Published: June 2025
When it comes to powered industrial trucks (PITs)—like forklifts, pallet jacks, and reach trucks— and mobile elevating work platforms (MEWPs)—like boom lifts, scissor lifts, and mast lifts— the margin for error is thin. Supervisors and safety managers know that just one oversight can lead to serious injuries, OSHA citations, or worse. In fact, OSHA reports that forklift-related violations consistently rank among the top 10 most cited workplace infractions year after year.
But this isn't just about compliance. It’s about protecting your people. So let’s walk through the 10 most common PIT safety violations and the practical steps you can take today to prevent them.
With each mistake listed in this article, a real-life, OSHA-investigated incident is described. This is to bring awareness and relevancy to the forefront of PIT safety. Further details can be found in the links to the OSHA accident database. Some reader discretion is advised, as many of the incidents can be quite startling.
What happens: Employees are assigned PITs without completing OSHA-compliant training or evaluations.
Case Study: January 2024, Muscoda, WI
An employee was operating a sit-down forklift in a dry materials warehouse with a large, view-obscuring load. A coworker was pushing a garbage bin down the aisle at the same time when the forklift operator struck and threw him to the concrete ground. It is assumed that a lack of operator training was the cause of this accident. The coworker did not recover from his injuries (Inspection: 1721848.015).
Avoid it: Make sure all operators are trained and certified per OSHA Standard 1910.178(l). Conduct refresher training every three years or after an incident, and document evaluations. Consider third-party programs like Prosafe to fill training gaps.
What happens: Operators skip daily checks or equipment with known defects stays in service.
Case Study: January 2020, Houston, TX
An operator was moving an aerial lift to a different location on the jobsite. A mechanical failure occurred and the operator—not wearing a restraint or seat belt—was launched out of the cab and struck the arm of the lift. He then fell another 12–16 feet to the concrete ground (Inspection: 1457567.015).
Avoid it: Require pre-operation inspections before every shift. Use a daily checklist and keep records. Make it easy for operators to report issues, and ensure maintenance is timely.
What happens: PITs are driven too fast, especially in tight or congested areas, increasing the risk of tip-overs or crashes.
Case Study: November 2017, Canton, OH
An employee operating a forklift at a steel mill was descending a ramp when the throttle pedal jammed and began accelerating the forklift beyond his control. The forklift struck a guardrail, pinning his foot between the vehicle and the barrier. The operator was hospitalized (Inspection: 1285857.015).
Avoid it: Set speed limits for different zones and post clear signage. Train operators to drive defensively and remain aware of pedestrians.
What happens: Loads are unstable, exceed capacity, or block the operator’s view.
Case Study: September 2024, La Vergne, TN
A forklift operator was transporting quartz slabs (800–900 lbs each) to a flatbed truck. Another employee was securing the slabs to the flatbed’s A-frame when the forklift operator’s attachment struck a stationary stack of quartz slabs, causing the forklift’s load to fall onto the employee on the flatbed. The employee sustained fatal blunt force trauma (Inspection: 1777677.015).
Avoid it: Educate operators on load center and capacity principles. Encourage proper stacking and require clear sightlines before transport.
What happens: Workers in PIT zones skip high-visibility vests, hard hats, or safety shoes.
Case Study: October 2024, Savannah, GA
An aerial lift was being used to access a bridge to set up concrete pouring materials. Two employees were in the elevated bucket arranging materials when one fell 30 feet to the ground. The injured employee was not equipped with proper PPE or fall protection (Inspection: 1783043.015).
Avoid it: Establish PPE rules for both operators and pedestrians. Provide gear and make compliance part of the safety culture.
What happens: PITs and pedestrians share the same space without visual or audible warnings.
Case Study: December 2024, High Point, NC
An employee standing on a loading dock was struck and run over by a box truck. The operator’s view was obstructed by ice on the windshield. The employee did not recover from his injuries (Inspection: 1793944.015).
Avoid it: Train operators to use horns and mirrors. Create dedicated pedestrian walkways and use warning lights on PITs. Communication is key.
What happens: PITs are left with forks raised, engines running, in unsafe locations, or brakes off.
Case Study: February 2024, Spartanburg, SC
A field service technician was doing maintenance on an aerial lift parked beneath overhead power lines. Despite instructions to move the lift, the technician began work under the lines and was later found unresponsive in the basket. He had been electrocuted (Inspection: 1729086.015).
Avoid it: Teach and enforce proper shutdown procedures. OSHA requires operators to fully lower forks, neutralize controls, set the brake, and turn off the truck when unattended.
What happens: Trucks with leaking hydraulics or cracked forks are still used; unauthorized attachments are added.
Case Study: August 2024, Giddings, TX
An employee was operating a scissor lift missing its entry/exit door, which also served as a fall prevention guardrail. The employee fell 18 feet through the gap and did not survive (Inspection: 1764015.015).
Avoid it: Never use damaged PITs. Enforce a strict tag-out policy and prohibit modifications without manufacturer approval.
What happens: PITs are driven on inclines, slick spots, or uneven ground.
Case Study: July 2024, Paris, AR
An employee operating a forklift deviated from a standard dirt route onto softer ground. The forklift tipped, pinning the operator between the roll cage and the ground. The operator did not survive (Inspection: 1764775.015).
Avoid it: Assess work surfaces regularly. Restrict PIT use in unsafe zones and provide training on how to handle slopes or wet conditions.
What happens: Operators lift loads beyond the machine’s rated capacity.
Case Study: September 2024, Houston, TX
Employees were lifting heavy-duty chains with an excavator to reinforce concrete pipes. Due to overloading, the lifting hook snapped, dropping the load onto a nearby worker. The worker did not survive (Inspection: 1775041.015).
Avoid it: Post load capacity charts in the cab. Train operators on load limits and the risks of exceeding them. It’s not just about tipping—it’s about total control.
Supervisors and safety managers are the front line of PIT safety. By identifying and addressing these top violations, you can help build a workplace where safety isn’t just a box to check—it’s part of the culture.
For more detailed guidance and tools, explore:
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