1

1 Title:
2 "Assessment on Worker Safety in Material Handling in a Cold Storage Warehouse"
3
4 Abstract
5
6 Worker safety in cold storage warehouses is an essential concern, especially in regions
7 with tropical climates like Cebu, Philippines, such facilities play an integral part in preserving
8 temperature-sensitive perishable goods. The study assesses worker safety in material handling in
9 a cold storage warehouse and the risks and hazards encountered and experienced by workers in
10 Cebu, Philippines. Influenced and adapting aspects mentioned in related literature, from different
11 countries and regions, the study assesses cold storage environmental risks, hazards, discomforts
12 and health effects, manual labor risks, mishandling and damaged goods, Absence of preventive
13 measures and worker safety. A quantitative approach was utilized and the data gathered was
14 through a Likert scale survey given to workers involved in material handling processes. Results
15 have indicated that the cold environment in the facility has a moderate hazard, which is related to
16 unmanaged working hours, limited visibility, and productivity problems. Workers also
17 experience discomforts such as numbness and sensory discomfort, indicating slightly elevated
18 health risks. Preventive measures and training programs are perceived to be present based on
19 worker response. Mishandling incidents have moderate impacts that lead to deadstock or
20 unsaleable goods. Manual labor risks remain relatively low but outliers mention slippery surfaces
21 and repetitive motion injuries. Overall the findings underscore the need for some targeted
22 interventions to enhance worker safety in cold storage warehouses in Cebu, Philippines, to ideal
23 conditions, which may emphasize the importance of tailored safety measures, comprehensive
24 training programs, and proactive risk management strategies to mitigate hazards and promote
25 worker well-being.
26
27 Keywords: Worker safety, Cold storage warehouses, Material handling, Cold Environment risks
28 and Hazard s, Discomforts and Health effects, Manual labor risks, Mishandling & Damaged
29 goods, Absence of Preventive measures & Training, (Cebu, Philippines), Likert scale survey.
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33 I. Introduction
34
35 A cold storage warehouse is a facility that stores goods at freezing temperatures. In the
36 tropical country of the Philippines, cold storage warehouses can be helpful for companies that
37 deal with food products that are perishable goods and are temperature-sensitive. Moreover,
38 working in this environment comes with concerns for safety and well-being, from cold-related
39 discomforts to manual work-related risks and hazards and possible chemical and compound
40 exposures that could affect work in material handling, increasing the frequency of accidents and
41 creating more costs for the company. According to Wahab et al. (2021), it is essential to
42 determine what causes mishaps in worker safety so that they can be prevented in the future,
43 minimizing harm, illness, and cost to the company. Furthermore, maintaining employee health
44 and well-being in cold storage is crucial for maintaining productivity, safeguarding reputation,
45 adhering to regulations, and mitigating risks. This study will assess worker safety in material
46 handling of a cold storage warehouse.
47
48 Cold storage warehouses maintain their temperatures at 10 to -30 degrees Celsius below
49 freezing, as stated by Mecalux (2022). Cox (2021) noted that working in cold environments is
50 challenging for workers. Further pointing out that human bodies regulate their temperature
51 depending on the conditions, trying to stay at 37 degrees Celsius and working in temperatures
52 below 10 degrees Celsius can have health effects and injuries. These risks include frostbite,
53 hypothermia, colds, and severe cases such as tissue damage, asthma, arthritis, heart conditions
54 and an increased rate of accidents. Subjecting workers to cold environments may affect the
55 workflow due to the cold conditions. Thetkathuek et al. (2014) uncovered that workers exposed
56 to the cold in the warehouse in Thailand experienced symptoms associated with musculoskeletal
57 effects, respiratory problems, and symptoms affecting cardiovascular health, along with other
58 general discomforts. Douglas (2017) and Mecalux (2021) point out that cold storage
59 environments can limit employee working time due to unfavorable effects and conditions
60 reducing the flow of labor. A study from Pakistan by Ghani et al. (2020) also described
61 symptoms associated with working in a cold storage environment and a decline in worker
62 performance in concentration and motivation observed in the groups of workers with prolonged

