Warehouses are busy places. The combination of people, materials, and machines in constant motion means that tasks get completed quickly, but it also increases the chance of hazards. By being educated about the most common warehouse risks, workers can stay safe on the job.
1. Forklift Hazards
Powered industrial trucks, commonly known as forklifts or stand-up forklifts, are some of the most dangerous pieces of equipment in a warehouse, especially when workers are not properly trained.
One major issue is understanding how forklifts operate. Accidents are more likely to occur when operators don’t know load limits, safe turning practices, or how to move the vehicle forward and backward.
- Workers can be struck by moving forklifts
- Loads can become unbalanced
- Forklifts can tip or roll-over
Another concern is equipment maintenance.
- Faulty brakes or steering can lead to crashes
- Hydraulic issues can cause forklift mass to drop
Prevention:
- Train all operators thoroughly, taking into account conditions on specific sites
- Inspect equipment regularly
- Follow load limits and make sure materials are balanced
- Safely and strategically utilize automation when possible
2. Injuries Related to Ergonomics and Material Handling
Repeated lifting and moving of items can put strain on the body, and over time, this can result in injuries. They often develop slowly but can become serious in the long term.
Some common issues include:
- Back strain from lifting heavy boxes
- Shoulder and arm injuries from repeated movements
- Musculoskeletal injuries from over exertion
This type of cumulative trauma can put workers out of commission for extended periods, so it’s important to address ergonomic issues early, before they get worse.
A survey of corporate executives by Liberty Mutual Insurance found that every $1 invested in safety, especially ergonomics, brings roughly $4 in return.
Prevention:
- Train workers on safe lifting techniques
- Rotate job tasks to reduce repeated strain
3. Racking and Storage Failures
Though warehouse racks and shelving are specifically designed to accommodate heavy loads, they can still fail if they get overloaded or damaged.
Some common warning signs include:
- Shelves that are bending or bowing
- Visible damage from forklift impacts
- Loads that exceed the rack’s weight limit
Ignoring these issues increases the risk of a collapse, which can injure workers and damage equipment.
Prevention:
- Label load limits on racks
- Inspect racks regularly and replace when damaged
- Install barriers to protect racks from forklifts
4. Slips, Trips, and Falls
Slips, trips, and falls are some of the most common warehouse injuries. They are usually caused by clutter, poor organization, or lack of cleanup.
Common hazards include:
- Broken pallets or loose materials on the floor
- Plastic wrap, trash, or debris in walkways
- Blocked or crowded work areas
Loading docks can also create fall risks, especially when no truck is present and there is an open drop.
Prevention:
- Keep floors clean from trash and spills
- Keep walkways clear from things like cardboard boxes and broken pallets
- Encourage workers to stay aware of their surroundings
- Establish and enforce good housekeeping protocol
5.Heat Stress
Heat stress is a serious health hazard, especially in warehouses that don’t have air conditioning. When workers perform physical tasks in high temperatures, the body can be affected quickly, with heat stress and illness coming on faster than expected.
Severe cases of heat stress can lead to heat stroke, a condition where the body is no longer cable to cool itself. Heat stroke can be fatal, so it’s important to intervene as soon as possible.
Prevention:
- Provide workers with water, regular breaks, and access to shaded areas
- Train workers to recognize warning signs of heat stress
- Allow new workers time to acclimate to the heat
- Educate workers on an emergency response plan
For more in-depth information, read the SHES post about heat safety on the job and watch our new heat safety videos Safety Tips for Mitigating Heat Illness, Exhaustion, Stroke
A Proactive Approach to Safety
Most warehouse accidents can be prevented. Prioritizing safety protects employees and allows operations to run smoothly and efficiently.
SHES and GaMEP are offering free warehouse safety training courses funded by a Susan Harwood grant. These one-hour and four-hour sessions are being offered onsite to private employers and employees from small and medium-sized businesses and to the general public at chosen locations throughout Georgia.
Schedule a company training or check for updates on upcoming training sessions here.
Authors: Trey Sawyers, M.S., SHES Health and Safety Consultant, and Bogna Grabicka, Ph.D., Project Manager for Safety and Sustainability at GaMEP