The U.S. forklift industry is a massive and highly regulated sector, driven by a $14.1 billion manufacturing industry and a market valued at $8.12 billion in 2025. Safety and compliance are the industry's cornerstones, with a primary focus on operator training, daily equipment inspections, and a significant shift toward electric and automated technologies.
The Regulatory Framework: OSHA is the Law
At the heart of forklift operations in the U.S. is the Occupational Safety and Health Administration (OSHA). Its standard for powered industrial trucks, 29 CFR 1910.178, is the definitive rule for forklift safety, and it is consistently one of OSHA's most frequently cited standards.
Key OSHA Requirements
Operator Training is Mandatory: OSHA mandates that all operators be trained and evaluated before operating a forklift.
Daily Inspections: OSHA requires that all forklifts be examined at least daily before being placed into service. If a forklift is used on a round-the-clock basis, it must be inspected after every shift.
Certification Documentation: Employers must certify that each operator has been trained and evaluated. The certification must include the operator's name, the name of the trainer/evaluator, and the dates of training and evaluation.
Three-Year Evaluation: An operator's performance must be evaluated at least once every three years.
Retraining Triggers: Refresher training is mandatory if an operator is observed operating unsafely, is involved in an accident, is assigned to a different type of forklift, or if workplace conditions change.
Forklift Certification: What It Is and Isn't
A common misconception is that forklift operators need a government-issued license. In the U.S., there is no such license.
Instead, forklift "certification" is an employer-based authorization. It proves that an operator has completed the required training and evaluation for their specific workplace and the specific types of forklifts they will use.
The Certification Process
Formal Instruction: This is the classroom or online theory portion. It covers topics like forklift physics, controls, and workplace hazards.
Practical Training: Hands-on training under the supervision of a qualified trainer.
Evaluation: A live, hands-on evaluation of the operator's skills in their actual workplace.
Online training can satisfy the formal instruction requirement, but it cannot replace the required hands-on evaluation.
The U.S. Forklift Market: Trends and Growth
The U.S. forklift market is dynamic, driven by e-commerce, automation, and a push for cleaner energy.
Market Size and Growth
The U.S. forklift market was valued at $8.12 billion in 2025** and is projected to reach **$13.59 billion by 2031.
The Forklift Manufacturing industry in the U.S. is valued at $14.1 billion in 2026.
Key Trends Shaping the Market
The Electric Shift: Electric forklifts captured 60.55% of the U.S. market in 2025, driven by zero-emission mandates and lower operating costs.
Lithium-Ion Dominance: Lithium-ion battery systems held a 54.62% revenue share in 2025 and are expected to see significant growth.
Class 2 & Automation: Class 2 (narrow aisle) trucks led the market with a 32.45% share in 2025, highlighting a focus on warehouse space efficiency.
E-commerce & Logistics: The logistics sector commanded 27.65% of market revenue in 2025, with retail and e-commerce as the fastest-growing segment.
Major Manufacturers in the U.S.
The U.S. market is served by a mix of global giants and domestic manufacturers.
Linde Material Handling: Manufactures forklifts in Summerville, South Carolina, specifically for the North American market.
Hyster-Yale: A major U.S.-based manufacturer of a wide range of forklifts.
UniCarriers Americas: Markets brands including Nissan Forklift, TCM, and Atlet in North America.
Other Key Players: The competitive landscape includes Toyota Industries, KION Group, Crown Equipment, Combilift, and Hoist Material Handling.
Other Important Safety Standards
Beyond OSHA, other standards provide additional safety guidance.
ANSI/ITSDF B56.1: The American National Standard for forklift safety.
ANSI/ITSDF B56.14-2020: Defines safety requirements for vehicle-mounted forklifts.
NFPA 505: The Fire Safety Standard for Powered Industrial Trucks, which helps mitigate fire and explosion hazards.
The bottom line: Forklift operations in the U.S. are governed by a strict OSHA framework that prioritizes operator training, certification, and daily equipment inspections. The market is rapidly evolving, with electric and lithium-ion technologies leading the shift toward sustainability and automation.