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63 exposure to cold temperatures. To add to the concerns of the cold environment, Gonzales (2021)
64 listed the diverse discomforts that workers may experience when working in a cold facility, from
65 numbness in the hands, feet, cheeks, nose, and ears to the extremes of frostbite or hypothermia
66 the former could lead to loss of limbs, permanent injury or disability, and the latter could lead to
67 fatality. Cold chain warehouses commonly use ammonia-based refrigeration. Inhalation of
68 ammonia and contact with the skin is a severe risk to workers, according to the Occupational
69 Safety and Health Administration (OSHA) of the USA, and according to the Centers for Disease
70 Control and Prevention (2023), people who survive exposure to ammonia can suffer long-term
71 effects in their lungs and eyes. This environment comes with concerns for safety and well-being,
72 from cold-related discomforts to manual work-related risks and hazards and possible ammonia
73 exposures that could affect work in material handling, increasing the frequency of accidents and
74 affecting overall workflow in material handling. Leonardo and Noroña (2021) and Zhan et al.
75 (2022) both stated that manual labor in cold storage has several health and injury risks, with
76 frequent use of heavy equipment, exposure to the cold environment, damp or slippery surfaces,
77 and accidents like trips and falls, overexertion of the body, and cold-related discomforts.
78 Conventional cold storage warehouses and unrefrigerated warehouses that rely on manual labor
79 and heavy equipment may create an environment prone to mishandling, damaged products, and
80 safety risks. According to Kamali (2019), mishandling and negligence resulted in accidents and
81 damage to the finished goods cold storage, which proved costly over time. Damaged goods due
82 to mishandling create deadstock or unsaleable stock. Jenkins (2021) states that it increases cost,
83 possible loss of opportunity to profit or break even, and less inventory space in warehousing.
84 Ware and Fernandez (2014) state that the manual handling process can present risk factors, such
85 as the body posture of workers and the frequency of handling the goods, in addition to their
86 respective weights. Dicarlo (2023) also Highlighted two concerns about repetitive motion
87 injuries (RSIs) resulting from the repetition of physical actions or movements when handling and
88 moving goods that are heavy or for a prolonged period without adequate rest and hazards
89 associated with material handling equipment and the dangers related to misuse, improper lifting
90 techniques, and excess loads, that result in falling materials and collapsing loads. In the USA, the
91 OSHA safety standards for warehousing, under the categories of hazards and solutions,
92 equivalently listed and mentioned hazards workers may encounter in the warehouse from the
93 previously cited studies, refrigerated warehousing being a distinct category within the

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94 warehousing safety standards, as cold storage warehouses operate at below-freezing

95 temperatures, creating unique risks and hazards for workers.
96
97 In the reviewed literature, working in a cold storage warehouse can impact worker health
98 and safety. The intertwining of the risks and hazards attributed to the cold environment of the
99 warehouse and manual labor may need further assessment to adequately understand and enhance
100 worker safety and reduce accidents in material handling. The reviewed literature was either for a
101 specific country or place or in a generalized context. There may be a need to conduct a study
102 here in the Philippines or in the local setting, considering the scarcity of information and public
103 data relating to worker safety, worker discomforts, and hazards in material handling and
104 conventional material handling methods that frequently lead to issues like mishandling, product
105 damage, and workplace accidents, data that may be useful to the local setting (Cebu,
106 Philippines). It is also necessary to consider workers not accustomed to constant low
107 temperatures and their ability to adapt to cold storage environments what they experience when
108 working in cold storage warehouses in a predominantly hot and tropical country.
109
110 There remains a notable gap in the local literature regarding worker safety in cold storage
111 warehouses and how it affects workers in the local environment who are not used to extreme
112 cold. This study seeks to fill this gap by choosing and adapting specific safety concerns, work-
113 related hazards, and workplace accidents faced by workers in cold storage warehouses and
114 assessing them in the local setting from the perspective of workers with the considerations of
115 their ability to adapt to cold storage conditions. By using a descriptive approach, we aim to
116 provide a comprehensive assessment of work-related hazards and health concerns such as those
117 highlighted by Thetkathuek et al. (2014), Ghani et al. (2020), Gonzales (2021), the (OSHA,
118 USA), and manual labor risk, human errors, and accidents, highlighted by Leonardo and Noroña
119 (2021), Zhan et al. (2022), Kamali (2019), Ware and Fernandez (2014), Dicarlo (2023) that can
120 be applied and adapted to the challenges faced by workers in cold storage warehouses in the
121 local setting (Cebu, Philippines). Based on the assessment results, the researchers will contribute
122 to the scarce pool of knowledge and data in the country and aid future studies related to the topic,
123 and the development of tailored safety measures and training programs to ensure the well-being
124 and productivity of workers in the local setting (Cebu, Philippines).

