BRIEF INCIDENT DESCRIPTION

A warehouse worker was fatally injured after falling seven feet from 

a wooden pallet elevated by a forklift. The warehouse inventory 

was stored on steel storage racks with the highest shelves about 

eight feet above the concrete floor. It was common practice for 

warehouse workers to place one foot or both feet on a pallet and 

move inventory on the top shelf (see Figure 1) while a coworker 

lifted them to the top shelf using the forklift, even though the 

equipment was not designed for this purpose. At the time of the 

incident, the worker slipped on the pallet while moving inventory 

and fell. The worker was taken to the hospital where he died from 

his injuries a few days later.

Likely Causes

Controls were not in place to prevent workers from improperly using 

equipment and falling to the ground. Specifically, the employer did not: 

• Provide workers with equipment for safely reaching inventory 

stored on elevated shelves.

• Follow manufacturer instructions and prohibit employees from 

using pallets on forklifts to access upper shelves.

• Provide training and certification to forklift operators on how to 

safely use and operate forklifts, including not using them to lift 

workers without an approved personnel lifting platform.

INCIDENT PREVENTION

Accessing warehouse storage shelves by lifting workers on pallets 

presents serious fall hazards. The employer must implement safe 

procedures and provide the proper equipment and training to 

prevent injuries and fatalities. Pallets are not designed for sitting or 

standing, nor should they be used for lifting workers with a forklift. 

Instead, employers should use manufacturer-approved personnel 

lifting platforms. 

INCIDENT SUMMARY

Incident type: .......................................................................Fall to lower level

Weather conditions/Time of day: ........................Indoors/approx. 6:30 AM

Type of operation: ...........................................Bulk wholesale warehousing

Size of work crew: ......................................................................................... 22

Worksite inspection conducted: ................................................................ No

Competent safety monitoring on site: ...................................................... No

Safety and health program in effect: ........................................................ No

Training and education for workers: .....................................................None

Occupation of deceased worker: .......................................................Laborer

Age/Sex of deceased worker: ................................................................ 33/M

Time on job: ...........................................................................................4 years

Time at task: ......................................................................................2-3 hours

Employment classification (FT/PT/Temporary): ............................ Full time

Language spoken: ...............................................................................Spanish

Union/Non-Union: .........................................................................Non-Union

FATALFacts 15No. 15 – 2017

Warehouse Fall from Pallet Elevated by Forklift

U.S. Department of Labor Occupational Safety and Health Administration www.osha.gov (800) 321-OSHA (6742)

Figure 1: Example of a worker unsafely pulling 

inventory on a raised pallet.

Photo courtesy of OSHA

You Have a Voice in the Workplace

The Occupational Safety and Health 

Act of 1970 affords workers the right to 

a safe workplace (see OSHA’s Worker 

Rights page, www.osha.gov/workers). 

Workers also have the right to file a 

complaint with OSHA if they believe 

that there are either violations of OSHA 

standards or serious workplace hazards. 

How OSHA Can Help

For questions or to get information or 

advice, to report an emergency, fatality, 

hospitalization, amputation or loss of an 

eye, or to file a confidential complaint, 

contact your nearest OSHA office, visit 

www.osha.gov or call our toll-free 

number at 1-800-321-OSHA (6742), 

TTY 1-877-889-5627. It’s confidential.

OSHA standards and regulations:

www.osha.gov/law-regs.html

OSHA publications:

www.osha.gov/publications

OSHA-approved state plans:

www.osha.gov/dcsp/osp

Free On-site Consultation services:

www.osha.gov/consultation

Training resources: 

www.osha.gov/dte

Help for Employers:

www.osha.gov/employers
To prevent a similar incident from occurring:

• Do not allow workers to ride on or 

occupy pallets lifted by forklifts. 

• Provide workers with the proper tools 

and equipment for each task, including 

accessing working surfaces (e.g., elevated 

storage shelves in a warehouse). 

• Equipment designed for lifting workers 

in a warehouse include:

o Manufactured personnel platforms, 

designed for lifting workers on 

a forklift, which incorporate 

fall protection (i.e., guardrail 

systems). This option requires prior 

written approval from the forklift 

manufacturer (29 CFR 1910.178(a)(4)).

o High-lift order pickers, a powered 

industrial truck class equipped with 

personal fall arrest equipment that are designed to lift the operator alongside the forks. (See Figure 2.)

• Provide training on forklifts to workers who operate and work near them. Training should include formal instruction 

and hands-on training at a level and in a language workers understand. Employers must ensure that workers 

do not operate a forklift with another worker on the pallet, and that they follow manufacturers’ instructions 

(29 CFR 1910.178(l)(1)).

• Provide workers with fall protection and ensure their proper use in accordance with the Walking-Working Surfaces rule, 

and personal fall protection system standards.

DTSEM FF-3916 8/2017

Note: The described case was selected as being representative of improper work practices which likely contributed to a fatality from an 

incident. The incident prevention recommendations do not necessarily reflect the outcome of any legal aspects of this case. OSHA encourages 

your company or organization to duplicate and share this information.

This Fatal Facts is not an OSHA standard or regulation and it creates no new legal obligations. The recommendations contained herein are advisory 

in nature and are intended to assist employers in providing safe and healthful workplaces. The Occupational Safety and Health Act of 1970 (OSH Act) 

requires employers to comply with safety and health standards promulgated by OSHA or by an OSHA-approved state plan. The requirements of OSHAapproved state plans can be reviewed by selecting the state’s website at: www.osha.gov/dcsp/osp. The OSH Act’s General Duty Clause, Section 5(a)(1), 

requires employers to provide employees with a workplace free from recognized hazards likely to cause death or serious physical harm.

Figure 2: High-lift order picker

Diagram courtesy of OSHA