HEALTH AND SAFETY

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Warehousing
A guide to health and safety
This short guide is to help those involved in warehousing and storage to reduce
the number of injuries and cases of occupational ill health. It contains simple advice
that you should be able to apply.
Causes of accidents.
The main causes of accidents in warehousing and storage are:
manual handling;
slips and trips;
work at height;
vehicles in and around the warehouse; and
moving or falling objects.

Manual handling
People suffer from work-related aches and pains in the warehousing and storage
industry, including problems such as lower back pain and neck pain. The biggest cause of
back injury at work is lifting or handling objects incorrectly. There are some steps that must
be followed in order to prevent injury and avoid back pain.
1.The lift must be planned and assessed in advance in case you require help from a
colleague not to injure yourself. The necessity of resting the load mid-way can also present
itself in which case you need to ensure you have a bench or a table nearby.
2.Keep the load close to your body for as long as possible while lifting so you can see
over it and since the distance of the load from the body increases considerably the effort put
on your spine and could have severe consequences.
3.Make sure the position you are in the moment of the lift is a stable one. Your feet
should be apart with one leg slightly forward to maintain balance (alongside the load if it's on
the ground).
4.Do not bend your back while lifting and avoid twisting your body in any way.
5.Keep your head up and look ahead when handling the load.
6.Try to move as smoothly as possible and know what your limits are.
The activities that involve manual handling are picking up and
putting down objects, pushing and pulling objects and carrying
objects.
You must always remember that you need to keep the loads close
to your body at all times.
The main purpose of a manual handling risk assessment is to
reduce or even eliminate the risk of hazard.
If a load is to heavy or bulky you must always get a mechanical help or somebody to help
you. You should not always pull a trolley and when it comes to team lifts, one person should
be in charge.
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People suffer from work-related aches and pains in the warehousing and storage industry,
including problems such as lower back pain and neck pain.
If there is a risk from a manual handling task, try to avoid the task first. If the task cannot be
avoided, the risk of injury occurring must be minimised.
Carry out a manual handling assessment for manual handling operations and tasks that
present a risk of injury. Consider:
the task;
the load;
the working environment;
individual capability; and
other factors.

Good handling technique for lifting

Here are some practical tips, suitable for use in training people in safe manual
handling. In the following section a basic lifting operation is taken as an example.
Think before lifting/handling. Plan the lift. Can handling aids be used? Where
is the load going to be placed? Will help be needed with the load? Remove
obstructions such as discarded wrapping materials. For a long lift, consider
resting the load midway on a table or bench to change grip. By using the natural pivot points
when lifting and lowering you are only taking the weight of an item when you have to, this
makes the task safer and easier.

Keep the load close to the waist. Keep the load close to the body for as long
as possible while lifting. Keep the heaviest side of the load next to the body. If a
close approach to the load is not possible, try to slide it towards the body
before attempting to lift it.

 Adopt a stable position. The feet should be apart with one leg slightly forward
to maintain balance (alongside the load, if it is on the ground). The worker
should be prepared to move their feet during the lift to maintain their stability.
Avoid tight clothing or unsuitable footwear, which may make this difficult.

Get a good hold. Where possible the load should be hugged as close as
possible to the body. This may be better than gripping it tightly with hands only.
Start in a good posture. At the start of the lift, slight bending of the back, hips
and knees is preferable to fully flexing the back (stooping) or fully flexing the
hips and knees (squatting).

Dont flex the back any further while lifting. This can happen if the legs begin to straighten
before starting to raise the load.
Avoid twisting the back or leaning sideways, especially while the back is bent. Shoulders
should be kept level and facing in the same direction as the hips. Turning by moving the feet
is better than twisting and lifting at the same time.
Keep the head up when handling. Look ahead, not down at the load, once it has been held
securely.
Move smoothly. The load should not be jerked or snatched as this can make it harder to
keep control and can increase the risk of injury.
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 Dont lift or handle more than can be easily managed. There is a difference between what
people can lift and what they can safely lift. If in doubt, seek advice or get help. To reach
items above head height use the correct access equipment and always try to work at shoulder
height.
Put down, then adjust. If precise positioning of the load is necessary, put it
down first, then slide it into the desired position.

