Forklift proof your warehouse or this could happen

Tis the season for forklift training and that means I have been spending a lot of time in warehouses.  As part of our training, I always show a few epic fails – where forklifts take out entire warehouses with a single impact.   Take a look at the video below and then let’s discuss how we can forklift proof our warehouses.

How to forklift proof your warehouse

Interesting video, but don’t think this is the only incident.  This type of accident happens every year.  And the proverbial question I get in our training classes is – how does that happen?

There are many reasons why the racks come tumbling down, but the biggest one is that a small forklift weighs upwards of 9,000 lbs.  When you set 9,000 lbs in motion, a 1/4 inch (or even 1/2 inch) bolt is not match for the sheer power of a forklift.  And the racks come tumbling down.

In City and School District warehouses, I rarely see any type of rack end protection, rack bollards or other initial impact protection.  This is one of the simplest and inexpensive ways to protection your warehouse racks from total destruction.

Full height bollards are capable of stopping trucks traveling at 50 mph, so your 3 mph forklift should not be a match for the bollards.

Other ways to forklift proof your warehouse are listed below:

forklift proof your warehouse


forklift proof your warehouse


forklift proof your warehouse


  • paint yellow or other high visibility lane markings
  • install signage
  • paint your storage poles approximately 10 feet up in a  high visibility / high contrast color
  • provide operator training
  • make sure your warehouse is not over storage capacity
Hope you enjoyed this article.  If you need more personalized assistance, you can work directly with us.  Reach out here.

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