Free warehouse workplace safety assessment

Start with these task groups. Use one worksheet per task, and add any task this list misses.

• Receiving and unloading

  Trailer movement, dock edges, unstable loads and workers near vehicles.

• Forklift and vehicle movement

  Crossings, blind spots, reversing, visibility and people entering travel routes.

• Storage and racking

  Damage, falling stock, load changes and access for inspection.

• Order picking and replenishment

  Reaching, lifting, repeated handling, ladders or elevated equipment.

• Packing and dispatch

  Cutting tools, repeated movements, congestion and handling loads.

• Battery charging or fueling

  Chemical contact, electrical hazards, ignition and task instructions.

• Conveyors and maintenance

  Moving parts, unexpected startup, access and energy control.

• Cleaning and shift changes

  Spills, temporary storage, reduced visibility and changing traffic patterns.

5. 5

   Chemical hazards

   Battery electrolyte, leaking freight, cleaning products and propane cylinders: product identification, safety data sheets, ventilation, spill response and eye or skin contact.

6. 6

   Lifting and repeated strain

   Repeated case picking, reaching into low pallet positions, lifting above shoulder height and pushing loaded carts or pallet jacks across dock plates.

7. 7

   Noise and vibration

   Conveyors, sorters, dock plates and forklift traffic that mask warnings, plus vibration during long periods of driving over uneven warehouse floors.

8. 8

   Heat, cold and physical agents

   Hot trailers during unloading, uncooled picking areas, freezer rooms and transitions between cold storage and warm docks during a shift.

9. 9

   Biological hazards

   Pest droppings in stored stock, mold on water-damaged cartons, contaminated returns and discarded sharps found while handling waste or cleaning restrooms.

10. 10

    Fire and emergencies

    Cardboard and pallet buildup, battery charging, propane storage, blocked exit routes and stock placed too close to sprinkler heads.

11. 11

    Confined or restricted spaces

    Compactor chambers, dock pits and storage bins entered for cleaning or repair: evaluate access, trapped energy and any atmospheric or engulfment hazards before entry.

12. 12

    Violence and lone work

    Isolated receiving doors, overnight security rounds, disputes with visiting drivers and workers opening or locking the warehouse alone.

13. 13

    Work organization and contractors

    Delivery peaks, picking targets, temporary staff, shift handovers and maintenance contractors sharing aisles with active vehicle routes or automated equipment.

14. 14

    PPE and exposure-control gaps

    Foot protection for pallet handling, gloves for sharp packaging, high-visibility clothing near vehicles and eye or face protection for battery tasks.

15. 15

    Additional job-specific hazards

    Anything pickers, packers, forklift operators or visiting drivers raise that this list misses, such as new freight, changed rack layouts or seasonal overflow.

Consider eliminating or substituting the hazard first, then suitable engineering controls, administrative arrangements and PPE. The right combination depends on the job and the requirements that apply to it; PPE alone does not resolve every risk.

1. Elimination — remove the hazard or the task that creates it.
2. Substitution — use a less hazardous material, product, method or piece of equipment.
3. Engineering controls — separate people from the hazard with guards, barriers, ventilation or layout changes.
4. Administrative controls — change how the work is done through procedures, scheduling, instruction, signs and supervision.
5. Personal protective equipment (PPE) — protect each worker with equipment chosen, fitted and maintained for the task.

Ideas to discuss for this workplace:

• Review whether the packing or picking station can be moved to reduce pedestrian crossings.
• Consider suitable physical separation and a traffic plan for the site with the people responsible for vehicle movement.
• Verify the change during delivery peaks and shift changes. Keep forklift authorizations, examinations and rack-capacity decisions in their own processes.

For each action, record the hazard, the people exposed, existing controls, the additional action, its priority and the basis for it, the responsible role, a target date, verification evidence and any remaining questions. Do not close a finding just because a document was created.

Describe shifts, handling equipment, storage layout, receiving peaks and manual handling tasks. Bring worker concerns, traffic plans, equipment records and recent changes. Include temporary agency workers and visiting drivers in the review where relevant.