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Forklift material unloading — real accidents & risk assessment
Real Forklift material unloading accident cases (AI-cleaned) plus example risk assessment, JSA and TBM. Free, no sign-up.
Real AI output
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Below are actual outputs generated by our AI engine (sample). After sign-up they are generated for your exact task.
Sample for: Forklift material unloading
12
Hazards
7
Unit tasks
8
Related laws
Criminal 4
Full risk assessment
| Unit task | Hazard / Cause | Current controls | Risk (F×S) | Controls | After | Legal |
|---|---|---|---|---|---|---|
| Pre-work planning & forklift inspection | Sudden runaway or entrapment during forklift inspection Gear not in neutral or brake not applied while engine is running during inspection Material Handling / Vehicles / Heavy Equipment | Operator safety training | 8· Medium 2×4 |
| 4· Medium | Art. 385 Handling Heavy Loads Criminal |
| Pre-work planning & forklift inspection | Forklift tip-over due to overloading or uneven surface Load exceeds rated capacity or tilt angle not adjusted on slope Material Handling / Vehicles / Heavy Equipment | Load capacity placard on forklift | 9· High 3×3 |
| 2· Low | Art. 385 Handling Heavy Loads Criminal |
| Pre-work planning & forklift inspection | Pedestrian struck by forklift due to blind spot Forklift operator's forward view obstructed by load; no pedestrian exclusion zone Material Handling / Vehicles / Heavy Equipment | Warning beacon and horn installed | 6· Medium 3×2 |
| 2· Low | Art. 171 전도 등의 방지 Criminal |
| Work-zone control & load positioning | Load falls from forks due to unstable stacking Uneven load distribution on pallet or load not secured with stretch wrap Falling Objects | Visual inspection before lift | 6· Medium 3×2 |
| 2· Low | Art. 385 Handling Heavy Loads Criminal |
| Work-zone control & load positioning | Back strain from manual handling of heavy materials during repositioning Worker lifts load by hand because forklift cannot reach the exact spot Musculoskeletal Disorder | Manual-handling guidance | 8· Medium 2×4 |
| 4· Medium | 제177조 싣거나 내리는 작업 Criminal |
| Forklift fork insertion & load lift | Worker's foot trapped under fork during insertion Worker stands too close while operator inserts forks into pallet Caught-in / Entrapment | Verbal warning before operation | 12· High 3×4 |
| 3· Low | 제177조 싣거나 내리는 작업 Criminal |
| Forklift fork insertion & load lift | Load shifts and falls during initial lift Pallet is damaged or forks not fully inserted before lifting Fall | Pre-lift visual check | 9· High 3×3 |
| 2· Low | 제393조 화물의 적재 Criminal |
| Load transport & alignment | Forklift strikes pedestrian during travel Speed too high for site conditions; intersection blind spot; no signal person Struck-by / Impact | Speed limit signage | 12· High 3×4 |
| 3· Low | Art. 171 전도 등의 방지 Criminal |
| Load transport & alignment | Forklift tips over on ramp or uneven surface while carrying load High load carried at full mast height on slope Overturning / Tip-over | Ramp speed guideline | 8· Medium 2×4 |
| 3· Low | 제176조 수리 등의 작업 시 조치 Criminal |
| Load lowering & fork retrieval | Load tips during lowering and crushes worker Lowering speed too fast or load not balanced when setting down Falling Objects | General training on controlled lowering | 6· Medium 3×2 |
| 2· Low | 제177조 싣거나 내리는 작업 Criminal |
| Load lowering & fork retrieval | Worker's hand or arm caught between load and racking during positioning Worker reaches into narrow gap to guide load by hand Caught-in / Entrapment | General warning | 12· High 3×4 |
| 3· Low | Art. 385 Handling Heavy Loads Criminal |
| Post-work forklift parking & cleanup | Forklift rolls away due to parking on slope without chocking Wheel chocks not applied; parking brake not fully engaged Material Handling / Vehicles / Heavy Equipment | Parking procedure reminder | 12· High 3×4 |
| 3· Low | Art. 385 Handling Heavy Loads Criminal |
Legal compliance (OSH rules)
Art. 385Handling Heavy Loads
CriminalMust-check
Art. 171Forklift Safety Devices
CriminalMust-check
Art. 172Forklift Operator Qualification
Must-check
Art. 93PPE Provision and Use
CriminalMust-check
Art. 86Work-Zone Marking
Art. 87Signal Person Requirements
Art. 88Load Securing
CriminalMust-check
Art. 94Travel Route Control
Grounding real accidents
During forklift unloading from a flatbed trailer, a steel beam slipped off the forks and struck a worker on the foot.
⚠ Falling load from unstable pallet
Forklift tipped over after one front wheel fell into an unmarked floor drain; operator pinned under overhead guard.
⚠ Ground irregularity causing tip-over
Worker crushed between forklift and shelving when operator reversed without checking behind.
⚠ Struck by reversing forklift in blind spot
Worker suffered lumbar injury trying to reposition a load that forklift could not place precisely.
⚠ Overexertion during manual last-metre handling
Forklift mast struck a sprinkler pipe when the mast was raised too high inside the warehouse.
⚠ Overhead obstruction struck by elevated mast
Bystander's foot run over by forklift at uncontrolled pedestrian crossing.
⚠ Pedestrian in forklift travel lane