Warehouse Safety Manual

What Should a Warehouse Safety Manual Include?

The contents of a Warehouse Safety Manual should reflect the operations performed at the facility.

A small storage warehouse using pallet racks and a few forklifts may require a different combination of programs than a large distribution center with loading docks, powered pallet jacks, conveyors, automated equipment, battery-charging stations, extensive order-picking operations, and multiple shifts.

Depending on the facility, the manual may address:

• Management and employee responsibilities.
• Hazard identification and workplace inspections.
• Forklifts and powered industrial trucks.
• Pedestrian and equipment traffic.
• Loading docks.
• Shipping and receiving.
• Pallet racks and material storage.
• Order picking.
• Material handling.
• Ergonomics.
• Conveyors and automated equipment.
• Walking-working surfaces.
• Fire prevention.
• Emergency procedures.

Programs should be selected according to the facility’s actual hazards and applicable requirements.

Warehouse Safety Program

An effective Warehouse Safety Program establishes responsibilities and procedures for identifying hazards, operating equipment safely, storing and moving materials, protecting pedestrians, training employees, and correcting unsafe conditions.

Management should provide the resources necessary to implement the safety program and establish clear expectations for safe warehouse operations.

Managers and supervisors should:

• Identify workplace hazards.
• Ensure employees receive required training.
• Enforce established procedures.
• Maintain safe traffic patterns.
• Correct unsafe conditions.
• Ensure equipment inspections are performed.
• Verify required PPE is available and used.
• Investigate incidents and near misses.
• Follow up on corrective actions.

Employees should follow established procedures, operate only equipment they are trained and authorized to use, report hazards and equipment defects, use required PPE, and avoid unsafe shortcuts.

Hazard Identification and JSA/JHA

Warehouse hazards should be evaluated through workplace inspections, employee observations, incident investigations, Job Safety Analyses, equipment inspections, and other appropriate methods.

A JSA/JHA may be useful for activities such as:

• Forklift operation.
• Loading and unloading trailers.
• Order picking.
• Pallet handling.
• Battery charging.
• Conveyor operation.
• Clearing equipment jams.
• Compactor or baler operation.
• Material handling.
• Non-routine maintenance.

The assessment should identify task steps, hazards, and the controls necessary to perform the work safely.

Warehouse Safety Inspections

Warehouses should be inspected periodically to identify unsafe conditions and verify that safety procedures are being followed.

Inspection topics may include:

• Forklifts and powered equipment.
• Pedestrian routes.
• Loading docks.
• Storage racks.
• Pallets.
• Material stacking.
• Aisles.
• Conveyors.
• Emergency exits.
• Fire protection.
• Walking surfaces.
• Chemical storage.
• Battery-charging areas.
• PPE.

Deficiencies should be documented and corrected in a timely manner.

Warehouse Traffic Management

Warehouses often have employees, forklifts, powered pallet jacks, trucks, and other equipment moving through the same areas.

Facilities should establish traffic controls appropriate to their operations.

Controls may include:

• Designated travel aisles.
• Pedestrian walkways.
• Barriers.
• Floor markings.
• Signs.
• Mirrors.
• Stop locations.
• Warning devices.
• Speed limits.
• Restricted areas.

Traffic patterns should be reviewed when warehouse layouts or operations change.

Forklift / Powered Industrial Truck Safety

Forklifts and other powered industrial trucks are commonly used to move pallets, materials, containers, and products.

Only trained and authorized employees should operate powered industrial trucks.

Operators should:

• Perform required pre-use inspections.
• Wear restraints when provided.
• Observe rated capacity.
• Maintain control of the vehicle.
• Keep loads stable.
• Maintain adequate visibility.
• Watch for pedestrians.
• Observe facility speed limits.
• Use warning devices where appropriate.
• Maintain safe clearance from dock edges and other hazards.

Unsafe forklifts should be removed from service until repaired.

Forklift Operator Training

Forklift operators should receive training appropriate to the type of truck they operate and the conditions present in the workplace.