Good handling technique for pushing and pulling

Here are some practical points to remember when loads are pushed or pulled.
Handling devices. Aids such as barrows and trolleys should have handle heights that are
between the shoulder and waist. Devices should be well maintained with wheels that run smoothly
(the law requires that equipment is maintained). When purchasing new trolleys etc, ensure they are
of good quality with large diameter wheels made of suitable material and with castors,
bearings etc which will last with minimum maintenance. Consultation with your
employees and safety representatives will help, as they know what works and what doesnt.
The SOP, Risk Assessment and Trolley Code have the information on how to safely move a
trolley.
Force. As a rough guide the amount of force that needs to be applied to move a load over a flat,
level surface using a well-maintained handling aid is at least 2% of the load weight. For example,
if the load weight is 400 kg, then the force needed to move the load is 8 kg. The force needed will
be larger, perhaps a lot larger, if conditions are not perfect (e.g. wheels not in the right position or
a device that is poorly maintained).
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The operator should try to push rather than pull when moving a load, provided they can see over it
and control steering and stopping.
Slopes. Employees should enlist help from another worker whenever necessary if they have to
negotiate a slope or ramp, as pushing and pulling forces can be very high. For example, if a load
of 400 kg is moved up a slope of 1 in 12 (about 5), the required force is over 30 kg even in ideal
conditions - good wheels and a smooth slope. This is above the guideline weight for men and well
above the guideline weight for women.
Uneven surfaces. Moving an object over soft or uneven surfaces requires higher forces. On an
uneven surface, the force needed to start the load moving could increase to 10% of the load
weight, although this might be offset to some extent by using larger wheels. Soft ground may be
even worse.
Stance and pace. To make it easier to push or pull, employees should keep their feet well away
from the load and go no faster than walking speed. This will stop them becoming too tired too
quickly.
If a tracker coach will observe that you are using incorrect manual handling techniques, he
will stop you, demonstrate the correct technique to you and ask you to demonstrate it back to
them and to ensure you are competent in the technique.
General risk assessment guidelines
General risk assessment guidelines.
There is no such thing as a completely safe manual handling operation. But working within
the following guidelines will cut the risk and reduce the need for a more detailed assessment.

Figure 2 Lifting and lowering

Use Figure 2 to make a quick and easy assessment. Each box contains a guideline weight
for lifting and lowering in that zone. (As you can see, the guideline weights are reduced if
handling is done with arms extended, or at high or low levels, as that is where injuries are
most likely to occur.)
Observe the work activity you are assessing and compare it to the diagram. First, decide
which box or boxes the lifters hands pass through when moving the load. Then, assess the
maximum weight being handled. If it is less than the figure given in the box, the operation is
within the guidelines.

 If the lifters hands enter more than one box during the operation, use the smallest weight.
Use an in-between weight if the hands are close to a boundary between boxes.
The guideline weights assume that the load is readily grasped with both hands and that the
operation takes place in reasonable working conditions, with the lifter in a stable body
position.
Twisting
Reduce the guideline weights if the handler twists to the side during the operation.
As a rough guide, reduce them by 10% if the handler twists beyond 45, and by 20% if the
handler twists beyond 90.

Frequent lifting and lowering

The guideline weights are for infrequent operations - up to about 30 operations per hour where the pace of work is not forced, adequate pauses to rest or use different muscles are
possible, and the load is not supported by the handler for any length of time. Reduce the
weights if the operation is repeated more often. As a rough guide, reduce the weights by 30%
if the operation is repeated once or twice per minute, by 50% if the operation is repeated five
to eight times a minute, and by 80% where the operation is repeated more than 12 times a
minute.
The right order in which you need to lift a load is to assess the weight of the load being lifted,
bend at the knees, maintaining the back`s natural posture and hold the load close to your body
at all times.

Slips and trips

Slips and trips can be a problem in the warehouse environment that can happen at any
time but that can also be easily avoided.
A contaminated floor must be dealt with immediately. Also the recommended
footwear should help reduce slips that is why you must follow the dress code the warehouse
is enforcing.
Trips are usually caused by what is called a trip hazard that happens when the floors
and the traffic routes are not free from obstructions. Good housekeeping is important and by
paying attention and inspecting the workplace regularly you can also make it happen; this
way you avoid any kind of tripping hazard.
Slip and trip accidents are a serious problem in warehousing and storage and can happen
anywhere. They are often seen as trivial and just one of those things, but most slip and trip
accidents can be avoided.
Slips
Slips usually happen because the floor is wet or contaminated. Within warehouses,
water, oil, cleaning products, dry powders and foodstuffs can all make the floor more
slippery. Other items, like stretch wrapping, label backing and plastic bags, can also cause
slips. Try to stop the floor getting contaminated, eg by maintaining equipment properly.
When contamination does happen, deal with it immediately, eg by cleaning. Most floors have
good slip resistance when they are clean, dry and level. However, smooth floors that become
even a tiny bit wet or contaminated will be slippery; the rougher the floor, the better it will
cope with water and other contamination and the less likely someone is to slip.
The right footwear can help reduce slips but only consider issuing footwear to control slip
risks as a last resort try to eliminate the root of the problem first.

