Term 9 Safety in

Warehouses
Dr. Mohamed Zakaria

Youssef Mohamed Mustafa 4820

Abdelrahman Mahmoud ElAswad 4751

Mohamed Ahmed Awad 5001

Abdullah Aly Issa 4915

Abdelrhman Gaber Khamis 4824

Table of Contents:

Introduction 2

Common Warehouse Injuries 2

Warehouse Safety 4

Personal Protective Equipment (PPE) 4

Handling and Movement 6

Vehicle Safety 11

Fire Safety 13

Natural Risks 18

Warehouse Signs 21

Recommendation 24

References 24

1
Introduction:

Safety in warehouses is one of the major concerns facing warehouse managers and
their employees. This worry arises from the warehouse industry workers suffering
many injuries and fatalities, with an average of 19 fatalities per year for years 2015
to 2018. This number can be brought down drastically if safety in warehouses is
treated as a priority. In this report, we will discuss the common warehouse injuries
employees suffer and the safety measures to avoid these injuries in the warehouse.

Common Warehouse Injuries:

The first step to create a safer workplace is to analyze common warehouse injuries
and their causes. The following are the most common causes of injuries:

- Heavy Equipment Accidents

The leading cause of injuries in warehouses are heavy equipment such as
forklifts and heavy pallets. It might also cause fatalities. There is a risk of
employees being hit or run over by forklifts, falling between the trailer and
the lift, or even falling from a high platform. These types of accidents
usually occur due to a warehouse being crowded, inadequate forklift safety
trainings, or simply unfortunate incidents.
- Slips, Trips, and Falls
Most injuries in a warehouse are caused by slips, trips, and falls. Such
accidents happen due to slippery floors, uneven floors, accumulation of
debris, grease, residue, or cords lying in walking areas.

2
- Exposure to Chemicals
Warehouses can be used to store hazardous chemicals or can use them for
production purposes. Accidents can happen in the form of spills or leakages
which are harmful to warehouse employees.
- Being hit by Falling Objects
Stacking items in shelves can always be a huge risk as these items can fall at
any point. These unfortunate accidents are caused by human errors or by
incompetent operations setup.
- Machine Entanglement
The most dangerous injury in a warehouse can happen due to machine
entanglement. This happens when workers get entangled with dangerous and
huge equipment while working.

The shoelace is trapped under the wheels of a trolley

3
Warehouse Safety:

To avoid the mentioned injuries above, a safety plan should be implemented and
perfectly executed where several safety tips should be followed. Safety tips
include:

Personal Protective Equipment (PPE)

Employees need to wear personal protective equipment in the warehouse to protect

them in any incident. Risks needs to be assessed in a warehouse to determine
which type of PPE the employees would need. Examples of PPE include:

− Head Protection Protects against head injuries and should be worn

whenever there is risk of falling objects.
− Eye and Face Protection Safety glasses, goggles or full-face shields
may be required based on the type of operation.

4
− Hearing Protection Protects the ear from noise and vibration that may
cause hearing loss. Ear plugs are most used, however, depending on the
operation.
− Respiratory Protection Masks provides basic protection from inhalation
of airborne substances. Respirators are required when working in the
presence of toxic airborne substances and hazardous materials.
− Torso Protection High visibility clothing such as vest, polo-tops,
singlets and jackets are required when working on low-light
situations. Aprons provide protection from hazards such as chemical
splashes.
− Hand Protection Gloves protects the hands from harmful substances and
temperature extremes. It helps prevent cuts and lacerations, puncture
injuries and burns.
− Foot Protection Safety shoes and boots provides protection against
falling or rolling objects, or objects that could pierce through the sole of
your foot. It also prevents slips and trips from occurring.

5
Handling and Movement

• Safety from Slips, Trips, and Falls

To prevent slips, trips, and falls:
− Ensure that employees always clean up spillages, keep paths free of
obstructions, keep cables tidied away, etc.