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125
126

127

128 II. Conceptual Framework

129 The study establishes itself on the theory that the cold environment of a cold storage
130 warehouse, accompanied by its risks and hazards, its discomforts and health effects, manual
131 labor risk, mishandling, and the presence or lack of preventative measures and training, can
132 affect worker safety in material handling, in the local setting (Cebu, Philippines).

133 Previous studies highlighted the impacts of cold temperatures on worker performance and
134 safety risk. Furthermore, these studies pointed out that prolonged exposure to cold conditions
135 may pose significant risks to worker health and the frequency of accidents. Moreover, it also
136 addresses the risk of ammonia-based refrigeration and its long-term effects on the human body.
137 And how mishandling creates damages, costs, accidents, manual labor risk, and improper
138 practices that may affect the human body and lead to more problems for the warehouse. The
139 body of knowledge offered insights that helped develop the theory and helped the researchers
140 adapt it appropriately in the context of the local setting (Cebu, Philippines).

141 These are the concepts and their variables, chosen, categorized and adapted from the
142 reviewed literature, that may be useful in a study to be conducted here in the local setting (Cebu,
143 Philippines):
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145 Cold storage environment, Risks and hazards. The cold environment can have various risks
146 and dangers that include exposure to cold conditions, ammonia or hazardous chemical or
147 compound exposure, slipping and falling due to slippery surfaces, and limited visibility or
148 eyesight, all of which contribute to the overall safety assessment of a cold environment.
149
150 Discomforts & Health effects. Factors that contribute to discomforts and health effects in cold
151 environments include numbness and sensory discomfort, cold-related health risks like frostbite
152 and hypothermia, long-term health effects caused by prolonged exposure to cold, and possible
153 respiratory and cardiovascular problems due to cold conditions.
154
155 Manual labor Risk. The risk factors involved with manual labor, mishandling and negligence,
156 risks associated with manual material handling in a cold environment, utilization of material
157 handling equipment, and repetitive motion/strain injuries (RSI) or musculoskeletal effects.
158
159 Mishandling & damaged goods. This assessment involves evaluating the rate of product
160 damage caused by mishandling in cold environments, evaluating dead stock resulting from such
161 damage, assessing the financial impact through mishandling cost, and considering how inventory
162 space availability is affected by mishandling.
163
164 Absence of preventive measures and training. It includes safety protocol compliance, training
165 programs to educate workers on proper material handling in cold environments safely, the usage
166 of protective gear, and emergency response preparedness among workers to prevent accidents
167 and health issues.
168
169 Worker Safety. It includes variables such as the rate of injury, the frequency of accidents, the
170 availability of safety equipment and personnel, the severity of accidents, and the frequency of
171 reporting these incidents.
172
173 These concepts and variables are well-suited to assess worker safety, risk and hazards,
174 and accident frequency in the local setting. By studying these variables, the study can gain

