The topic of safety in warehouse traffic with forklift trucks is regularly on the to-do list of business owners and plant managers. The protection of employees is the top priority.

When it comes to forklift truck safety, many people first think of the dangers for the drivers. However, many other people work in a warehouse, often in the immediate vicinity of forklift trucks. They are travelling on foot, pushing roll containers or pulling hand pallet trucks and are exposed to a high risk of accidents: Because if they get in the way of a forklift unnoticed, there is only one winner. The annual report on accidents at work published by the DGUV (German Social Accident Insurance) shows that the risk of accidents when working around forklift trucks should not be underestimated. In 2024, forklift trucks were the leading cause of reportable accidents with almost 6,000 cases, closely followed by non-motorised tiller trucks, i.e. manual hand pallet trucks and high-lift trucks.

In the RIDDOR* accident reports of recent years, it was noted that a second person was involved in over 40 per cent of accidents involving forklift trucks. Of these, over 60 per cent were pedestrians – employees working nearby – and around 20 per cent other people (inspectors, passers-by) and 15 per cent delivery drivers.

These accidents often have devastating outcomes with serious health consequences for those affected and for the company itself: They often result in reputationally damaging investigations, costly compensation claims, legal proceedings and fines. Every company has a duty to ensure the safety of its employees and to minimise all risks as far as possible. Forklift driver training and regular instruction are therefore a must for every company with industrial trucks in use. At the same time, it is equally important to ensure the safety of those who work unprotected in the vicinity of free-moving forklift trucks.

Tips for more protection for pedestrians

Separation is the safest means

The smartest advice for pedestrians in the warehouse is: keep your distance from forklift trucks. Do not enter areas where forklift trucks are manoeuvring and do not enter areas that are closed to pedestrians – not even as a “shortcut” under time pressure!

If pedestrians and forklift trucks are working in the same area, there should be designated walkways separated from other traffic. These should be protected by barriers and emphasised by markings.

Never be tempted to walk or work under a raised load – always keep a safe distance.

If a forklift truck is equipped with zone warning lights, you should not enter this area under any circumstances. The blue warning lights on the forklift truck mark the danger zone in front of the vehicle. Red marks the danger zones around the forklift truck.

Do not take any risks

Do not ride as a passenger on a forklift truck and never allow yourself to be lifted with the load or the forks.

Never attempt to stabilise a load that is sliding off the forks and do not try to act as an additional living counterweight. People are regularly killed trying to act as a counterweight.