Workplace Hazards in Warehousing & How to Improve Employee Safety

Workplace hazards exist across every occupation and industry. However, warehousing and logistics can be particularly dangerous for employees. Warehouses often have a variety of potential safety hazards including heavy pallets, forklifts, and flammable materials.

According to the Occupational Safety and Health Administration (OSHA), the warehousing industry has a disproportionately high accident rate and fatality rate compared to other employment sectors. The U.S. Bureau of Labor Statistics estimates that 5% of all warehouse workers will be injured on the job this year.

In this guide, we’ll cover the most common safety hazards faced by warehouse employees, OSHA safety guidelines, and best practices for improving warehouse employee safety.

What are the most common workplace hazards in warehousing?

A warehouse floor can be a dangerous work environment. There can be many different types of hazards, including heavy pallets, falling objects, and dangerous equipment.

A hazard assessment can help identify safety hazards that are unique to the types of workplaces your employees operate in. In general, here are a few of the most common safety hazards faced by warehouse workers:

• Forklifts: Forklifts are critical to warehouse operations. However, they can weigh up to 9,000 pounds—and when operated incorrectly, they can cause very serious injuries. OSHA estimates that forklifts are involved in 35,000 serious injuries and 62,000 non-serious injuries annually. Overturning is the most common cause, accounting for 25% of all forklift accidents. With increased safety training for forklift operators, OSHA estimates that 70% of forklift accidents could be avoided.

• Tripping, slipping, and falling: Pallets, cords, spilled inventory, and poor lighting can present a serious tripping risk to warehouse employees. All areas of the warehouse floor should be sufficiently lit, allowing employees to see potential tripping hazards in their work area. Make sure to mark spills with proper signage and clean up any slip hazards immediately.

• Falling objects: Inventory stored on high shelves or stacked precariously can pose a serious risk to worker safety. Employees should be trained on proper racking and lifting techniques and always wear appropriate PPE to help avoid serious injury in case of falling objects in their workspace.

• Loading docks: Loading docks can be loud, busy, and dangerous. Workers can fall through open dock doors, and forklifts can run off the dock and strike another person. Warehouse employees should be trained on loading dock safety guidelines to avoid preventable dock incidents.

• Conveyor equipment: Conveyors are often used to transport inventory. When not used properly, unguarded machinery such as conveyors can be a serious safety hazard to workers—including getting caught in the equipment. Poorly-maintained or faulty equipment can also be dangerous, especially for lone workers who may not have someone nearby to help.

• Manual lifting and material handling: Injuries are often caused by ergonomic hazards, such as improper manual lifting and poor posture. Failure to follow safety guidelines, such as proper lifting techniques, can lead to sprains, strains, and torn muscles.

• Chemical hazards: Some warehouse employees may need to handle hazardous materials, such as certain chemicals and solvents, as part of their jobs. Without proper handling, storage, and disposal, these hazardous materials can cause adverse health effects including skin irritation and breathing problems, especially when handled in confined spaces. Employees handling hazardous or flammable materials should be regularly trained on proper handling guidelines and the use of appropriate PPE to avoid adverse effects.

• Physical hazards: Physical hazards are hazards within the work environment that can harm employees without them touching anything. Physical hazards in warehouses can include loud noises, carbon monoxide, and even asbestos exposure.

• Fire hazards: Some of the most common fire hazards within warehouses include electrical equipment, flammable liquids, and even cigarettes. Electrical hazards such as frayed cords or improper wiring can also be a serious fire risk. Employees should be educated on how to minimize these safety risks, and sprinkler or fire suppression systems should be inspected regularly.

What safety protocols does OSHA require to minimize warehouse safety hazards?

The Occupational Safety and Health Administration (OSHA) is the arm of the federal government responsible for the implementation of workplace health and safety guidelines. OSHA regulations are meant to help create safer work environments and working conditions for employees by identifying and minimizing common workplace hazards.