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175 insight into what workers experience when working in material handling processes in cold
176 storage warehouses.
177
178
179
180
181 III. Methodology
182
183 The study will utilize a quantitative research method, a survey collecting data from
184 workers in a cold storage warehouse in the local setting (Cebu, Philippines). The approach
185 chosen is similar to a study by Hofstra et al. (2018), Assessing and Facilitating Warehouse
186 Safety, utilizing a quantitative method and Likert scale to gather and interpret the data. The
187 researchers will record the data collected with the consent and anonymity of the respondents
188 involved, and the location or company will also not be explicitly stated within the study or
189 results to maintain confidentiality. Moreover, this study will use a 6-point Likert Scale. Through
190 the questionnaires given, the respondents will identify their level of agreement on a 6-point scale,
191 namely 1 (strongly disagree) to 6 (strongly agree. (1) is the lowest level of agreement, while (6)
192 indicates the highest level of agreement with the items or questions provided. Furthermore, there
193 will be a total of 60 respondents to the survey questionnaires who are involved in the material
194 handling processes, namely strippers, checkers, pickers, and forklift operators. Results will then
195 be analyzed, and based on the average means score each category, if it falls within a certain
196 range, will be given an interpretation representative for the category.
197
198 IV. Results and Discussions

199

RESULTS INTERPRET
CATEGORY MEAN SD
(N=58) ATION
Cold Cold
Environment Environment MODERATE
1.0 3.22 0.94
and its Risk Degree of HAZARD
& Hazards: Hazard
2.0 Discomforts Level of 3.07 0.92 SLIGHTLY
and Health Health Risk ELEVATED

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HEALTH
Effects: Level
RISK
Absence of Presence
Preventive /Absence of PROBABLY
3.0 2.30 1.12
Measures & Preventive PRESENT
Training: Measures
Manual Degree of
4.0 2.56 0.80 LOW RISK
Labor Risk: Labor Risk
Mishandling Mishandling
MODERATE
5.0 & Damaged and Damage 3.05 1.15
IMPACT
Goods: Effect
Degree of
Worker MODERATE
6.0 Worker 2.92 1.11
safety RISK
Safety
COLD
HAZARD
Degree of
AND MODERATE
OVERALL Worker 2.85 0.79
WORKPLAC D RISK
Safety
E SAFETY
LEVEL
200 Legend

201 Category 1.0.

202 The cold environment and its risk and hazards, the degree of hazard yielded a mean score of 3.22
203 with a standard deviation of 0.94 based on the responses of the 58 participants, based on its mean
204 its indicates that there is "Moderate hazard" within the facility, the outliers contributing to its
205 score are, item no. 1 stating that working hours in the cold storage warehouse is not managed or
206 exceeds a set limit accumulating a mean score of 3.55, a highly elevated concern among the
207 participants, item no. 4 states there is limited visibility due to the cold conditions, is a concern,
208 with a mean score of 3.45, and item no. 6 states that the extreme cold slows down work, with a
209 mean score of 3.38, a study by Thetkathuek et al. (2014) from Thailand found that the average
210 working hours of warehouse workers or material handlers were 8 hours or more per day, the
211 majority of which (83%) work six (6) days per week with an average overtime of 3.48 hours per
212 the study also uncovered that the warehouse workers or material handlers had many abnormal

