Is Your Warehouse as Safe as You Think?

Warehousing is one of the highest-risk sectors in the UK, with over 7,000 injuries reported annually and ranking the third most common sector for fatal injuries. The warehousing sector is one of the most familiar areas we come across in businesses large and small; we look at the risks more closely.

Why is the risk so high?

The combination of vehicle movement, manual handling, and stored loads creates a complex and hazardous working environment. Every year, approximately 1,300 people are involved in forklift-related accidents in the UK. Contrary to what you might expect, it’s not the lift truck operators who are most at risk; it’s everyonearound them.

What are the relevant regulations?

In terms of safety legislation there are a number of regulations that apply within warehousing, some more obvious than others:

• Workplace (Health, Safety and Welfare) Regulations 1999
• Management of Health and Safety at Work Regulations 1992
• Provision and Use of Work Equipment Regulations 1999
• Lifting Operations and Lifting Equipment Regulations 1998
• Control of Substances Hazardous to Health Regulations 2002
• Working at Height Regulations 2005
• Manual Handling Regulations 1992

So, what are the main risks?

Slips, trips and falls: 31% of workplace injuries are due to poor housekeeping, obstructed aisles, spills and uneven surfaces

Manual handling: 30% of workplace injuries are due to lifting heavy or awkward loads, repetitive movements and poor lifting technique

Vehicle and forklift operations: 25% of workplace injuries are due to pedestrians being struck by vehicles, poor segregation, reversing and blind spots

Falling objects, including racking failures: 10% of workplace fatalities are due to poor stacking and collapse of racking due to damage, overloading or impact from forklifts

Vehicle collisions: 14% of workplace fatalities are the result of vehicle collisions including areas in the yard, loading and unloading, and maintenance activities

Other: alternative factors include driver fatigue, distraction and stress; poor vehicle maintenance; hazardous or unstable loads, and temperature-controlled environments such as cold stores.

How can we eliminate or reduce these risks?

Engineering controls: segregated pedestrian and vehicle routes, clearly marked walkways and aisles, safe racking systems with load limits, mechanical handling aids and adequate lighting

Management controls: creation of traffic management plans, routine inspections of vehicles, racking and equipment, clear housekeeping standards, risk assessments and audits

Training and compliance: operator training on the specific forklift trucks in use, manual handling training, inductions and refresher training, and awareness training for pedestrians

Safe systems of work: maintain clear aisles and emergency routes, enforce PPE use including hi-visibility clothing and safety footwear, regularly inspect and maintain equipment, control access to high-risk areas and monitor compliance with procedures

Warehousing presents multiple high-risk activities occurring simultaneously but most incidents are preventable with good planning and controls. Pedestrians are those most at risk, particularly around vehicles; by focusing on vehicle safety, manual handling and storage systems, you can significantly reduce injury rates and improve overall safety performance. Effective risk management in warehousing relies on robust systems, safe design and workforce competence, so inspection, segregation and training are critical.

We take a straightforward, supportive approach that focuses on real-world solutions rather than unnecessary complexity.

Managing workplace health risks properly protects your employees, supports your business reputation, and helps you operate with confidence.

To discuss your requirements, contact our Health & Safety team:
 healthandsafety@skaltd.co.uk
 01427 420 403

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