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Warehouse workers face many hazards, but proper design, planning and training can keep them safe.
Warehouses are a constant moving mix of people, vehicles and equipment. Forklift operators must be properly trained to ensure understanding of the working environment. This prevents injuries to operators and pedestrians and damage to other warehouse equipment (storage racks, stored materials, etc.).
Forklift Operations
- Only trained and certified workers may operate a forklift. (See 29 CFR 1910.178). No one under the age of 18 may use a forklift.
- Operators must be trained on the type of vehicle in use, and on workplace conditions.
- Before operating the vehicle, examine it for hazardous conditions which would make it unsafe to operate.
- Always wear a seatbelt, if available.
- Never exceed the rated load and ensure it is stable and balanced.
- Ensure you have enough clearance when raising, loading, and operating the vehicle.
- Follow safe procedures for picking up, putting down and stacking loads.
- Keep a safe distance from platform, ramp, and loading dock edges. Never back up a forklift to the dock’s edge.
- Watch for pedestrians and observe the speed limit.
- Slow down in congested areas and those with slippery surfaces.
- Use horns at cross aisles and obstructed areas.
- Do not give rides or use the forks to lift people.
- If required to park a vehicle on an uneven surface, set the emergency brake.
Other Considerations
- Maintain safe clearances for aisles and at loading docks or passages.
- Provide visual warnings near dock edges.
- Follow required procedures when refueling gas or propane fueled forklifts.
- Train workers on the hazards associated with the combustion byproducts of forklift operation, such as carbon monoxide.
Materials Handling
Safe storage and handling of material in warehouses is critical to preventing worker injury and property damage.
Storage and Handling
- Inspect and maintain shelving and racking to prevent collapse. If damage occurs, immediately isolate the affected area.
- Install rack upright guards to prevent damage from incidental forklift contact.
- Ensure materials stored on racks, shelving, and other storage devices do not create a hazard.
- Ensure bags, containers, bundles, etc. are stored in tiers that are stacked, blocked, interlocked and limited in height so that they are stable and secure to prevent sliding or collapse.
- Properly stack loose/unboxed materials to prevent falling hazards.
- Keep storage areas free from accumulation of materials that could lead to tripping, fires, explosions, or pest harborage.
- Place heavier loads on lower or middle shelves.
- Ensure that storage shelving and rack load capacities are not exceeded.
- See Ergonomics and Musculoskeletal Disorders, above, for materials handling hazards and solutions.
Conveyors
- Inspect conveyors regularly.
- Ensure that pinch points are adequately guarded.
- Develop procedures for locking out conveyors when necessary (e.g., when materials have fallen off or become jammed), and training workers in these procedures.
- Provide proper lighting and working surfaces in the area surrounding the conveyor.
Mechanical Handling Equipment
- Provide periodic maintenance of pallet jacks and fork lifts so they can operate with the minimum amount of hand, arm, and finger force.
- Ensure elevators and hoists for lifting materials are used with adequate safe clearances, no obstructions, appropriate signals, and directional warning signs.
- Ensure sufficient safe clearances in aisles, at loading docks, through doorways, and wherever turns or passage must be made.
- Mark boundaries of permanent aisles and passages where handling equipment is used to ensure proper clearance.
- Keep aisles and passageways clean and unobstructed.
- Keep floors well maintained (e.g. no ruts or bumps) to reduce force when using manual materials handling equipment and whole body vibration/shock from driven equipment.
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