Enhancing Forklift Pedestrian Safety with Proximity Warning Systems and RTLS

Introduction

Forklifts are essential in warehouses and industrial environments, ensuring the smooth movement of goods and materials. However, their presence also introduces serious safety hazards, particularly for pedestrians working in the same space. With limited visibility, fast-paced environments, and shared work zones, the risk of forklift-pedestrian incidents is a constant concern.

According to OSHA, forklift-related accidents resulted in 24 fatalities and hundreds of injuries in 2024, often caused by blind spots, insufficient warning systems, and a lack of real-time awareness. Beyond the devastating human impact, these accidents lead to costly downtime, legal liabilities, and operational disruptions.

To improve pedestrian safety, many warehouses are adopting proximity warning systems—a solution designed to detect nearby workers and automatically alert forklift drivers and workers. Using cutting-edge technologies like RFID, Bluetooth, and Ultra-Wideband (UWB), these systems provide real-time alerts to reduce risks and enhance situational awareness. For even greater safety and control, Real Time Location Systems (RTLS) can be added as an additional layer of protection. By continuously tracking forklifts and pedestrians, RTLS not only prevents accidents in real time but also provides valuable insights and enables location driven safety improvements.

Understanding Forklift Hazards for Pedestrians

Warehouses and industrial workplaces are fast-paced environments where forklifts and pedestrians frequently share the same space. This close interaction creates a high risk of accidents, especially when proper safety measures are not in place. According to NIOSH, nearly 20% of all forklift-related incidents involve a pedestrian being struck, making forklift pedestrian safety a critical concern.

To reduce risks and enhance workplace safety, it’s essential to understand the most common causes of pedestrian-forklift accidents:

• Blind Spots & Limited Visibility – Forklifts have restricted sightlines, making it difficult for operators to see pedestrians, especially near racks, corners, or pedestrian access points.
• Speeding or Reckless Operation – Operating at unsafe speeds, particularly in high-traffic areas, significantly increases the likelihood of accidents.
• Lack of Warning Systems in High-Risk Zones – Without proximity alert systems, workers may not be aware of approaching forklifts.
• Forklift Noise & Distractions – Loud warehouse environments can make it difficult for pedestrians to hear forklifts approaching, reducing reaction time.

The Financial & Operational Costs of Forklift Accidents

Beyond the human impact, forklift accidents lead to significant financial and operational consequences for businesses, including:

• OSHA Fines & Legal Penalties – Non-compliance with forklift safety regulations can result in hefty fines, lawsuits, and liability claims.
• Injury Claims & Medical Costs – Workplace injuries can lead to long-term worker compensation claims, lost productivity, and increased insurance premiums.
• Downtime & Productivity Loss – Investigations, safety audits, and repairs following an accident can disrupt operations and reduce efficiency.

How Proximity Warning Systems Improve Forklift Safety

What Are Proximity Warning Systems?

Proximity warning systems are advanced safety solutions that help prevent pedestrian-forklift collisions by detecting nearby workers, equipment, or other forklifts. These systems use sensor technology to continuously monitor surroundings and issue real-time alerts when a potentially dangerous situation is detected. By warning both operators and pedestrians, they allow for immediate corrective action.

Types of Proximity Sensors & Comparison

Different proximity sensor technologies offer advantages and challenges. Below is a comparison based on cost, infrastructure requirements, accuracy, and implementation factors:

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How Proximity Warning Systems Alert Operators & Pedestrians

Proximity warning systems not only issue alerts through multiple channels but can also adjust the active warnings based on how close a forklift is to a pedestrian. This graduated alert system ensures that responses are proportional to the level of danger

• Audio Alerts – Loud beeping sounds notify workers of approaching forklifts.
• Visual Signals – LED warning lights or dashboard indicators alert operators.
• Vibration Alerts – Wearable devices can provide haptic feedback to workers in high-risk zones.
• Automatic Speed Reduction – Some systems can slow down or stop forklifts automatically when detecting nearby pedestrians.