Training should address applicable topics such as:

• Controls and instrumentation.
• Steering and maneuvering.
• Visibility.
• Fork and attachment operation.
• Capacity.
• Stability.
• Load handling.
• Pedestrian traffic.
• Narrow aisles.
• Ramps.
• Loading docks.
• Workplace-specific hazards.

Operators should be evaluated as required before being authorized to operate independently.

Pre-Use Forklift Inspections

Forklifts should be examined before being placed in service as required.

Depending on the equipment, inspections may include:

• Tires.
• Forks.
• Mast.
• Chains.
• Hydraulic systems.
• Controls.
• Steering.
• Brakes.
• Horn.
• Lights.
• Warning devices.
• Seat belt or restraint.
• Battery or fuel system.

Defects that make the truck unsafe should be reported and corrected before further operation.

Forklift and Pedestrian Safety

Pedestrians and forklifts frequently share warehouse space.

Employees on foot should remain alert to equipment movement and use designated pedestrian routes where provided.

Forklift operators should:

• Watch for pedestrians.
• Slow down in congested areas.
• Use the horn at obstructed intersections where appropriate.
• Maintain visibility.
• Avoid approaching employees with an elevated load.
• Keep employees away from loads and forks.

Pedestrians should never stand or walk beneath elevated forks or loads.

Travel, Intersections and Blind Corners

Warehouse intersections, doorways, rack aisles, and blind corners can create collision hazards.

Controls may include:

• Mirrors.
• Stop signs.
• Floor markings.
• Barriers.
• Horn requirements.
• Reduced speed.
• One-way traffic patterns.

Operators should slow down where visibility is restricted.

Forklift Load Handling

Before lifting a load, operators should determine that the load is stable and within the rated capacity of the equipment.

Loads should be:

• Centered when practical.
• Properly supported.
• Stable.
• Positioned to maintain visibility.
• Carried at an appropriate travel height.

Damaged pallets or unstable loads should be corrected before movement when practical.

Forklift Stability and Capacity

Operators should understand that forklift stability can be affected by:

• Load weight.
• Load position.
• Load height.
• Turning.
• Speed.
• Slopes.
• Attachments.
• Uneven surfaces.

Rated capacity should not be exceeded.

Operators should avoid sudden turns, stops, or other movements that could reduce stability.

Narrow-Aisle Operations

Narrow aisles can increase collision and struck-by hazards.

Operators should maintain appropriate speed and clearance and remain alert for:

• Pedestrians.
• Rack uprights.
• Stored materials.
• Intersections.
• Other equipment.

Facilities should consider whether traffic restrictions or specialized equipment are necessary in narrow-aisle areas.

Powered Pallet Jacks

Employees operating powered pallet jacks should receive appropriate training and understand the equipment’s controls, stopping characteristics, load limitations, and workplace hazards.

Operators should:

• Inspect equipment before use.
• Maintain control.
• Keep feet and body parts clear.
• Watch for pedestrians.
• Maintain visibility.
• Use caution on ramps and dockboards.
• Avoid overloading.

Defective equipment should be removed from service when necessary.

Manual Pallet Jacks

Manual pallet jacks should be maintained in safe condition.

Employees should inspect wheels, handles, forks, and controls and avoid exceeding equipment capacity.

Employees should use controlled force when moving loads and avoid placing feet or other body parts beneath pallets.

Mechanical assistance should be used when loads cannot be moved safely.

Forklift Battery Charging

Battery-charging operations can expose employees to electrical, chemical, fire, and material-handling hazards.

Charging areas should be appropriately designated and maintained.

Procedures may address:

• Positioning the truck.
• Applying brakes.
• Battery handling.
• Ventilation.
• Ignition-source control.
• PPE.
• Eyewash and emergency washing.
• Spill response.

Smoking and open flames should be prohibited where battery-charging hazards require such controls.

Propane and Fueling

Warehouses using propane, gasoline, diesel, or other fueled industrial trucks should establish appropriate fueling procedures.

Employees should:

• Control ignition sources.
• Inspect connections.
• Handle cylinders or fuel safely.
• Report leaks.
• Follow equipment and facility procedures.

Fueling areas should be maintained to reduce fire and spill hazards.

