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Warehouse workers face many hazards. Nearly 144,000 American warehouse workers experienced injuries severe enough to require time off work in 2021-2022, according to the U.S. Bureau of Labor Statistics. These incidents highlight serious risks caused by improper storage, shelving, and racking practices, which can lead to crushing injuries and death. Fortunately, many of these incidents are preventable. Through smart design, proper planning, and thorough training, these workplace hazards can be greatly reduced. The following tips can help keep warehouse workers safe from injuries related to shelving and racking:
1 Regularly inspect shelves and racks to prevent collapse.
Monitor shelves and racks to make sure they are safe and secure. Install rack upright guards — usually bolted to the floor — to prevent damage from forklifts. Block off the area immediately if you find any damage, and fix safety issues before injuries occur.
2 Ensure proper storage practices.
Stack materials straight and evenly on a level surface to prevent sliding or collapse. Use interlocking rows with cross-ties or block materials like plywood sheets between the layers when stacking loose or unboxed materials. Place heavier items closer to the floor for stability. Secure the materials with banding, cross-ties, or shrink wrap to prevent spreading or tilting. Keep aisles clear to avoid tripping, fires, or pests.
3 Manage height and load distribution.
Never overload shelves beyond their weight limits. Make sure the weight is evenly distributed on racks to keep them stable. Mark maximum stacking height with paint or tape on walls or posts.
4 Follow conveyor safety rules.
Regularly check conveyors for safety and ensure pinch points are protected. Train workers on proper lockout/tagout procedures for maintenance or repairs. Provide good lighting around conveyor areas.
5 Maintain handling equipment.
Regularly maintain pallet jacks, forklifts, and other mechanical equipment to ensure proper functioning. Ensure elevators and hoists have enough aisle clearance and proper signage. Keep floors in good condition so equipment can move safely.
6 Address visibility hazards.
Ensure employees can see clearly when moving around the warehouse. Look for things that block visibility, like pallets at the ends of rows and near pedestrian walkways. Use floor tape to mark boundaries between stacked materials and aisles. Ensure aisles, loading docks, and doorways have enough space for safe movement.
7 Provide proper training.
Train workers on safe loading and unloading of shelves and racks. Teach about techniques for lifting and operating material handling equipment safely. Ensure all employees know emergency procedures and the location of safety equipment.
For more information on warehouse shelving and racking safety, review OSHA’s Materials Handling and Storage publication, or contact an Occupational Safety and Health Consultation (OSHCON) Program safety professional for free onsite or virtual help to ensure your warehouse practices meet or exceed OSHA standards: 800-252-7031, option 2.