Trips
Objects on the floor or uneven surfaces are usually the cause of trips. Trip hazards
can include items like goods, waste packaging, banded strapping loops and pallets.
Plan workflows and storage to make sure that goods, equipment and waste do not
cause obstructions or project into places where people may walk. Keep floors and
traffic routes free from obstructions. Check that floor surfaces are even both inside
and outside buildings and fill in any holes. Provide good lighting. Good housekeeping is
important; if items fall onto traffic routes, clear them as soon aspossible.
Also inspect the workplace regularly to make sure that there are no trip hazards.

Moving objects
Mechanical handling
Mechanical handling equipment (eg a fork-lift truck) should be suitable for the job
it is used for. All industrial truck operating areas should be suitably designed and properly
maintained.
When working on site with Mechanical Handling Equipment, never walk under or over the
forks, always keep the safe designated distance away from operating MHE and never walk
past a piece of MHE in use without the permission from the driver.
Industrial truck operators need to be trained by a competent person. Operator
training should include the following three stages:
basic training;
specific job training; and
familiarisation training.

Storage systems
Storage areas should be properly designated and clearly marked. The layout of
storage and handling areas should avoid tight corners, awkwardly placed doors, pillars,
uneven surfaces and changes of gradient.
Inspect pallets each time before use to make sure that they are in a safe condition.
Take damaged pallets out of use for repair or destruction. Handle empty pallets carefully do
not drag or throw them about. Pallets should be loaded correctly to ensure load stability;
banding, shrink or stretch wrap can help with this.
If you use pallet racking in your warehouse, make sure the pallets you use are suitable for
the type of racking you have. Racking systems should be properly designed and installed, this
includes being able to safely take the load of the goods being stored. Protect racking if it is
likely to be struck by lift trucks and other vehicles.
Inspect racking regularly to make sure it is repaired and maintained properly and is
safe.
You should use three types of inspection:
immediate reporting of damage and defects;
visual inspections at regular intervals; and
expert inspections carried out at intervals by a competent person.
Where you find damage that affects the safety of the racking system, offload the racking
and introduce controls to prevent it being used until remedial work has been carried out.

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Reporting accidents and incidents at work

RIDDOR is the law that requires employees and other people in control of work premises
to report and keep records of:
work-related accidents which cause death;
work-related accidents which cause certain serious injuries (reportable injuries);
diagnosed cases of certain industrial diseases; and
certain dangerous occurrences (incidents with the potential to cause harm).
Reporting certain incidents is a legal requirement. The report informs the enforcing
authorities (HSE, local authorities and the Office for Rail Regulation (ORR)) about injuries,
occupational diseases and dangerous occurrences, so they can identify where and how risks
arise, and whether they need to be investigated. This allows the enforcing authorities to target
their work and provide advice about how to avoid work-related deaths, injuries, ill health and
accidental loss.
Dangerous occurrences are certain, specified near-miss events (incidents with the potential
to cause harm.) Not all such events require reporting. For example:
the collapse, overturning or failure of load-bearing parts of lifts and lifting equipment;
plant or equipment coming into contact with overhead power lines;
explosions or fires causing work to be stopped for more than 24 hours.
Boxes that are stacked safely on a pallet will never be a near miss.
At work everybody is responsible for Health and Safety. The first thing you need to do if
there was an accident and someone was injured is to report it immediately to a First Aider.
Employers must report diagnoses of certain occupational diseases, where these are
likely to have been caused or made worse by their work.
These diseases include :
carpal tunnel syndrome;
severe cramp of the hand or forearm;
occupational dermatitis;
hand-arm vibration syndrome;
occupational asthma;
tendinitis or tenosynovitis of the hand or forearm;
any occupational cancer;
any disease attributed to an occupational exposure to a biological agent.
To help prevent accidents you should see the Risk Assessments and Standard Operation
Procedures. In that way you ensure that you`re working in a safe manner.
Employers are responsible for ensuring that employees receive immediate attention if they
are taken ill or are injured at work. Accidents and illness can happen at any time and first aid
can save lives and prevent minor injuries from becoming major ones. Employers must report
all the accidents. A Safety Rep or a Team Leader will always be prepared to assess your
concerns about health and safety.
Upon hearing the fire alarm first you should do is evacuate immediately via the nearest fire
exit. If the fire exit is blocked, unblock it, if possible, and then report it to your Line Manager.
Fire fighting equipment on site (E.g. Fire extinguishers) can be used only by trained people
and authorised to do so.

