A persistent increase in severe pedestrian collisions
OSHA has recorded 2,749 severe incidents involving pedestrians struck by powered vehicles in nonroadway areas. These events frequently result in life-altering injuries, with fractures accounting for 55.6 percent of all reported cases.
The physical impact of heavy industrial vehicles often causes severe damage to the lower body. Leg and foot injuries represent over 28 percent of all reported cases, frequently leading to complex surgeries and long-term mobility challenges.
Over the last decade, the frequency of these collisions has increased by 23.6 percent. Industrial vehicles and material hauling equipment are the primary sources of danger, involved in 57.3 percent of all recorded incidents.
Manufacturing and transportation sectors face the highest risk, collectively accounting for nearly 45 percent of all cases. These environments often feature high-traffic zones where heavy machinery and workers on foot operate in close proximity without adequate separation.
Top causes based on OSHA incident reports
Struck-by incidents typically occur when workers are performing routine tasks near active forklift lanes or loading docks. Common scenarios involve workers being pinned against structures, run over by reversing equipment, or struck by falling loads that shift during transport. These accidents often happen when visibility is obstructed by tall loads or when communication between operators and pedestrians fails.
| Injury Type | Incidents | |
|---|---|---|
| 1 | Fractures | 1,466 |
| 2 | Traumatic injuries or exposures— unspecified | 482 |
| 3 | Amputations, avulsions, enucleations | 188 |
| 4 | Severe wounds or internal injuries and other injuries | 115 |
| 5 | Cuts, lacerations, punctures without injury to internal structures | 89 |
| 6 | Injuries to internal organs and major blood vessels | 80 |
| 7 | Intracranial Injuries | 60 |
| 8 | Bruises, contusions | 38 |
Employers are legally required to maintain safe traffic patterns under 29 CFR 1910.178, which dictates strict operational requirements for powered industrial trucks. Failure to implement physical barriers, designated pedestrian walkways, or proper signaling systems often constitutes a violation of the General Duty Clause, which mandates a workplace free from recognized hazards likely to cause death or serious physical harm.
Where these injuries occur most frequently
Manufacturing leads all sectors with 23.7 percent of these incidents, followed closely by transportation and warehousing at 21.2 percent. In these high-volume environments, the constant movement of heavy materials creates a high-risk intersection between human workers and powered transport equipment.
In manufacturing and warehousing, employers must adhere to 29 CFR 1910.178 regarding forklift safety and 29 CFR 1926.601 for motor vehicles in construction. These regulations require employers to ensure operators are trained, equipment is maintained, and traffic zones are clearly marked to prevent pedestrian contact.
From actual OSHA investigation files
The documented incident reports reveal a recurring pattern of failure where workers are struck while performing inspections or exchanging tools near active machinery. These accounts frequently involve forklifts with obstructed views or equipment that malfunctions during loading, highlighting the critical need for strict separation between pedestrian paths and vehicle traffic.
"An employee was inspecting a flatbed truck for air leaks. A forklift was offloading a pallet from the flatbed truck when the pallet caught the edge of a bundled lumber unit. The lumber unit slid off the bed of the truck and struck the employee's hip. The employee sustained a fractured pelvis and a hip injury."
"An excavator operator and the injured employee were exchanging a hand tool on a utility right of way. After the tool exchange the excavator moved forward and the tracks ran over the big toe of the injured employee's right foot. The toe was crushed, resulting in amputation of the tip."
"An employee was fulfilling orders when their foot was run over by a center-rider forklift. The employee was hospitalized with a fractured foot."
"Employees were unloading bundles of 20-foot long steel bars from the back of a container truck using a forklift with a crane boom attachment. As the forklift traveled down a ramp from the truck, a strap broke and a bundle fell on the injured employee's foot. The employee was hospitalized and their fourth toe and part of the third toe were medically amputated."
"An employee was walking across the dock, interacting with forklift drivers on what was being loaded. A forklift drove forward with a tall load on the forks. The employee was struck by the load (running board/rocker panel rack) on the forklift. The employee sustained several contusions and an injury to their right Achilles tendon that required surgery."
"An employee was working to change the tires and brakes on a vehicle. He pulled the vehicle out of the bay. The brakes failed, and the car drifted backward into another bay where it pinned the injured employee against the arm of a vehicle lift. The injured employee sustained seven fractured ribs on his left side."
"An employee was on a dock inspecting a load of freight. A lift struck the load, causing it to fall and strike the employee. The employee was hospitalized with injuries to their face, back, and leg."
"A team was setting a vertical turbine pump for a chill water sump. To align the bolt holes, a forklift was used to bump the pump a small amount. The injured employee was checking if the holes were aligned when the pump was bumped again. Their right index finger was caught inside a bolt hole resulting in a fingertip amputation. "
"An employee was loading machinery onto a trailer. The trailer had to be moved while the machinery was already on it. The employee was walking next to the tractor trailer when a piece of machinery shifted. The employee reached for the equipment and became caught between the moving trailer and the opening of the overhead garage door. The employee sustained fractures."
"An employee was inspecting materials in a warehouse area. While she was in a main aisle, a forklift backed into her foot. She suffered a possible fracture to the foot and was hospitalized."
The ClaimsBoost Research Team aggregates official government data to help workers understand workplace injury trends and their coverage options.
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