Forklifts are heavy machines. This makes speed a great risk factor when operating them since a forklift that can’t stop in time can easily turn into a 10,000 lb. missile.

Let’s discuss some of the risks of speeding forklifts below.

Compromised Steering

It’s easy to understeer when speeding on a forklift, which can cause a loss of control.

This also comes with the risk of collisions with people, equipment, infrastructure, products/materials, and walls.

In fact, OSHA says that forklift trucks striking pedestrians is the number one cause of lift truck-related work fatalities.

Risk of Tip-Overs

According to OSHA, forklift tip-overs (overturning) are the second leading cause of fatal accidents in warehouses and factories.

And many tip-overs result from high speed, which can cause instability, especially when rounding corners.

This is why operators are advised to reduce speed around corners as well as turn the steering wheel in a smooth, sweeping motion to prevent excessive sway.

HOW LONG DOES IT TAKE TO STOP A FORKLIFT AT FULL SPEED?

At 9 mph (which is about the average forklift top speed), it can take over 51 feet to bring a forklift to a full stop.

It takes about 7 feet of travel between the time a forklift operator recognizes the need to stop and applies the brakes (assuming the operator is entirely conscious of their surroundings).

It takes an additional 10 feet to stop the truck once the brakes are applied.

Other guidelines for forklift stopping distance at certain speeds are:

At 4 mph, the forklift needs 17+ feet for a full stop

At 8 mph, it needs 42 feet for a full stop

Because it can take a considerable distance to fully stop a forklift, it’s essential to maintain 20+ feet from pedestrians, trucks, and objects to avoid impacts.

HOW TO DETERMINE A SAFE FORKLIFT SPEED LIMIT

Setting a safe forklift speed limit involves balancing the need for workplace safety with the ability to achieve production goals.

If the speed is set too high, safety can be compromised.

But if it’s set too low, productivity will suffer.

Overall, it involves some trial-and-error to balance the two.

Consider Your General Work Environment

No two business operations are exactly the same.

That makes it necessary to consider any characteristics unique to your operation which may negatively impact safety with respect to the maximum speed your lift trucks can travel.

For example, what is the terrain type? Is the ground rough and uneven? Or are you operating on smooth floors?

Forklift speed limits in rough, uneven terrain like a construction site are different from a smooth or level surface like inside a warehouse.

This is because lift trucks are more susceptible to tip-overs or sliding on uneven terrain than on level ground.

Also, consider what’s on your floors.

Dust, oily surfaces, humidity, or moisture accumulation on the floor increase braking distance, which limits forklift maximum speed.

Another factor is inclines and declines, such as ramps and loading docks.

On these terrain types, you'll need to keep the truck’s speed lower - especially when going down slopes where speed invariably increases.

Consider Operator Visibility

Speed should not impact an operator’s vision.

Thus, slow speeds are recommended in areas where operators have blind spots, such as when crisscrossing aisles and backing up.

In these cases, it's recommended to slow down and sound the horn when navigating aisle intersections, corners, and other sight-limiting obstacles

Consider Your Forklift and Tire Types

Not all forklifts are built the same.

Some are heavier to handle weightier loads while others are light for light-duty tasks.

But it's important to remember that the greater the weight, the more cautious operators need to be with their speed.

Because greater weight makes it harder to stop in time for pedestrians, infrastructure, and equipment.

On a related note, you should also consider the lift truck tire type - specifically if it has cushion or pneumatic tires.

This is because cushion tires generally don't provide as much traction as pneumatics, especially on wet or cold surfaces, such as in cold storage warehouses.

Consider Pedestrian Traffic

As we've noted, forklift accidents involving pedestrians are one of the top causes of injuries in the workplace.

So when setting a safe forklift maximum speed, it's critical to consider the number and proximity of pedestrians to your lift trucks.

In general, it's a good idea to impose speed limits in parts of the facility where there is more pedestrian traffic or obstacles to avoid.

Furthermore, separating the area between pedestrian traffic and forklift traffic can help reduce accidents.

And finally, operators should never drive up to a pedestrian in front of a fixed object or wall.

That can cause them to become pinned and cause great injury or worse.