Warehousing remains one of the most dangerous industries in the U.S., with non-fatal injuries occurring at a rate of 3.7 per 100 full-time workers—almost 30% higher than the private industry average (Source: U.S. Bureau of Labor Statistics). Forklift accidents, falls, and struck-by incidents continue to drive these numbers, leading to thousands of workers sidelined every year and millions lost to direct and indirect costs (Source: Herc-U-Lift). The good news? Most of these injuries are preventable. With the right safety protocols—and smarter use of technology, like AI-powered video analytics—warehouses can cut risk, boost compliance, and protect their people.
In this guide, we’ll break down the top 5 injuries that happen most in warehousing—and show how a practical, tech-supported approach can help you prevent them. We’ll cover real-world risks, proven controls, and the crucial role video intelligence now plays in creating safer, more accountable workplaces.
The Top 5 Preventable Injuries in Warehousing (and How to Stop Them)
Warehousing workflows are fast-moving, complex, and filled with potential hazards. But five injury types consistently top the list—each with clear prevention paths, and each directly addressable by video intelligence.
1. Forklift and Vehicle Collisions
Picture this: A forklift rounds a blind aisle corner at full speed, just as a pedestrian steps into the intersection. In a split second, a serious injury—or worse—can occur. Forklift-related incidents cause between 35,000 and 62,000 injuries annually in the U.S., including about 87 fatalities (Source: Herc-U-Lift).
The impact: Beyond fractures and crushing injuries, vehicle-related incidents rack up massive direct and indirect costs—averaging $43,000 per serious injury (Source: Certex).
How video intelligence helps: AI cameras can monitor intersections, detect unsafe vehicle speeds, alert for unauthorized pedestrian entry into vehicle zones, and provide instant replay for post-incident analysis.
2. Slips, Trips, and Falls
A worker hurries across the warehouse floor, stepping onto a hidden spill. They slip, fall, and are sent to the ER with a fracture. Slips, trips, and falls account for 19.2% of all warehouse injuries—and 28% of fatal incidents in the UK alone (Source: HSE).
The impact: Falls are a leading cause of fractures, with injuries to feet, ankles, hands, and heads most common (Source: OSHA). The indirect costs—lost time, overtime, investigations—multiply the pain.
How video intelligence helps: AI cameras instantly flag spills, clutter, or blocked exits. Real-time alerts let supervisors act before a minor hazard becomes a major injury.
3. Struck-by Moving Objects
It happens in a flash: A pallet teeters on a high rack, falls, and hits a worker below. Or a box slides off a conveyor belt into a busy aisle. Struck-by incidents are responsible for 18% of warehousing fatalities (Source: HSE).
The impact: Struck-by injuries often mean fractures, head trauma, or even fatalities. These are not “freak accidents”—they’re foreseeable and preventable.
How video intelligence helps: AI monitors load stability, detects unsafe access to high racks, and triggers alerts if items fall or barriers are breached.
4. Falls from Height
An employee climbs a ladder to grab a box from a top shelf—no harness, no guardrail. A misplaced step, and they’re on the ground below. Falls from height make up 28% of warehouse fatalities (Source: HSE).
The impact: These incidents result in severe injuries—fractures, spinal trauma, even death. OSHA now mandates strict fall protection for any work above four feet.
How video intelligence helps: AI video detects when workers are at height without proper PPE, monitors for guardrail breaches, and sends real-time alerts for unsafe ladder use.
5. Caught-in or Crushed by Machinery
A worker reaches into a conveyor to clear a jam, forgetting to lock out the equipment. The machine starts unexpectedly. Result: a crushing injury, or worse, an amputation. Caught-in/crushed injuries represent 13.4% of warehouse incidents, with 10.3% of those resulting in amputations (Source: OSHA).
The impact: These injuries are severe and often permanent. The cost—in lives and dollars—is staggering.
How video intelligence helps: Cameras confirm guard presence, flag unauthorized access during maintenance, and provide crucial video evidence for root-cause investigations.
Challenges and Impact of the Injuries
Let’s see how these top risks play out on the warehouse floor—and how data and tech support prevention.
| Injury Type | Challenges | Impact | Role of Data & Technology |
|---|---|---|---|
| Forklift & Vehicle Collisions | Blind spots, operator fatigue, poor visibility, unauthorized pedestrian presence | Severe injuries, fatalities, massive downtime, regulatory penalties | AI cameras monitor intersections, alert on near-misses, and verify protocol compliance |
| Slips, Trips, and Falls | Hidden hazards, wet floors, cluttered walkways, poor lighting | Fractures, lost time, high workers’ comp claims, repeat incidents | Video analytics flag spills, blocked exits, and unsafe shortcuts in real time |
| Struck-by Moving Objects | Overloaded racks, improper stacking, barrier bypass, unstable loads | Head injuries, fractures, fatalities, costly litigation | Cameras detect falling objects, monitor racking integrity, and alert for unapproved access |
| Falls from Height | Unprotected edges, lack of guardrails, unsafe ladder use | Fatalities, spinal injuries, OSHA fines, long-term disability | AI detects PPE non-compliance, monitors at-height work, and sends instant alerts |
| Caught-in/Crushed by Machinery | Skipped lockout/tagout, unguarded machinery, poor training | Amputations, crushing injuries, lawsuits, equipment damage | Video confirms guard status, monitors maintenance, and automates incident documentation |
How Technology Strengthens Injury Prevention
Warehousing safety teams face a tough job: Preventing injuries in busy, unpredictable environments. Technology, especially video intelligence, amplifies your ability to spot risks and intervene fast—without adding headcount or complexity.