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Safety Attitude
We've talked about many different safety procedures that can prevent injury and accidents
in a warehouse. There's one more, which is all-important. That's your attitude. No matter how
good the protective equipment and how strict the rules, you can't be safe unless you make
safety a priority. You should always make sure your PPE(Personal Protective Equipment) is
properly maintained, report faulty equipment to a team leader and wear it where and when
you are supposed to.
You have to take it seriously and use the equipment and procedures. You also have to use
your common sense. For example:
Pay attention to warning signs and signalsand obey them.
Watch where you're going; work is no place for daydreaming.
Walk, don't run. You'll get there almost as quicklyand more importantly, you'll get
there.
Hand tools and materials to other people; don't throw them.
Don't fool around; there are too many potential hazards here to allow horseplay.
If you have an accident / near miss / see a potentially dangerous Health & Safety hazard on
site you must report it immediately to your Line Manager.
Under health and safety law, employers are required to report and keep a record of certain
injuries, incidents and cases of work-related disease. Keeping records helps employers
improve the quality of the first aid provided to you and it is also necessary for the insurance
company in case of a work-related claim.

Packing and Unpacking

You also have to be aware of hazards and safety procedures when you pack and unpack
containers. Any cutting tool demands caution. Hold and use it in a manner that won't cut you
or someone else. On site or in the warehouse the type of knife should only be used is a safety
knife.
Don't leave an open blade on the floor or any surface where it creates a hazard.
Take care with metal and plastic strapping, too. If it whacks you in the face or eyesor
anywhere else, for that matteryou'll regret it. Always wear heavy gloves and goggles when
you attach or remove strapping.
Use cutting tools that don't leave sharp edges. If you're doing packing, be sure to put the
straps on with just the right tensionnot too loose or too tight. Don't lift by the strap unless
it's designed for that purpose. When you remove the straps, use one hand to hold down the
strapping and one to cut. Make sure that the sharp strapping end will go away from you when
you cut. Once the straps are cut, place them immediately in a trash container so they don't
hurt someone while lying on the floor. All the waste packaging should be disposed of
immediately in the correct way.

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Wrap-up
The warehouse is not a dangerous place, but it does contain many potential hazards. We
don't want to get so caught up in getting materials moved in and out that we forget to do it
safely. Fortunately, the safe way to run a warehouse is also the most efficient way. So
following safety rules and guidelines isn't just a legal requirementit's good sense.
Good housekeeping is one of the best ways to assure warehouse safety. We have to keep
the entire warehouse clean and neat, with everything in its place. The housekeeping on your
site is everyones responsibility.
Don't block aisles or leave materials around for someone to trip or fall over. Don't place
items on shelves or racks or ladders so unsteadily that they might fall on someone below.
Wear necessary protective gear and pay attention to warning signs and to the work that's
going on around you. Give the right of way to forklift trucks and even hand trucks. Operate
material handling equipment carefully; watch where you're going and keep your loads stable
and secure. When you lift and carry, do it properly so your legs do the worknot your back.
Preview every job before you start to make sure your equipment is in good condition and
that you are properly protected. Don't forget to alert others around you to tasks that could put
them in danger.
In other words, every day, all day, pay attention to what's going on around you and
precautions that will keep you and others safe.

Assessment guide for lifting operations

Load weight/frequency

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 Hand distance from the lower back

Observe the task and examine the horizontal distance between the operatives
hands and their lower back.

Vertical lift region

Observe the position of the operatives hands at the start of the lift and as the lift progresses.

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 Torso twisting and sideways bending

Observe the operatives torso as the load is lifted.

Assessment guide for carrying operations

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 Hand distance from the lower back

Observe the task and examine the horizontal distance between the operatives
hands and their lower back.

Asymmetrical torso/load
The operatives posture and the stability of the load are risk factors associated with
musculoskeletal injury.

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Assessment guide for team handling operations

Load weight

Hand distance from the lower back

Observe the task and examine the horizontal distance between each operatives
hands and their lower back.

Vertical lift region

Observe the position of the operatives hands at the start of the lift and as the lift
progresses.

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Warehouse Signs

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MANDATORY SIGNS:

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PROHIBITION SIGNS:

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FIRE SIGNS:

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WARNING SIGNS:

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SAFE SIGNS:

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