The Hidden Costs of Forklift Impacts and How to Prevent Them
Guest blog by MHI Member “Save”ty Yellow Products
Warehouses and distribution centers depend on forklifts to keep operations moving. But when it comes to safety and infrastructure, the same equipment that powers productivity can also cause serious damage. Forklift impacts are among the most common safety risks in material handling environments, and their true cost goes far beyond bent rack or dented steel.
The Real Cost of a Forklift Collision
At a glance, a minor impact may seem like no big deal. But even low-speed collisions can carry significant consequences:
• Rack damage that compromises structural integrity and requires costly inspection or replacement
• Inventory loss due to falling pallets or damaged goods
• Downtime while equipment is repaired or areas are blocked off
• Injury liability when workers are nearby
• Facility repairs to columns, doors, or dock equipment
• Increased insurance rates or, in some cases, difficulty obtaining coverage after a claim
• Risk management concerns that can affect safety audits and vendor relationships
According to OSHA, employers are responsible for maintaining safe working conditions under the General Duty Clause (Section 5(a)(1)) of the Occupational Safety and Health Act. While OSHA doesn’t mandate specific guarding products, it has cited companies for failing to provide adequate protection where known hazards like forklift traffic exist.
In addition, OSHA 1910.176 states that material handling equipment must be stored in a manner that does not create a hazard, and passageways must be kept clear and safe. Forklift collisions often violate these standards when they damage storage systems or obstruct egress paths.
High-Risk Impact Zones to Watch
While every facility layout is different, certain areas consistently carry higher risk for impact:
• End of Aisles: Where turns are tight and visibility is reduced
• Rack Uprights: Especially at intersections and transfer aisles
• Building Columns: Often positioned near high-traffic zones
• Dock Doors: Where forklifts frequently enter and exit with limited clearance
• Pedestrian Paths: Crossovers and shared spaces with foot traffic
• In-Plant Offices & Traffic Patterns in Front of Them: Frequent forklift traffic near offices poses collision risks
• Washrooms, Lunch Rooms, and Maintenance Offices: High foot traffic zones that need clear separation from equipment movement
Preventing damage in these zones doesn’t just reduce risk; it protects long-term productivity and helps maintain positive insurance and risk management standing.
How to Prevent Forklift Damage with Physical Barriers
The most reliable way to reduce forklift-related damage is through properly installed, impact-rated barriers. These systems act as passive protection, reducing reliance on perfect driving or constant supervision.
Common solutions include:
Guardrail Systems: Designed to absorb and redirect forklift impact away from vulnerable infrastructure and personnel.
Post Protectors: Installed directly onto rack uprights or in front of them, these protect against low-level strikes that could compromise racking.
End of Aisle Protection: Reinforces the most exposed parts of rack systems with welded, curved barriers.
Dock Gates and Door Track Protectors: Prevent forklifts from rolling off open docks and damaging overhead door equipment.
Bollards: Provide general facility protection, shielding building corners, walkways, equipment, and more from incidental forklift impact.
All protective equipment should be selected based on application, speed, and exposure level. For example, facilities with high-speed forklift traffic or heavier lift equipment may require more robust guardrails or heavy duty posts with larger baseplates. In contrast, lighter-duty environments may benefit from slim-profile solutions that still maintain compliance without taking up excessive space. It’s also important to assess how frequently an area is accessed, whether it’s shared with pedestrians, and what kind of assets need protection, all of which inform the right product choice.
Conclusion: A Small Impact Can Have a Big Price Tag
Forklift impacts are often underestimated, but their effects ripple throughout a facility’s operations. From OSHA liability to repair costs and unplanned downtime, the long-term consequences are real.
Investing in the right physical protection is not just about compliance, it’s about keeping your people, products, and productivity intact.
