Nonroadway vehicle collisions at Work — Injury Statistics and Claims Information
Nonroadway vehicle collisions at Work
Incident rates show an increasing trend
OSHA recorded 2,188 severe incidents involving nonroadway vehicle collisions over the last decade. These events frequently result in fractures, which account for 47.8 percent of all reported cases.
The severity of these incidents is reflected in the high rate of amputations, which make up 14.8 percent of injuries. Feet and toes are the most commonly affected body parts, appearing in 16.4 percent of all reported severe cases.
What's Driving the Trend?
The 10-year trend shows a 3.7 percent increase in these incidents, despite a recent 15.8 percent decline over the last five years. Powered industrial vehicles remain the primary source of these collisions, accounting for 85.8 percent of all reported events.
Transportation and warehousing industries lead with 29.0 percent of cases, followed by manufacturing at 22.6 percent. These environments often involve high-speed vehicle operation in confined spaces, creating significant risks for workers.
Injury Types from Nonroadway vehicle collisions
Top causes based on OSHA incident reports
These incidents typically occur when operators of powered industrial vehicles, such as forklifts or pallet jacks, lose control or strike stationary objects like racking, bollards, or building structures. Common scenarios include reversing into protective barriers, striking support beams, or losing balance during sudden stops. These collisions often pin limbs between the vehicle and the object, leading to crushing injuries.
| Injury Type | Incidents | |
|---|---|---|
| 1 | Fractures | 1,035 |
| 2 | Traumatic injuries or exposures— unspecified | 390 |
| 3 | Amputations, avulsions, enucleations | 321 |
| 4 | Cuts, lacerations, punctures without injury to internal structures | 150 |
| 5 | Severe wounds or internal injuries and other injuries | 60 |
| 6 | Intracranial Injuries | 46 |
| 7 | Bruises, contusions | 41 |
| 8 | Injuries to internal organs and major blood vessels | 30 |
Why This Matters for Your Case
Employers must comply with 29 CFR 1910.178, which mandates rigorous training and safe operating procedures for powered industrial trucks. Failure to maintain clear travel paths, enforce speed limits, or ensure proper vehicle maintenance often constitutes a violation of these federal safety standards.
Industries with Most Nonroadway vehicle collisions
Where these injuries occur most frequently
Transportation and warehousing industries account for 29.0 percent of these collisions, while manufacturing follows at 22.6 percent. The high volume of material movement and the density of racking systems in these facilities create constant exposure to potential vehicle-object impacts.
High-Risk Industries and Your Rights
Employers in these sectors are required to adhere to 29 CFR 1910.178, which governs the safe operation of powered industrial trucks. This includes conducting regular site hazard assessments and ensuring that all operators are certified and competent to navigate their specific work environment.
Real Incident Reports
From actual OSHA investigation files
Reported incidents reveal a recurring pattern of workers sustaining fractures and amputations when operating forklifts or pallet jacks in warehouse and construction settings. These narratives frequently involve collisions with racking, bollards, or structural elements, often resulting from visibility issues or floor hazards that lead to a loss of vehicle control.
"An employee was moving an aerial lift across the mechanical room when he struck a hanging duct structure. The employee sustained lacerations to the face and a fractured jaw."
"On July 29, 2025, an employee was using a riding pallet jack to load gaylords (corrugated boxes) into a trailer. While reversing out of the trailer, the pallet jack backed into a protective bollard. The employee's hand was crushed between the pallet jack and the bollard. He sustained fractures, requiring hospitalization and surgery."
"An employee was operating a standup forklift in the warehouse. The forklift struck racking, causing the employee to lose their balance. Their left foot became caught between the forklift and the racking and was fractured."
"An employee was riding in a utility task vehicle (UTV) with several children (patrons). One of the children pressed the gas pedal of the UTV and the vehicle struck a fence post. The employee was thrown from the UTV and sustained five broken ribs, a partial pneumothorax to the right lung, an abrasion to the right arm, and contusions to the body. The employee was hospitalized."
"An employee was driving a forklift when the forklift slipped on butter that was on the floor, causing it to strike a rack. The employee's left big toe contacted the rack, resulting in an amputation."
"An employee was being trained to use a counterbalance forklift. While operating the forklift under the supervision of his trainer, the employee exited one aisle and began turning into another when his left foot struck the end of a racking angle iron (rack protector). The employee was hospitalized with multiple foot and ankle fractures."
"An employee was driving a pickup truck into an auction lot when it collided with a security hut, causing the airbags to deploy. The employee was hospitalized due to a broken right hip; broken ribs number three, five, and seven on the right side; a chest contusion; a laceration to the top of the head; and a concussion."
"An employee was operating a stand-up cart tugger and was returning from delivering a cart of I-beams to a staging area. The vehicle struck a rock on the concrete pad and then suddenly swerved to the left. The employee lost balance and fell out of the vehicle, landing on his hip. The employee was hospitalized with a fractured right hip and required surgery."
"An employee was traveling through a loading dock area on a stand-up forklift. His foot was pinned between the forklift and a column, resulting in fractures to the foot and the heel."
"An employee was driving a carry deck/small crane when its boom made contact with an overhead support beam. The employee was jostled in the cab and suffered a concussion."
Common Questions About Nonroadway vehicle collisions Claims
The ClaimsBoost Research Team aggregates official government data to help workers understand workplace injury trends and their coverage options.
ClaimsBoost is not a law firm and does not provide legal advice. ClaimsBoost is not affiliated with, endorsed by, or connected to any government agency. Performance scores, rankings, and statistics displayed on this site are calculated by ClaimsBoost using publicly available government data from OSHA severe injury reports. Individual results may vary. Nothing on this site should be construed as legal advice or a guarantee of benefits. If you need legal help, we can connect you with licensed attorneys in your area.Some written content on this page was created with the assistance of AI to help interpret and explain the data. AI can make mistakes — all content has been reviewed for accuracy, but we encourage you to verify any information that is important to your situation.