- Forklift and Vehicle Collisions: AI video platforms watch key intersections and blind spots, alerting you the moment a pedestrian enters a vehicle zone. Some systems even integrate with vehicle telematics to cut near-misses by up to 80%.
- Slips, Trips, and Falls: Video analytics identify slippery areas, clutter, or trip hazards as soon as they appear. Instead of waiting for someone to report a spill, you get a real-time notification—so you can prevent the next fall.
- Struck-by Moving Objects: Cameras with AI analyze stacking practices and detect when items are stored unsafely or barriers are bypassed. If a load shifts or a box falls, the system flags it for immediate response.
- Falls from Height: AI-powered video monitors at-height work zones, checking for missing guardrails, harnesses, or other critical fall protection. Alerts go out if someone stands on a pallet or enters a restricted area without PPE.
- Caught-in/Crushed by Machinery: Cameras verify that machine guards are in place, and monitor maintenance activity for lockout/tagout compliance. If a worker enters a danger zone without authorization, the system notifies supervisors instantly.
Spot AI is built for this reality—giving your frontline teams the power to find, search, and act on safety video easily, and supporting your existing safety programs every step of the way.
Practical Implementation of Safety Technology
So, how do you make safety technology work for you—not the other way around? Here’s what practical rollout looks like in 2025:
- Integrate with what you have. AI video systems like Spot AI work with most existing camera infrastructure, so you don’t have to rip and replace.
- Focus on high-risk zones first. Start with loading docks, aisle intersections, and at-height picking areas—where the data shows most injuries occur.
- Align with your safety goals. Use tech to support (not replace) your existing training, incident reporting, and audit processes. Think of video as your safety “second set of eyes.”
- Involve frontline workers. Make sure everyone understands how technology supports safety and respects privacy. Use it to empower—not police—your team.
- Evaluate for your needs. Choose solutions that offer real-time alerts, easy video search, and compliance reporting tailored to warehousing. Look for platforms that are simple, open, and help you solve your biggest safety headaches without adding IT overhead.
Ready to take the next step? Safety technology is only as strong as the people and processes behind it. The best results come from combining proven protocols with smarter, faster visibility.
Take Charge of Warehouse Safety: Partner for Better Outcomes
Warehousing safety isn't just about compliance—it's about protecting your people, your uptime, and your reputation. You know your risks. Now, you have powerful new tools to manage them, faster and more effectively than ever.
Want to see how video intelligence can make your safety program smarter, not harder? Let’s make your team the hero. Book a safety consultation with Spot AI and see what’s possible when technology works for you.
Frequently asked questions
What are the most common preventable injuries in warehousing?
The most common preventable injuries are forklift and vehicle collisions, slips/trips/falls, struck-by moving objects, falls from height, and caught-in/crushed by machinery. These account for the majority of severe incidents and can be significantly reduced through a mix of strong protocols, training, and video intelligence (Source: OSHA Report, 2025).
How can AI cameras help reduce forklift accidents?
AI cameras monitor key risk zones like aisle intersections and pedestrian crossings. They can alert supervisors in real time if a pedestrian enters a restricted area or if a forklift is speeding, helping to prevent collisions before they happen (Source: Powerfleet).
What’s the best way to integrate safety technology with my current systems?
Choose video analytics platforms that work with your existing camera infrastructure and safety processes. Look for solutions with open, easy integration, real-time alerts, and simple search capabilities. Involve your IT and safety teams early to ensure a smooth rollout.
Are there compliance requirements for video surveillance in warehouses?
Yes. OSHA requires safety monitoring, incident documentation, and regular hazard assessments. AI video systems help document compliance, support incident investigations, and verify that protocols like lockout/tagout and PPE use are being followed (Source: OSHA 1910.178).
How do I ensure my team buys into new safety technology?
Involve frontline workers in the rollout, clearly explain how the technology supports their safety, and use it to empower them to report hazards and near-misses. Respect privacy and use video as a tool for positive change, not surveillance.
How do AI video analytics support incident investigations?
AI-powered video makes it fast and easy to find the exact footage of an incident. This helps clarify root causes, verify protocol compliance, and train staff on what went wrong and how to prevent it next time (Source: EMag).
About the author
Mike Polodna
Head of Customer Success at Spot AI
Mike has spent over a decade helping organizations maximize safety, efficiency, and value through practical technology solutions. He specializes in guiding warehousing and logistics teams through successful adoption of video intelligence, always focusing on real-world results and user empowerment. Mike’s work bridges the gap between frontline operations and smart, scalable safety programs.
