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Forklift in the United States: Regulations, Market, and Major Players

Published time：

2026-06-21

Author：

Xin Hong Guang

Source：

Xin Hong Guang

Abstract

The U.S. forklift industry is a massive and highly regulated sector, serving as the backbone of the nation's logistics, warehousing, and manufacturing operations. With a market valued at over $10 billion in 2025 and a strict regulatory framework enforced by OSHA, the industry is undergoing a significant transformation driven by electrification, automation, and sustainability mandates.Market Size and GrowthThe U.S. forklift market is on a strong growth trajectory:Metric Value2025 Market Revenue $10.73 billion2033 Projected Revenue $27.07 billionCAGR (2026–2033) 12.6%Forklift Manufacturing Industry Revenue (2025) $14.1 billionElectric forklifts are the largest and fastest-growing power source segment. In 2025, electric units captured 60.55% of the U.S. market, driven by zero-emission mandates and lower operating costs. Lithium-ion battery systems held a 54.62% revenue share and are forecast to grow at 13.85% CAGR through 2031.Class 2 trucks (electric narrow aisle) led the market with

The U.S. forklift industry is a massive and highly regulated sector, serving as the backbone of the nation's logistics, warehousing, and manufacturing operations. With a market valued at over $10 billion in 2025 and a strict regulatory framework enforced by OSHA, the industry is undergoing a significant transformation driven by electrification, automation, and sustainability mandates.


Market Size and Growth

The U.S. forklift market is on a strong growth trajectory:


Metric Value

2025 Market Revenue $10.73 billion

2033 Projected Revenue $27.07 billion

CAGR (2026–2033) 12.6%

Forklift Manufacturing Industry Revenue (2025) $14.1 billion

Electric forklifts are the largest and fastest-growing power source segment. In 2025, electric units captured 60.55% of the U.S. market, driven by zero-emission mandates and lower operating costs. Lithium-ion battery systems held a 54.62% revenue share and are forecast to grow at 13.85% CAGR through 2031.


Class 2 trucks (electric narrow aisle) led the market with 32.45% share, while logistics commanded 27.65% of end-use revenue, with retail and e-commerce growing fastest at 12.11% CAGR. By load capacity, sub-5-ton models accounted for 44.35% of the market in 2025.


Key Market Drivers:


E-commerce expansion: Daily parcel volumes surpassed 16.5 million units in late 2024


Shift to electric: Emission regulations, especially California's zero-emission rules, are accelerating the migration from internal combustion to electric power


Warehouse automation: Smart forklifts and telematics are reshaping buyer priorities


Reshoring and infrastructure investment: Driving demand across manufacturing and logistics


Regulatory Framework: OSHA and Safety Standards

The Occupational Safety and Health Administration (OSHA) regulates forklift operations under 29 CFR 1910.178—Powered Industrial Trucks. This standard is consistently one of OSHA's most frequently cited regulations.


Key OSHA Requirements


Operator Training and Certification (1910.178(l)) : Operators must be trained before use. Training must combine formal instruction (lecture, video, computer-based) and practical training (demonstrations and exercises), followed by an evaluation of operator performance in the workplace. Training must be truck- and site-specific. Employers must document training, evaluation dates, and trainers. Evaluations must be conducted at least once every three years. Training must be conducted by persons with the knowledge and experience to train operators and evaluate competence.


Daily Inspections (1910.178(q)(7)) : Forklifts must be examined at least daily before being placed into service.


Unattended Trucks (1910.178(m)(5)(ii)) : A forklift shall not be left unattended when the operator is 25 feet or more away.


Employer Duties: Employers must develop and implement a training program based on the general principles of safe truck operation, the types of vehicles being used, and the hazards of the workplace. Failure to comply can result in significant OSHA citations and penalties.


Major U.S. Forklift Manufacturers

The U.S. forklift market is served by a mix of domestic and global manufacturers, with the top five players (Toyota Material Handling, Crown Equipment, Kion Group, Hyster-Yale, and Raymond Corporation) holding approximately 45-50% of the North American market.