Loading Dock Safety

Loading docks can expose employees to falls, forklifts, trucks, trailers, shifting loads, and caught-between hazards.

Procedures should address:

• Dock edges.
• Trailer movement.
• Dockboards and levelers.
• Forklift traffic.
• Pedestrians.
• Lighting.
• Communication.
• Housekeeping.

Employees should avoid unnecessary exposure to unprotected dock edges.

Dock Edges

Open loading-dock doors and platform edges can create fall hazards.

Facilities should evaluate dock-edge exposures and provide required fall protection or other appropriate controls.

Visual warnings, barriers, chains, gates, or other measures may be appropriate depending on the operation and applicable requirements.

Employees should not sit, stand, or walk unnecessarily near unprotected dock edges.

Dockboards and Dock Plates

Dockboards and dock plates should be appropriate for the equipment and loads crossing them.

Before use, employees should verify that the device is:

• Properly positioned.
• Secured as required.
• In safe condition.
• Capable of supporting the anticipated load.

Employees should avoid using damaged or improperly positioned dock equipment.

Trailer Restraint

Unexpected trailer movement can cause a forklift or other equipment to fall between the trailer and dock.

Appropriate methods should be used to prevent trailers from moving while loading and unloading operations are in progress.

Depending on the facility, these methods may include:

• Vehicle restraints.
• Wheel chocks.
• Other suitable systems.

Drivers and warehouse employees should understand the facility’s procedures before loading or unloading begins.

Truck and Trailer Loading

Before entering a trailer with powered equipment, employees should verify that conditions are safe.

Considerations may include:

• Trailer restraint.
• Trailer floor condition.
• Dockboard position.
• Lighting.
• Load stability.
• Trailer capacity.
• Pedestrians.

Damaged trailers or unsafe conditions should be reported before loading continues.

Shipping and Receiving

Shipping and receiving areas should be organized to reduce conflicts among employees, forklifts, truck drivers, and other vehicles.

Procedures should address:

• Material staging.
• Pedestrian routes.
• Vehicle movement.
• Dock assignments.
• Load inspection.
• Communication.
• Housekeeping.

Materials should not be staged where they block exits, aisles, fire equipment, or traffic routes.

Yard Traffic

Warehouse yards may contain tractor-trailers, delivery vehicles, forklifts, employees, and contractors.

Facilities should establish appropriate traffic procedures addressing:

• Speed.
• Parking.
• Backing.
• Pedestrian routes.
• Trailer positioning.
• Lighting.
• Restricted areas.

Employees should remain alert to backing vehicles and avoid unnecessary presence in vehicle maneuvering areas.

Pallet Rack Safety

Storage racks should be maintained in safe condition and used according to their design.

Employees should report:

• Bent uprights.
• Damaged beams.
• Missing components.
• Loose connections.
• Impact damage.
• Unstable loads.

Areas affected by significant rack damage should be appropriately controlled until the condition is evaluated and corrected.

Rack Inspections

Storage racks should be inspected periodically and after significant impacts or other events that may have caused damage.

Inspections may evaluate:

• Uprights.
• Beams.
• Connections.
• Anchors.
• Bracing.
• Protective devices.
• Load placement.
• General condition.

Damage should be evaluated by an appropriate person and corrected when necessary.

Damaged Racking

Employees should report forklift impacts and other rack damage promptly.

Loads may need to be removed or the affected area isolated when damage could compromise rack stability.

Employees should not attempt unauthorized repairs or modifications to structural rack components.

Rack Capacity

Storage racks should not be loaded beyond their intended capacity.

Employees responsible for storing materials should understand applicable load limitations.

Changes in products, pallet weights, storage configuration, or rack arrangement should be evaluated before substantially different loads are placed on existing systems.

Pallet Safety

Damaged pallets can contribute to falling loads and unstable storage.

Employees should identify pallets with:

• Broken boards.
• Damaged stringers.
• Protruding nails.
• Severe contamination.
• Other defects affecting safe use.

Unsafe pallets should be removed from service or otherwise controlled.

Material Storage and Stacking

Materials should be stored so they remain stable and secure against sliding, falling, or collapse.

