Most business owners think safety is about their OSHA posters, safety gear policies, and some drills here and there. But the real danger lies in the overlooked hazards that don’t make the safety newsletter. These are the injuries that blindside companies and crush productivity.
The good news is that most of these injuries are preventable if you know how to identify and fix the gaps before an accident happens.
Here are some of the most common workplace injuries that people don’t see coming.
- Forklift injuries
A forklift doesn’t need to be moving fast to cause catastrophic damage. Even at low speeds, the weight and force can crush limbs, cause internal injuries, and even cause death. According to the Bureau of Labor Statistics, forklifts are involved in around 70 U.S. workplace fatalities and 7,000 nonfatal injuries every year. Many of these incidents are caused by tip-overs, struck-by accidents, and workers being pinned between a forklift and another object.
While most companies are aware that forklift operators need to be trained and certified before they can operate a forklift, that doesn’t always happen. Sometimes corners are cut and casual demonstrations and informal training is substituted for real training. This is extremely dangerous and there’s no excuse. Forklift certification is easy to obtain for entire teams and it can even be done online. Operators still need hands-on experience, but online certifications can provide a thorough understanding of safe operations beyond what an in-house trainer can accomplish.
On the other side, it’s important to train employees working near forklifts to stay on designated walkways, heed warning signals, and maintain safe distances from forklifts. Safety training can save between $4 and $6 for every $1 spent. Without this training, even a careful operator can’t avoid a distracted worker stepping in their path.
- Fatigue
Fatigue may not seem like a serious threat, but the consequences can be severe. When employees are tired, their reaction times slow and their judgment becomes clouded, increasing the likelihood of errors. Lost productivity can cost companies millions, even billions, of dollars.
To prevent fatigue, avoid stacking long or overnight shifts because it doesn’t allow for adequate rest between. Rotating schedules should be predictable to support regular sleep patterns. Breaks should also be enforced, not just offered. Supervisors need to ensure workers take all their required breaks. Even one skipped 15-minute break can cause a near miss or injury.
- Slips, trips, and falls in “safe” areas
You’d expect people to slip and fall on the warehouse floor or in the bathroom, but office spaces, break rooms, and even parking lots can be just as dangerous. When a floor is wet or uneven, people are more likely to fall, even in areas that don’t seem likely.
While you can’t prevent every accident, you can perform walkthroughs every week to check for potential hazards before they cause injury. It also helps to invest in non-slip mats to prevent accidents. A single slip can lead to injury and a workers’ comp claim that will drive up insurance premiums.
- Chemical exposure in unexpected places
Hazardous chemicals are everywhere, not just in industrial plants. Offices and retail stores all have cleaning supplies for various tasks and without proper handling, some of these substances can cause injury. Even common cleaning products can be dangerous when handled improperly.
It’s crucial to label everything clearly to ensure workers know what they’re handling. Material Safety Data Sheets (MSDS) should be readily available and staff should be trained to read these documents. Most importantly, some chemicals require PPE like gloves and goggles, and this equipment should be stored near the use areas, not in a closet somewhere across the building.
- Non-obvious hazards
While heavy machinery gets training budgets, less dramatic risks like repetitive motion injuries, ladder misuse, and improper lifting often go unaddressed. These injuries aren’t minor. They’re costly and cumulative. For example, a Liberty Mutual study found that overexertion is the top cause of injury, costing companies $13.7 billion annually.
To prevent injury from less obvious dangers, it’s critical to train all staff on safe practices and provide them with the right equipment. It’s equally important for company leaders to model safe behavior to reinforce the importance among team members. Small hazards are just as likely to turn into chronic injuries and expensive insurance claims.
Safety is in the details
It’s tempting to focus only on large risks like heavy machinery, hazardous chemicals, and obvious slip-and-fall risks. But it’s often the overlooked hazards that halt productivity and harm employees. Preventing unexpected workplace injuries requires ongoing training and strong leadership. Companies need to be willing to address risks before they contribute to an incident.
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