Clear pathways and aisles should be maintained within the warehouse

− Schedule cleaning outside of working hours to decrease risk on

employees. Also, make sure cleaning staff put out the appropriate
warning signs while working.
− Use anti-slip paint that prevents accumulation of dust, reduce slip of
floor surfaces, and reduces wear and tear.
− Use anti-slip tapes and shoes. Anti-slip tapes are used for areas where
paint can not be used, while anti-slip shoes help workers stay safe
when they encounter a slippery floor.

6
− Ensure floor levels are even as uneven floors can lead to people losing
their footing. This is dangerous particularly for workers carrying a
load.
− If cables are needed to run across the floor, make sure they are
covered to prevent trips and to protect the cables in case vehicles run
over them.
− Employees should be trained to safely work at heights. Ladder safety
is one the most important things as its misuse or using an unstable
ladder can lead to serious injury and sometimes death. Workers
should not use a ladder for more than 30 minutes and when they do,
they should always maintain three points of contact. (two feet and one
hand).

7
• Warehouse Walkway requirement
− The safety standard for the minimum walkway width in a warehouse is 1.2m
to maintain the safety of workers.
− 1.2m allows two people to walk past each other side by side safely.
− Use anti-slip paint to guide the workers to the permitted walkway in order
not to be injured.

Painting guides for walkways

8
• Minimizing Lifting Risks
Warehouse staff usually perform lifting activities either manually or with the
assist of machinery, which can cause a serious injury if not performed
safely. To prevent any lifting-related injuries, the following steps should be
taken:
− Operators should be familiar with the maximum safe working load. This
is usually printed on equipment or included in the manufacturers’
instructions. Following this instruction is important to prevent strain,
which might cause the load to fall off or the equipment to wear down.
− Employees should be trained in manual handling safety. They should be
familiar with their manual handling weight limits (around 20 kg for most
people) and the techniques to properly handle objects to minimize strain.
− Employees should avoid manual lifting as much as possible and should
instead use lift trucks, trolleys, pallet trucks, etc.
− Chains should be properly used and stored to prevent metal fatigue,
bending or rusting. Also, they should be inspected regularly for issues.

Operator traveling with load lowered Do not travel with the load elevated

9
• Handling of environmentally hazardous substances
Any warehouse should be following the proper laws and regulations when
dealing with hazardous substances:
− Make sure all hazardous substances are stored correctly.
− Make sure all hazardous substances are labelled correctly.
− Isolate substances if required.
− Follow the correct procedures when dispensing materials.
− Use appropriate safety equipment.
− Have emergency plans in place.
− Dispose hazardous wastes appropriately according to the laws.
− Conduct regular safety inspections.
• Pallets and Racking Safety
In warehouses, the staff loads and unloads pallets on racking either by hand
or with the assist of machinery. These tasks should be carried out safely to
prevent pallets being dropped on people, affect the stability of racking, or
damage to other equipment.
− Staff should be trained to load pallets safely by using a stretch
wrapping to support pallets and follow an appropriate stacking pattern
according to the manufacturer recommendation.
− Staff should follow the safe stacking height and weight capacity as
recommended by the manufacturer. Ensure even stacking with heavier
pallets on the bottom.
− Pallets should be inspected by staff before use as they should not
include any loose nails, splinters, cracks, or any issue.
− Warn the staff not to lean on, climb, or walk over pallets or racking.

10
 − Ensure staff use suitable equipment to reach higher shelves like
ladders and not pallets or forklifts.

Vehicle Safety

Vehicle safety, whether it is forklifts or lift trucks, are of paramount importance to

prevent impact or crush injuries. To maintain vehicle safety:

− Only the employees who received practical training can drive vehicles.
Also, they should be above the age of 18.
− Make sure employees follow speed limits. Signs can be used to warn
them not to exceed speed limits.

Stop signs posted to regulate Observe all posted speed limit

− Set up one-way routes to ensure employees avoid reversing so that they

can always see where they are going. If drivers need to reverse, always
make sure they have someone to watch over them to avoid running over
anybody. Also, set up side mirrors to maximize drivers’ vision when
maneuvering around corners or reversing.