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213 symptoms, including repeated pain in the musculoskeletal system, disturbances felt by their
214 bodies, respiratory effects, and symptoms in their fingers due to cold exposure in p though they
215 did not touch upon limited visibility or if the cold exposure slowing down work nevertheless, if
216 not mitigated long-term or unmanaged exposure to the cold may lead to discomfort and even
217 health effects.
218 Category 2.0.
219 Represents the Discomforts and health effects workers encountered while working in a cold
220 storage warehouse, with a mean score of 3.07 and a standard deviation of 0.92 indicating that
221 there is a "Slightly elevated risk" present within the facility, contributing factors for the score are
222 concerns underscored by the outliers, item no. 2 states that workers experience numbness in parts
223 of their body and sensory discomfort while working, with a mean score of 3.67, an elevated
224 concern among the workers, item no. 1 asks if respiratory health or cardiovascular health is
225 negatively affected by the cold working conditions, with a mean score of 3.40, item no. 4 asking
226 if workers believe that working in the cold storage warehouse may lead to long-term health
227 effects generating a mean score of 3.31. The study by Ghani et al. (2020) in Pakistan found that
228 the respondents experienced and observed pain, discomfort, stiffness and the numbing of the
229 hands while working in the cold environment of a cold storage warehouse, 62% experienced
230 numbness, 45% experienced pain in their fingers, and 51% experienced stiffness. The study also
231 observed the colouration of the fingertips tips of the workers and found that 65% had blue
232 fingers and a significant 80% had red or purple fingers, attributing to a circulatory disturbance or
233 a sign of frostnip and frostbite and noted that it may be due to improper protection of the hands
234 and feet to the cold. Additionally, Ghani et al. (2020) and Thetkathuek et al. (2014) found
235 respiratory problems or symptoms from their participants resulting from cold exposure, though
236 not mentioning long-term health effects did find adverse health effects experienced by the
237 workers. Addressing the concerns may help the workers by mitigating the same problems
238 workers experience in Pakistan and Thailand.
239 Category 3.0.
240 The presence or absence of preventive measures & training when working in the cold storage
241 warehouse yielded a mean score of 2.30 with a standard deviation of 1.12. Its mean indicates that
242 the preventive measures & training are “Probably Present” within the facility. The outliers
243 contributing to its score are, item no.3 with a mean score of 2.40 states that the workers cannot
244 consistently follow the safety protocols established for material handling in the cold storage
245 warehouse, item no.1 with a mean score of 2.34 asking if signages are not set up clearly to
246 protect workers from risky and hazardous areas and item no.6 with a mean score of 2.29 asking
247 if workers are not encouraged or reminded to prioritize safety in their work. The study by Wahab
248 et al. (2021) agrees that safety training and education are vital in teaching safe attitudes and
249 providing feedback on the effectiveness of current safety procedures. This study puts importance
250 on workplace safety and health programs and those for accident prevention included in safety
251 training. Prevention can be carried out successfully when employees understand better the work's
252 potential hazards and risks because having preventive measures and training can contribute to a
253 low accident rate in the warehouse.
254 Category 4.0.

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255 The degree of manual labor risk when working in the cold storage warehouse yielded a mean
256 score of 2.56 with a standard deviation of 0.80. Its mean shows that there is “Low Risk” when it
257 comes to working within the facility. The outliers contributing to its score are, item no. 6 with a
258 mean score of 3.22 states that there are slippery surfaces in the facility that can cause accidents,
259 item no.1 with a mean score of 2.74 indicating if workers experience repetitive motion injuries
260 (RSI) or musculoskeletal effects that are a significant concern to the workers, and item no.5 with
261 a mean score of 2.71 asking if falling heavy loads are a common occurrence in the day to day
262 labor. A study by Leonardo & Norona (2021) proves that one of the most challenging aspects is
263 to incorporate ergonomic concerns to safeguard their workers' health and avoid potential risks
264 that come with manual activities at work. This study shows that risk exposure of a worker to
265 accidents and injuries is related to a series of improper movements made by the workers when
266 doing jobs such as material handling of heavy loads, transitioning between different activities at
267 irregular intervals, executing only one function or movement for an extended duration, and
268 sudden lifting of loads.
269 Category 5.0.