Since OSHA first introduced workplace safety guidelines in 1970, the number of occupational fatalities in the U.S. has declined by 60% and the number of workplace-related injuries and illnesses has decreased by 40%. This shows how effective OSHA guidelines can be when followed properly.

But what safety rules does OSHA require for warehouses specifically? Warehouse operations fall under OSHA’s general requirements. Here are some of the most important OSHA requirements to be aware of for employee safety:

• Personal protective equipment (PPE): Employers are responsible for not only supplying appropriate PPE to warehouse workers but also ensuring they know how to use it properly. Educating employees on the correct use of PPE, such as hard hats and gloves, should be part of any warehouse safety training program.

• Hazard communication: An official hazard communication (or “hazcom”) program is necessary for any warehouse that handles hazardous materials, including biological hazards and chemical hazards, so employees understand the risks and how to protect themselves.

• Fire safety: Warehouses employing 10 or more employees should have an official fire prevention plan that is kept updated and available for reference. Fire extinguishers and sprinklers should be unobstructed and inspected regularly.

• Emergency action plan (EAP): In case of a fire or other emergency, warehouse operators should have an emergency action plan (EAP) that details the actions employees should take, including emergency exit routes.

• Fall protection systems: As part of OSHA’s requirements for walking and working surfaces, fall protection systems should be in place for warehouse employees working at heights (such as on elevated platforms).

• Lockout/tagout procedures: Any warehouse that uses energized equipment must have clear lockout/tagout (LOTO) procedures for ensuring that equipment is properly turned off. LOTO protocols help prevent employees from being electrocuted or otherwise harmed by energized equipment.

How can you improve warehouse employee safety?

Although warehouses can be a dangerous place, you can protect employees by implementing the proper training, procedures, and technology to minimize safety hazards. Here are a few warehouse safety tips to consider when creating or reinvesting in your safety program:

• Mitigate common workplace hazards on the warehouse floor: Safety starts with creating a safe work environment. Consider doing a risk assessment to identify potential safety hazards unique to your warehouse, such as chemical hazards, biological hazards, or electrical hazards. 

• Train employees on common safety hazards and how to avoid them: Safety training is essential—but it must be frequent and engaging to be effective. Provide regular training on appropriate PPE use, ergonomic hazards, and other potential risks to remind employees about important safety guidelines that are easy to forget.

• Ensure you have 360° visibility into what’s happening across the warehouse floor: Warehouse management is made more difficult by the sheer scale of a warehouse floor. With employees spread across hundreds or even thousands of square feet, it’s challenging to know what safety hazards might cause the next serious incident. But visibility is key to safety—and that’s where cameras can help. Warehouse cameras can help you monitor high-risk areas for unsafe activity and ensure safety standards are being followed. Warehouse cameras can also be incredibly helpful for safety training. You can use real footage of near misses to coach warehouse employees on real-life safety hazards, helping reinforce safe practices and avoid serious injuries in the future.

• Leverage digital forms and checklists to improve employee safety: Forms and checklists are commonly used to track compliance with OSHA safety protocols. However, requiring employees to fill out these forms manually can be time-consuming and error-prone. Using a digital forms solution to streamline form management, organizations can ensure data accuracy, enhance operational efficiency, and improve warehouse employee safety.

Minimize workplace hazards & improve warehouse employee safety with Samsara

To ensure OSHA compliance and reduce workplace hazards, modern organizations are leveraging digital forms solutions like Samsara Connected Workflows. A digital forms solution allows organizations to easily digitize custom forms, unlocking improvements across safety and efficiency. Some benefits of digital forms include:

• Digitize paperwork: Easily digitize paper-based forms for any site operation, enabling workers to complete them accurately and on the go. 

• Resolve issues faster: Reduce manual work with pre-populated data from your assets, proactive alerting, and collaborative issue resolution. 

• Consolidate data: Consolidate operations data in one unified platform and unlock insights to proactively prevent accidents. 

If you’re curious about how Samsara can help you minimize workplace hazards and improve employee safety, reach out for a free demo or trial today.