11
 Operator's clear view of work

− Remind employees working on the warehouse floor to look both ways

when they leave an aisle.
− Enforce a zero-tolerance policy for dangerous driving.
− Make sure to keep aisles free of obstruction.
− Maintain the vehicles regularly to avoid any issues.
− Keep the drivers informed to do daily checks.
− Maintain the floors to prevent any damage to vehicles.
− Put warning labels on a powered industrial truck showing actions to take
in the event of a tip over.

Instructions in case of a tip over

12
Fire Safety

When fires in warehouses do occur, they almost

always have devastating consequences. This is
because difficulties often arise when trying to
control and extinguish fires at the initial stage, even
when automatic fire-extinguishing systems are
installed throughout the warehouse.

The variable factors that have a significant

effect in causing a fire are:

- Late discovery of the fire.

Results of a fire in a perfume warehouse
- Rapid fire spread.
- Inadequacies in storage space layout and design.
- Lack of categorization.
- Bad housekeeping.
- A disproportionate amount of stored goods.
- Generation of a high level of toxic fumes and gases.
- Absence of automatic sprinklers.

Ignition sources

• Fuel (e.g., paper, cardboard, or petrol).

• Oxygen (air).
• Energy (e.g., flame, sparks, or lightning).

Risk of having plastic material

stored near lighting

13
Safety against electrical fire risk

- Goods must be stored at least 1meter from any lighting or heat-producing

source (an air heater, a ventilation fan, a blow torch etc.…).
- Introduce predictive maintenance to prevent fires due to the existence of
electrical installations in poor condition This includes carrying out thermal
imaging (thermography) at least once a year.

Thermal imaging analysis of a main switchboard

- The battery-charging area must be free of ignition sources and well

ventilated.
- Necklaces, bracelets, watches, or any other metallic objects which could lead
to short-circuits or sparks must not be worn during battery handling and
charging operations.

14
Safety against Other fire risk

- Lighters or live flames must not be used to check charging levels.

Sparks from filing processes can be propelled a considerable distance

- Creating specific smoking areas and forbid smoking

elsewhere.
No-smoking signs must be displayed.
- If the warehouse contains a high-risk product (for example, paint, oils, or
aerosols) in a small quantity in relation to the overall products stored, it is
recommended that this product is isolated and given specific protection.
External storage as shown in the figure below or confinement using
segregation devices or partitions providing at least one hour’s resistance to
fire is advisable.

Ideal external storage arrangement

15
- The aisles and corridors separating goods width depends on the foreseeable
seriousness of possible fires, but in general terms, aisles of 2.4 meter will
suffice.

2.4m
mmm

- A separation distance of at least 60 cm should exist between the stored

goods and the walls of the building. This is particularly important if the
product expands when wet.
- Goods should not be stored so that they are higher than the lower part of roof
beams or too close to roof trusses.
- 1-meter separation distance exists between the highest storage point and the
sprinkler heads.
- Concentration of combustible materials must be avoided in areas used for
packing, unpacking, classification, and so on.
- The presence of a firewall between buildings as shown in the figure below or
different zones can prevent a fire from spreading from the roof of one
building to the adjacent building.

16
 A dividing wall separating two buildings

Safety of Fire protection system

- Test fire alarms and check smoke alarms weekly or at least monthly.
- Also, fire extinguishers and sprinklers should be inspected regularly.
- Fire escape routes, exits, and signs must be well-lit so people can see them
from a distance and escape safely.
- Automatic extinguishing systems. The best way to prevent a warehouse fire
from spreading is by installing sprinklers.
- For manual extinguishing equipment layout of the storage space and goods
must not involve an increase in the safe distances specified for manual fire
protection systems, which are as follows for any occupied area,
• 25 m to the nearest fire hose cabinet.
• 25 m to the nearest alarm button.
• 15 m to the nearest extinguisher containing suitable extinguishing
agents.

17
Ventilation

Good ventilation is a crucial part of a safe warehouse as limited air circulation

might cause stagnation of fumes and vehicle exhaust in the warehouse, which
affects both employee comfort and safety. Installing exhaust fans can help ensure
the warehouse is well ventilated.