270 Mishandling & Damaged Goods encountered by material handlers working in a cold storage
271 warehouse. The degree of effects yielded a mean score of 3.05 with a standard deviation of 1.15
272 indicating that there is a "Moderate Impact" effect within the facility, the outliers contributing to
273 its score are, item no.3 stating that mishandling incidents have created a significant volume of
274 deadstock, with a mean score of 3.47, item no.2 stating that mishandling has led to deadstock or
275 unsaleable in the warehouse, with a mean score of 3.38, and item no.1 states that damaging
276 goods in the cold storage warehouses is a common occurrence, with a mean score of 3.09. A
277 study by Kamali (2019) concluded that recent accidents and harsh treatment have damaged
278 finished products and raw materials. According to reports, the cost of damaged materials has
279 increased due to inappropriate techniques, outdated materials, and improper equipment.
280 However, moving, sorting, counting, stocking, and preparing materials for storage or shipment
281 requires time and effort from the employees to evaluate and if possible, make amends to reduce
282 the loss of revenues due to rejected stocks that are detected by the machines.

283 Category 6.0.

284 The Worker Safety of the workers in a cold storage warehouse. The degree of safety yielded a
285 mean score of 2.92 with a mean score of 1.11 based on the responses of 58 participants
286 indicating that there is "Moderate Risk" present within the facility, the outliers contributing to its
287 score are, item no.5 stating that a minor injury from work is a common occurrence, with a mean
288 score of 3.55, item no.4 stating that when accidents happen, they tend to lead to injuries, with a
289 mean score of 3.07, and item no.6 states that near miss accidents tend to happen frequently, with
290 a mean score of 3.00. According to Kamali (2019), the material handling equipment (MHE) used
291 in operations is changing and new machines are usually used more efficiently with modern
292 technologies. In addition, MHEs with an automated warehouse also become more efficient in
293 terms of safety procedures which allows, as stated, to reduce accidents and dangerous situations
294 in the warehouse.

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295 Overall, the cold hazard and workplace safety level accumulated a mean of 2.85 suggesting that
296 the respondents perceive a “Moderate risk” in the cold storage warehouse, associated with
297 unmanaged working hours, workplace environment hazards, productivity issues due to cold,
298 general cold discomforts and health effects, and surprisingly concerns of frequent mishandling
299 creating unsaleable stocks or deadstock. The standard deviation overall is 0.79 indicating some
300 variability, suggesting that while the average perception leans towards moderated risk, there are
301 differing opinions among the respondents.

302

303

304 V. Conclusion

305 Based on the local respondents' perception in (Cebu, Philippines), the company's degree
306 of cold hazards and workplace safety in the cold storage environment is scored and determined
307 to be at moderate risk and indicated noteworthy cold environment hazards and health and safety
308 risks that affect the workers in material handling in the cold storage warehouse. While the overall
309 perception of the degree of hazard in the cold storage environment is at moderate risk, there are
310 also noteworthy variations in the workers' responses to the specific risks and hazards stated in the
311 questions during the survey, interpreted to be low to more moderate, or sometimes considerably
312 higher than the most common answers for each of the categories. The variations indicate a
313 complex interplay of factors influencing the worker's responses, from the level of awareness,
314 their individual experience, the effectiveness of preventive measures and training and a
315 reluctance to address the concerns. These safety concerns underscored are related to unmanaged
316 or excess working hours, general workplace hazards, issues in productivity that have led to
317 discomfort and health effects because of the frigid conditions of the facility, and the presence of
318 mishandling incidents that may cause labor and safety risk and cost to the company.

319 Although the findings are not as severe or indicative of any more prominent problems or distress
320 found in other related studies from different localities, the concerns uncovered may lead workers
321 to experience more severe discomforts, health effects and accidents if left unresolved.
322 Furthermore, the findings underscore the need for comprehensive cold risk and hazard
323 management measures and strategies to safeguard workers' safety and well-being. Addressing
324 issues related to the cold work environment and its risks and hazards, cold discomforts,
325 mishandling incidents and damaged goods may improve the overall safety level to a lower risk or
326 ideal conditions for the workers of the company or any other cold storage warehouse here in
327 (Cebu, Philippines).

328

329 References:

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330 Ammonia: Exposure, Decontamination, Treatment. (2023, February).

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