Efficiency

Overlooked warehouse safety hazards and how to address them

By Rick Pedley

Photo: Sunan Wongsa-nga / iStock / Getty Images Plus

Forklift Incidents
    While forklifts (including order pickers and powered platform trucks) pose well-known risks in the warehousing industry, they remain a primary source of worker injuries due to their frequent operation in congested environments. In 2023, forklifts caused 67 work-related deaths and 24,960 injuries that resulted in days away from work, restricted work activity, or job transfer (DART).
    -overs account for 42% of serious forklift injuries, often caused by uneven surfaces, elevated loads, or sharp turns. Meanwhile, pedestrian collisions make up 36% of forklift-related fatalities, frequently occurring in blind spots or near stationary objects. According to OSHA, nearly 70% of these incidents are preventable, yet a persistent lack of accident awareness and safety training means many operators fail to exercise the caution these powerful machines demand.

Best Practices
    Ensure all operators are certified and receive regular refresher training, as required under OSHA standard 29 CFR 1910.178. This standard sets forth detailed requirements for the design, maintenance, and operation of powered industrial trucks (PITs), which include forklifts, tractors, platform lift trucks, and motorized hand trucks.
    Conduct daily inspections and remove unsafe equipment from service. Before each shift, operators should inspect brakes, steering, tires, forks, warning devices, and fluid levels. Any forklift found to be in unsafe condition must be tagged out and repaired before use.
    Designate clear traffic zones and pedestrian pathways. Warehouses should use floor markings, mirrors, and signage to separate forklift routes from pedestrian areas. Congested layouts and blind corners are common contributors to collisions and tip-overs.
    Outfit workers with high-visibility workwear for increased visibility in high-traffic zones. This simple measure can significantly reduce the risk of pedestrian collisions, especially in areas with limited sightlines or frequent forklift movement.

Slips, Trips, and Falls
    While slips, trips, and falls are common hazards across industries, they’re particularly prevalent in warehousing environments. The unrelenting interplay of people, vehicles, and equipment, combined with slick loading docks, cluttered aisles, uneven flooring, or poor lighting, makes warehouse workers particularly vulnerable. Even a quarter-inch change in floor level qualifies as a tripping hazard under OSHA guidelines.

Best Practices
    Follow OSHA’s Walking-Working Surfaces standard (29 CFR 1910 Subpart D). This regulation requires employers to maintain clean, dry, and hazard-free walking surfaces. It also mandates safe access and egress routes, regular inspections, and prompt repair of damaged flooring.
    Assign responsibility for promptly cleaning spills, removing clutter, and replacing worn mats or flooring. High-traffic areas, such as entrances, break rooms, and loading zones, should be inspected frequently.
    Install bright, unobstructed lighting in stairwells, aisles, and transition zones. Use temporary signage to mark wet floors or elevation changes. Remember to remove signs once the hazard is resolved to avoid desensitization.
    Finally, encourage workers to report hazards and near misses immediately. Quick reporting allows supervisors to address issues before they escalate. Whether it’s a wet floor, a loose pallet, or poor lighting, maintaining open and consistent communication and accountability helps reinforce a proactive safety culture across all warehouse zones.

Falling Objects
    In warehouses where vertical storage is essential, even small items dropped from height can cause severe injuries. Forklift impacts and PIT-related vibrations can dislodge unsecured goods from unstable racking systems, especially in high-traffic zones. Meanwhile, bent beams, missing safety clips, or corroded uprights can compromise structural integrity and increase the risk of collapse.

Best Practices
    Comply with OSHA’s General Industry Standards 29 CFR 1910.28 and 1910.29. These standards require employers to protect workers from falling object hazards using toeboards, screens, guardrails, and other physical barriers. Employers must also ensure proper training and regular inspections of elevated work areas and storage systems.
    Follow ANSI MH16.1 and RMI guidelines for load capacities, anchoring, and rack design. These are the primary safety standards for steel storage racks, which are referenced in building codes across the US.
    Install rack backing or netting to prevent items from falling into walkways. This added layer of protection helps contain loose goods and minimizes the risk of injury from falling tools, boxes, or equipment.
    Remember, load capacities are not just simple estimates. They must be calculated by a qualified design professional and take into account a variety of factors, including the strength of the steel components (beams, columns, bracing), the beam-to-column connections, and seismic considerations for the specific warehousing environment.

Ergonomic Injuries from Manual Handling

Repetitive manual handling tasks, such as lifting, lowering, pulling, pushing, and carrying, are leading causes of musculoskeletal disorders (MSDs). These injuries often develop gradually through repetitive strain, awkward postures, or overexertion, and can result in chronic pain, reduced mobility, and long-term disability. Unfortunately, these injuries often develop gradually and go unnoticed until they sideline workers.

Best Practices
    Use lift-assist devices, height-adjustable tables, and smooth-rolling carts to reduce strain. Store heavier items at waist level and lighter items higher to minimize bending and reaching.
    Educate workers on how to lift with their legs, avoid twisting, and recognize early signs of strain. Encourage prompt reporting of discomfort to prevent minor issues from becoming chronic injuries.
    Rotate tasks and schedule micro-breaks to reduce fatigue. Job rotation and short stretch breaks throughout the shift help prevent repetitive strain and improve overall musculoskeletal health.
    For more detailed guidance on safe lifting techniques, equipment use, and storage protocols, check out OSHA’s comprehensive material handling guidelines.

Airborne Hazards and Chemical Exposure
    Warehouses often contain a mix of dust, fumes, vapors, and gases that can pose serious health risks with prolonged exposure. In these fast-paced environments, diesel exhaust, packaging dust, and chemical off-gassing are often overlooked, potentially causing respiratory issues, skin irritation, and even long-term conditions like asthma or chemical sensitization.

Best Practices
    Comply with OSHA’s Hazard Communication Standard (29 CFR 1910.1200). This regulation requires employers to maintain Safety Data Sheets (SDS), label hazardous substances clearly, and train employees on chemical risks and protective measures. It also mandates that workers understand how to handle, store, and respond to chemical exposure incidents.
    Monitor air quality and implement engineering controls. Conduct scheduled air sampling to detect harmful concentrations of dust, fumes, or vapors and install local exhaust ventilation (LEV) systems near high-risk zones. Install fixed gas detectors or have workers wear portable gas monitors when necessary.
    Equip workers with NIOSH-approved respirators, gloves, and eye protection when handling hazardous substances. Ensure proper fit testing and training on PPE use.
    We recommend consulting workplace safety or atmospheric hazard experts to evaluate your facility’s unique risks. A tailored professional assessment can help reveal hidden risks and ensure your team’s safety.

Final Words
    Whether you're overseeing a sprawling distribution center or managing a tight-knit warehouse crew, creating a workplace where safety is prioritized and enforced requires consistent leadership and open communication. In addition to following OSHA protocols and providing proper PPE, conducting regular safety walkthroughs, toolbox talks, and worker-led safety audits can foster a shared sense of ownership.
    While the pressure to meet strict delivery schedules is pressing, so is the responsibility to ensure your team goes home safe.