Toyota Material Handling North America – The market leader with over 15% market share. Known for high-quality products and innovative technology, offering electric, internal combustion, and pallet jacks.


Crown Equipment Corporation – A major U.S.-based manufacturer known for sit-down and stand-up forklifts and order pickers, with a strong focus on innovation and sustainability.


Hyster-Yale Group – A well-known U.S. manufacturer offering electric, internal combustion, and reach trucks, known for durable and reliable products.


Raymond Corporation – A trusted name in narrow aisle forklifts, pallet trucks, and order pickers.


Mitsubishi Logisnext Americas (MCFA) – A joint venture between Mitsubishi Heavy Industries and Caterpillar, manufacturing in Houston, Texas. MCFA has a network of more than 130 authorized dealerships with more than 250 locations across North, Central, and South America.


Other Major Players: Doosan Industrial Vehicle America, Komatsu America, Clark Material Handling, and UniCarriers Americas.


U.S. Forklift Manufacturing Facilities

Contrary to the perception that little is manufactured in the USA, the majority of forklifts sold in the country are domestically produced. States with forklift manufacturing sites as of 2024 include: Alabama, Illinois, Indiana, Iowa, Kansas, Kentucky, New York, North Carolina, Ohio, Mississippi, South Carolina, and Texas.


Linde Material Handling (Summerville, SC) – Since 1985, Linde has produced forklifts engineered for the unique demands of the North American market at its Summerville facility. The HT25T-HT35T series is designed, engineered, and manufactured in the United States.


Mitsubishi Logisnext (Houston, TX) – The notable exception to the rural manufacturing trend, this facility produces Caterpillar-branded and Mitsubishi forklifts.


Crown Equipment (New Bremen, OH) – A major manufacturing hub in the industrial heartland.


Clark Material Handling (Various locations) – Has a rich manufacturing history across multiple states.


Dealer Network and Distribution

The U.S. forklift market is supported by an extensive dealer network. Authorized dealerships provide sales, rentals, parts, service, and training across all 50 states.


Major Dealer Networks:


UniCarriers Americas: 130+ authorized dealerships with 250+ locations


Forklift-International.com: 150 dealer locations with over 10,000 equipment listings


Leavitt Machinery: 55+ locations across the U.S. and Canada


Dealer networks are continually expanding, with major brands adding new authorized dealers in key markets.


Industry Trends and Outlook

Electrification is the dominant trend. The traditional 60–40 split in favor of internal combustion trucks is rapidly shifting as electric models become more capable. Electric forklifts now represent approximately 63% of all forklift exports.


Automation is accelerating. Autonomous Mobile Robots (AMRs) and Automated Guided Vehicles (AGVs) are altering the future of warehouse automation, with the North American AMR/AGV market expected to grow at 12.5% CAGR. SLAM (Simultaneous Localization and Mapping) systems allow forklifts to operate without fixed infrastructure.


Safety Technology is advancing. Advanced sensor systems for obstacle detection and improved safety compliance are becoming standard features. Ergonomic controls, automatic braking, and load stability systems are advancing operator safety.


Service and Support are critical. 88% of purchasers rate after-sales support equal to equipment performance. Forklift-as-a-service subscription models are gaining traction in urban centers.


Challenges include grid-upgrade constraints and skilled-operator shortages, which are being addressed through battery-buffer systems, workforce training, and semi-autonomous functions.


The bottom line: The U.S. forklift industry is a $10.73 billion market governed by strict OSHA regulations under 29 CFR 1910.178. Major manufacturers include Toyota, Crown, Hyster-Yale, Raymond, and Mitsubishi Logisnext, with domestic production facilities across more than a dozen states. The industry is rapidly electrifying, with electric units capturing 60.55% of the market in 2025. Automation, safety technology, and service-oriented fleet contracts are reshaping buyer priorities. OSHA requires comprehensive operator training, daily inspections, and three-year performance evaluations. As e-commerce, manufacturing, and infrastructure investment continue to grow, the U.S. forklift market is projected to reach $27.07 billion by 2033.

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