Key Benefits of Proximity Warning Systems

By integrating proximity sensors into existing warehouse safety protocols, businesses can significantly reduce accidents. The main benefits include:

• Reduces Blind Spot Risks – Sensors detect pedestrians in areas where operators have limited visibility.
• Prevents Pedestrian Collisions – Early alerts give both operators and workers time to react.
• Improves Overall Workplace Awareness – Enhances safety culture and reduces workplace injuries.
• Enhances Compliance with OSHA Standards – Helps businesses meet workplace safety regulations and avoid OSHA fines.

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Enhancing Proximity Warning Systems with RTLS

While proximity warning systems provide an excellent first layer of protection, integrating Real-Time Location Systems (RTLS), such as the Pozyx UWB RTLS, takes forklift safety to the next level.

Key Benefits of RTLS-Enhanced Forklift Safety

1. Real-Time Tracking of Forklifts & Workers‍

RTLS provides continuous visibility of all forklifts and pedestrian workers on a digital warehouse map.

• Live Monitoring – Operators and safety managers can track forklift and pedestrian locations in real time, reducing the risk of unexpected encounters.
• Proactive Hazard Avoidance – With real-time tracking, forklift operators receive alerts when approaching high-risk areas or when a pedestrian is nearby.
• Optimized Navigation – Operators can make informed decisions about routes, reducing congestion and improving workflow efficiency.

2. Geofencing for High-Risk Areas

• Speed Control in Pedestrian Areas – When a forklift enters a designated pedestrian zone, the system automatically reduces speed or triggers a warning.
• Restricted Access Alerts – RTLS can define restricted zones where forklifts should alert drivers when entering pedestrian-heavy areas.
• Adaptive Safety Zones – Dynamic geofencing allows warehouses to modify safety zones based on current traffic patterns and shift changes.

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3. Historical Data & Heatmaps‍

RTLS doesn’t just improve real-time safety—it also helps identify long-term safety risks through data analytics.

• Incident Reconstruction – Provide a detailed breakdown of near-miss events, including who was involved, their exact locations, and movement patterns leading up to the event.
• Near-Miss Analysis – RTLS collects movement data to identify areas where frequent near misses occur, helping managers address potential hazards before accidents happen
• Heatmaps for Risk Hotspots – By analyzing historical forklift and pedestrian traffic, warehouse managers can restructure layouts to minimize collision risks.
• Continuous Safety Optimization – Data insights allow for better training programs, improved workflows, and smarter warehouse designs that reduce accident-prone areas.

4. Advanced safety signal control

‍Instead of relying solely on forklift-based alerts, RTLS allows for warehouse-wide safety signal control based on real-time locations of pedestrians, forklifts, and other equipment.

• Location-Based Alerts – Warning lights, audio signals, or visual indicators can be activated dynamically based on the proximity of forklifts and workers.
• Location-Based Alert Configuration – RTLS enables dynamic adaptation of safety alerts based on real-time conditions. For example different safety rules for different areas, such as restricted zones, shared walkways, or high-risk loading docks.

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While integrating RTLS significantly enhances the capabilities of a proximity warning system, it is not necessarily required to deploy a full RTLS installation for effective forklift pedestrian safety. The proximity warning system can operate independently without any RTLS infrastructure, still providing essential real-time alerts to prevent accidents. However, wherever the RTLS is available, businesses can unlock the advanced functionalities described above. This flexible approach allows warehouses to gradually scale their safety solutions based on their specific needs and infrastructure.

Conclusion

Forklift pedestrian safety is a critical challenge in warehouses and industrial environments, where accidents can happen in an instant. Proximity warning systems provide a proactive safety solution, alerting both forklift operators and pedestrians before accidents can occur.

For an even more comprehensive safety approach, combining proximity warning systems with Real-Time Location Systems (RTLS) delivers added benefits, including real-time tracking, geofencing, and data-driven safety improvements.

With extensive experience in industrial safety and location-based technologies, Pozyx delivers cutting-edge solutions that enhance forklift pedestrian safety. Our advanced RTLS and proximity warning systems provide unparalleled accuracy and reliability, ensuring warehouses can proactively prevent accidents and improve operational efficiency. By combining real-time tracking, geofencing, and automated safety alerts, Pozyx helps businesses create a smarter, safer, and more efficient workplace.

Is your warehouse equipped with the right safety technology? Contact us today to learn how proximity warning systems and RTLS can help enhance workplace safety.