Natural Risks

Natural forces cause natural risks that leads to losses. The size of the losses
depends on the intensity of the natural phenomenon, construction methods, and the
protection methods against this type of disaster. Even though these types of
catastrophes occur rarely, their damage potential is quite massive. Natural risks are
caused by:

− Wind:
Strong winds can tear off roofs and collapse walls of the warehouse if they
were designed only as an enclosure to the structure without providing
resistance to excessive pressures or loads. Design regulations allow
calculation of the wind loads exerted on the building and its roofs. Factors
affecting design choices include the wind regime and the building’s location.
To avoid the roof being torn off, the design stage must contain sufficient
anchoring provision. Also, as a general construction rule, it is desirable to
utilize systems that distribute wind loads down to the foundation. Such
systems include the use of supporting or load-bearing walls as an example.
And to obtain a tougher enclosing structure without adding too much weight,
steel bar reinforcements can be used.

18
− Flooding:
Flooding resulting from heavy rainfall or other natural surface waterways
can cause the warehouse to collapse if its structure was not efficiently
designed to withstand such disaster. Other possible damages include leaks,
burst water pipes or drains, collapsing roofs, and damage to the stored goods
which can cost more than the building itself.
To prevent these damages from happening, warehouses should have sloping
floors, sloping roofs, and underground drainage to collect water.
Furthermore, to ensure goods are safe during a flooding, it is advisable to
place them in areas with the least exposure to such risk. For multi-floor
warehouse, goods should be stored on the upper floors and never in the
basements. Another way for storing goods to reduce water damage is to
place them on pallets, boards or blocks which keeps them at least 10 cm
above floor level.
Most damage to warehouses or goods can be prevented during heavy
rainfalls by periodic checks and proper maintenance of roofs, ceilings,
drainpipes, and drains.

− Lightning Strikes:
During storms, lightning can cause harm to person or damage to goods.
Damages due to lightning strikes can be in the form of fire and dangerous
sparks or damage to electronic equipment.
Considering the type of construction of a warehouse, its use, rate of
occupation, and activities performed in it, if the estimated strike rate is
higher than the acceptable level, a lightning protection system must be

19
installed. Lightning protection systems are based on intercepting the
lightning before it strikes a certain object so the current can pass to the
ground without causing harm to people or damaging goods. When installing
a lightning protection system, it is important to ensure that it will provide
adequate cover for warehouse protection.

Lightning protection system

20
Warehouse Signs:

The use of signs and stickers is the most cost-effective way of keeping warehouses
safe from hazardous situations. These help employees prevent serious injuries.
Furthermore, emergency exits, and routes should be clearly marked.

Sign Meaning
People here need to be wearing a
personal protective equipment.

The door swings outward 180 .

A necessary sign to ensure that all the

fire exits are kept clear.

21
 This place is allowable to park the
forklift.

Indication for the presence of first aid

kit.

To warn workers and people to be

away from any electrical panel at least
36 Inches.
It glows in the dark to be always
visible.

Means forklifts are not allowed to be in

this area.

22
 Provide a notice that this area is for
pedestrian activity only.

This area has a high voltage, and this

sign calls your attention to operations
or items that could be dangerous

To Keep the area in front of fire

extinguishers clear and not blocked to
make it easy to access during a fire
emergency.

This sign indicates welding areas to

call the attention of the workers and to
warn them of any dangers.
These areas could be provided also
with a sign of PPE

23
Recommendation:

Finally, we recommend the employer himself to undertake a high level of training,

that covers every essential safety topic in detail. Also, employees training in health
and safety is desirable. They should understand how to work with warehouse
equipment safely and be conscious of the different types of hazards in the
warehouse and how to minimize them.

References:

• Warehouse Safety: 10 Tips to Keep Your Employees Safe (cyzerg.com)

• Warehouse Safety Procedures | 40 Top Tips | High Speed Training
• Warehouse Risk Management: Is Your Facility Secure? (clearrisk.com)
• cubierta_almacenes_ingles (mapfrere.com)
• What is Floor Marking? | Graphic Products
• Durable Warehouse Floor Signs and Safety Signage (asgonlinestore.com)

24