximately 6-8 hours to complete. According to OSHA, proper training should include the following topics:

• Surface conditions
• Maneuvering and controlling the vehicle
• Forklift attachments and other tools 
• Load stability
• Vehicle capacity and stability
• Inspection and maintenance
• Workplace hazard mitigation
• Safety of pedestrians and other workers 

Top 5 OSHA Safety Violation Citations

The most common forklift-related safety violations are the following.

Unsafe Operations – These include speeding with heavy loads, driving too close to impact barriers, and ignoring safety procedures. Additionally, operators may fail to communicate dangers to other workers in the area, which can lead to striking a pedestrian. 

Failure to Provide Refresher Training – Forklift operators must be recertified every three years, or they may be asked to complete additional training sooner if they have demonstrated improper use of these dangerous tools.

Missing or Inadequate Operator Certification – Anyone who uses a forklift must have the proper certification to prevent serious injuries.

Failure to Perform Inspections – All forklifts should receive pre-shift inspections to ensure their safety for operators.

Failure to Remove Dangerous Forklifts from Service – All operators should be aware of any warning signs that the forklift truck is damaged and follow proper lockout/tagout procedures. They should clearly and immediately inform their colleagues if they suspect there may be an issue with a particular forklift. 

Forklift Accident Victim Statistics

• 20% of all forklift accidents involve hitting a pedestrian. 
• According to OSHA forklift accident statistics, workers working more than 12 hours are 37% more likely to be in an accident. 
• From 2021 to 2022, 84.59% of forklift injuries occurred in men, with only 15.41% occurring in women. 
• On average, forklift injuries require 18 days off work. 
• Workers aged 25 to 34 had the highest injury rate. 

Forklift Injury Statistics

According to the Bureau of Labor Statistics, the most common forklift injuries requiring medical attention include:

• Soreness and pain
• Fractures
• Bruises and contusions
• Sprains, strains, and tears
• Cuts, lacerations, and punctures
• Multiple traumatic injuries, including head trauma
• Amputations
• Punctures
• Heat burns

If you’ve been in a forklift accident, immediately visit your local emergency room, such as UChicago Health or Northwestern Memorial Hospital. Next, inform your employer and gather evidence from the scene, such as photos. You should then speak to our workplace accident attorneys to learn about your legal options before talking to an insurance company. 

Forklift Fatality Statistics

• Around 75 and 100 people are killed annually because of forklifts, with a rough average of around 87.
• In 2022, 73 people died in forklift accidents nationwide. 
• According to recent Occupational Safety and Health Administration estimates, 36% of all forklift fatalities involve pedestrians.
• In 2022, fatalities peaked among workers aged 55 to 64. 
• In 2022, 90.41% of deaths due to forklift accidents were men, with only 9.59% of forklift fatalities being women. 

Forklift Accident Prevention

Many common forklift accidents are wholly preventable. To ensure the safety of yourself and others, follow these tips:

• Always inspect your forklift to prevent mechanical failures.
• Properly secure all equipment and packages to avoid falling loads.
• Ensure strategic placement of loads to keep a clear line of sight.
• Install floor tape to identify out-of-bounds areas.
• Slow down when you have a heavy load.
• Honk your horn when turning into blind spots.
• Set up barriers to protect pedestrians when working.
• Always set the brake when leaving the vehicle.
• Always look in the direction of travel, especially when backing up.
• Don’t overload the vehicle to prevent overturning.

Statistics About Workers’ Compensation Claims for Forklift Injuries 

• The average workers’ compensation claim for a forklift accident is around $41,003. 
• In 2020 and 2021, an amputation claim cost approximately $126,033. 
• Head injury or central nervous system damage cost employers approximately $94,285 per claim in 2020-2021. 
• Workplace injuries resulting from fracture, crush, or dislocation cost approximately $62,240 per claim in 2020-2021. 

Forklift Accident Settlement Statistics

The personal injury attorneys at Rosenfeld Injury Lawyers have secured millions for our clients, including those injured in forklift accidents. 

$3,500,000 – Our client suffered severe injuries when a forklift struck him while working at a factory. This settlement included workers’ compensation and a third-party claim against the forklift operator. 

$11,000,000 – This wrongful death suit was filed on behalf of the family of a laborer who was crushed to death when a forklift backed into him. We resolved the case in mediation with the company despite claims that the temporary worker was violating company policy.

$4,400,000 – A settlement for a worker who suffered crush injuries when a forklift overturned onto him, causing severe injury to his legs and pelvis.

$990,000 – An unlicensed forklift operator hit a construction worker, causing major injuries.

$1,250,000 – Settlement for a customer of a home improvement store when he was struck in the parking lot by a forklift driver. 

$575,000 – A food delivery driver was pinned by the prongs of a forklift, causing significant injuries.

Consult a Forklift Accident Attorney Near You!

As forklift accident statistics reveal, these useful workplace vehicles can also be dangerous or deadly. If you’ve been harmed due to workplace negligence, Rosenfeld Injury Lawyers can assist you in recovering damages through workers’ compensation or a civil lawsuit. We’ve recovered millions on behalf of our clients and work on a contingency fee basis, meaning that you owe us nothing unless we can win your case.

To schedule a free consultation with a personal injury lawyer in Chicago, call us at (888) 424-5757 or use our online contact form.

All content undergoes thorough legal review by experienced attorneys, including Jonathan Rosenfeld. With 25 years of experience in personal injury law and over 100 years of combined legal expertise within our team, we ensure that every article is legally accurate, compliant, and reflects current legal standards.