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You are here: Home / Equipment / Forklifts / 6 Health Risks for Forklift Operators and How to Prevent Them
6 Health Risks for Forklift Operators and How to Prevent Them

Updated May 17, 2022

6 Health Risks for Forklift Operators and How to Prevent Them

This article is all about the health risks forklift operators face on a daily basis.

Between long shifts, sitting for hours at a time in a cramped cab, and twisting and craning your neck to see behind you, you’ve no doubt experienced some side effects from driving a forklift.

That’s why we asked Dr. Chad Hoffman from Lifestyle Chiropractic, in Green Bay, Wisconsin for his expert advice on what you can do to minimize the health impacts of driving a forklift.

Let’s dig in.

Table of Contents

  • 1. Neck and Back Pain
  • 2. Shoulder Pain
  • 3. Knee Pain
  • 4. Whiplash
  • 5. Musculoskeletal Injury
  • 6. Fatigue
6 Health Risks for Forklift Operators: Neck & Back, Shoulder, Knee, Whiplash, Musculoskeletal, Fatigue

1. NECK AND BACK PAIN

Neck and back pain is often directly related to your work environment.

It can also result from any poor habits you may have picked up along the way.

Model gripping neck and back in pain
Operating a forklift can cause or aggravate neck and back pain

A few causes of your pain could be whole body vibration, sitting for long periods, and poor posture.

WHOLE BODY VIBRATION

Whole-body vibration is the vibration, shaking or jolting of the body transmitted through a supporting surface.

In this case, vibration is transmitted from your forklift seat, floor or back rest.

And it can make you predisposed to back pain or aggravate existing back problems.

Blurred Forklift in Warehouse
Limiting and counteracting vibration while driving can help ease neck and back pain

To avoid whole-body vibration injuries:

  • Lower your speed

  • Use an air suspension seat, as they decrease the vibration transferred to your body

  • Minimize your travel over uneven surfaces

SITTING FOR LONG PERIODS

Sitting for long periods may be unavoidable as a forklift operator.

Plus, twisting often in your seat can cause strain to your muscles.

Dr. Hoffman’s Advice

Even in cramped quarters where you have to maintain generally the same position for extended periods of time, do your best to regularly stretch your neck and surrounding muscles.

Begin by gently tilting your head to one side and then the other, breathing deeply (don't hold your breath!). Next, tilt your head forward and back very slowly to relieve any muscular discomfort.

While sitting for extended periods may be unavoidable at work, do your best to break that pattern outside of work.

Do simple body weight exercises such as squats, push-ups, sit-ups and walking/running to enliven your muscles and release any tension.

It's crucial to move your body when you can - it not only helps you feel better (not as stiff), but will help boost circulation, lower blood pressure and improve your muscle strength, allowing your body to better adjust to any neck, back or joint pain you are experiencing.

To alleviate issues caused by sitting for long periods of time:

  • Take breaks to stretch. Simple stretches that can be done on the job will do

  • Readjust your seat when you return to your forklift. Your feet should rest comfortably and you should be able to easily reach the steering wheel, pedals and hydraulic controls

  • Use your seat's backrest to take pressure of your back

POOR POSTURE

Poor posture can sneak up on you when you’ve been sitting in the same position for hours.

Dr. Hoffman’s Advice

Studies show that posture also affects mindset. If you have poor posture regularly, chances are you aren't in the greatest of moods.

Sure, work sometimes might get difficult, but do your best to sit up straight and your mind, not to mention your body, will thank you.

To combat poor posture:

  • Avoid slumping forward to reach the controls

  • Remove your wallet from your back pocket. Your back will adjust for the uneven seating surface, causing you to strain

2. SHOULDER PAIN

Your muscles can get stiff and sore thanks to the amount of time you spend on a forklift.

Steering, operating the hydraulic controls, and repetitive motion can cause strain in your shoulders.

Model gripping shoulder in pain
Repeated arm motions, like steering and operating hydraulic controls, can cause shoulder problems

Keep these tips in mind to avoid muscle fatigue and shoulder pain:

  • Keep your elbows in while driving

  • When operating your controls try to keep your hand out in a handshake position rather than palm down

  • Stretch regularly

  • Ask about getting a seat with an armrest – it can help protect your shoulders

3. KNEE PAIN

Forklift operators that drive stand-up forklifts can often experience knee pain.

Simply standing for a long time puts pressure on your lower body.

When you’re also bracing yourself against the movement of the forklift, the pressure and strain increases.

For operators of sit-down forklifts – anytime you twist around, you can also be stressing your knees.

Model gripping knee in pain
Stand-up forklift operators are especially susceptible to knee pain

Take care of your knees and avoid pain by:

  • Using a knee brace

  • Sitting down (if you’ve been standing) or walk for a few minutes every hour

  • Using three points of contact whenever you enter or exit the lift instead of jumping on or off

4. WHIPLASH

Aggressive acceleration and stopping can cause whiplash injuries.

Some symptoms that you may experience include:

  • Neck pain

  • Stiffness

  • Headaches

  • Dizziness

  • Difficulty concentrating

Did You Know?

Speeding is a leading cause of forklift accidents. Learn more about the top 10 most common forklift accidents.

To avoid whiplash injuries:

  • Take care to start and stop smoothly

  • Pay attention to the forklift speed limits in your work environment

5. MUSCULOSKELETAL INJURY

Musculoskeletal injuries can involve damage to your muscles, tendons, nerves, discs, blood vessels and more.

These injuries can be caused by jerking or repetitive movements that damage the muscle tissue.

Early signs appear in the upper body including the neck, upper back, shoulders and forearms.

If left untreated, severe pain and reduced movement can lead to the eventual inability to work.

Dr. Hoffman’s Advice

If you are experiencing severe pain, or if the severity of a particular source of discomfort increases over time, it's in your best interest to see a health professional.

Musculoskeletal injuries will likely not heal nor necessarily decrease in severity on their own.

To avoid musculoskeletal injuries:

  • Stretch regularly

    Stretching before and after your shift can reduce strain on your muscles caused by repetitive movements. Take breaks to stretch during your shift to minimize your risk

  • Use ergonomic seating if possible

    Some features include swiveling bases, arm rests and weighted suspension which can make your shift more comfortable by protecting your neck, head, shoulders, back and legs

  • Pay attention to the early signs

    In addition to the signs listed above, fatigue is commonly associated with musculoskeletal injury

6. FATIGUE

Fatigue is a serious hazard for forklift operators.

Inattentiveness due to fatigue can cause injury and damage to forklift operators, pedestrians, and product alike.

So it's important to be aware of the signs of fatigue, including:

  • Lack of energy

  • Muscle weakness

  • Shortness of breath

  • Difficulty concentrating

  • Impaired decision making

  • Reduce alertness

Fatigued warehouse worker taking a break
Fatigue can cause forklift operators to make mistakes, furthering the risk of injury

To avoid fatigue:

  • Get a full seven to eight hours of sleep each night

  • Know your limit and don’t overwork yourself

  • Stay active. Physical activity is known to boost energy levels

  • Drink plenty of water

Conclusion

There you have it: the 6 top health risks for forklift operators - and what you can do to prevent them.

Now we’d like to hear from you.

Do you suffer from any of the ailments listed above?

If so, what have you tried to alleviate your symptoms?

What’s worked and what hasn’t?

Let us know in the comments below!

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