Storage practices should consider:

• Weight.
• Height.
• Shape.
• Packaging.
• Pallet condition.
• Rack capacity.
• Employee access.

Heavier materials should generally be placed where they can be handled safely without creating unnecessary overhead hazards.

Falling Object Prevention

Improperly stored products can fall from racks or stacked materials.

Controls may include:

• Stable stacking.
• Appropriate pallets.
• Rack protection.
• Load containment.
• Safe placement.
• Exclusion from hazardous areas.

Employees should not stand beneath unstable or suspended materials.

Aisles and Passageways

Aisles used for material handling should provide adequate clearance for the equipment and loads being moved.

Aisles and passageways should be:

• Kept clear.
• Maintained in safe condition.
• Appropriately marked where required.
• Free from unnecessary storage.

Temporary staging should not create traffic or evacuation hazards.

Order Picking Safety

Order-picking activities may expose employees to repetitive lifting, reaching, bending, equipment traffic, falling materials, and elevated work.

Work should be arranged to reduce unnecessary:

• Reaching.
• Twisting.
• Bending.
• Heavy lifting.
• Repetitive movement.

Frequently handled materials should be positioned to reduce ergonomic stress where practical.

Elevated Picking

Employees retrieving materials from elevated locations should use equipment designed for employee access.

Employees should not:

• Climb storage racks.
• Stand on pallets.
• Stand on forklift forks.
• Use boxes or other unstable objects for elevation.

Ladders, mobile ladder stands, order pickers, or other appropriate equipment should be used according to their design and applicable requirements.

Packing and Shipping

Packing and shipping work may involve repetitive movement, cutting tools, lifting, conveyors, packaging equipment, and material staging.

Workstations should be arranged to reduce awkward postures and unnecessary reaching.

Cutting tools should be used and stored safely.

Packaging materials should not be allowed to create trip, fire, or access hazards.

Replenishment Operations

Replenishing pick locations may involve forklifts, pallets, elevated storage, and pedestrian interaction.

Employees should coordinate replenishment activities so that materials are not placed over or near employees who could be struck by falling products.

Temporary exclusion zones may be appropriate during certain operations.

Material Handling

Material-handling procedures should reduce the risk of strains, struck-by injuries, caught-between hazards, and falling materials.

Mechanical equipment should be used when practical for heavy or awkward loads.

Employees should understand how to:

• Evaluate a load.
• Maintain control.
• Avoid pinch points.
• Use mechanical assistance.
• Coordinate team lifts.
• Store materials safely.

Manual Lifting

Warehouse employees may repeatedly lift boxes, containers, products, and other materials.

Employees should:

• Evaluate the load before lifting.
• Obtain assistance when necessary.
• Use mechanical aids when practical.
• Keep loads controlled.
• Avoid unnecessary twisting.
• Avoid reaching while handling heavy loads.

Work design should reduce unnecessary manual lifting where feasible.

Ergonomics

Warehouse work can involve repetitive lifting, lowering, reaching, pushing, pulling, bending, carrying, and order picking.

Ergonomic evaluations should consider:

• Load weight.
• Frequency.
• Reach distance.
• Work height.
• Posture.
• Repetition.
• Travel distance.
• Push/pull forces.

Engineering improvements should be considered where practical.

Repetitive Lifting

High-frequency material handling can contribute to fatigue and musculoskeletal injury.

Controls may include:

• Mechanical assistance.
• Improved storage height.
• Reduced package weight.
• Workstation redesign.
• Job rotation where appropriate.
• Appropriate work/rest practices.

Employees should report symptoms before they become more serious.

Pushing and Pulling

Carts, pallet jacks, and other manually moved equipment can require substantial force.

Wheels and equipment should be maintained in good condition.

Floors should be maintained to reduce unnecessary resistance.

Employees should avoid attempting to move loads that cannot be controlled safely.

Conveyor Safety — When Applicable

Conveyors can expose employees to pinch points, nip points, caught-in hazards, falling products, and unexpected movement.

Procedures should address:

• Guarding.
• Emergency stops.
• Safe loading.
• Employee access.
• Inspection.
• Maintenance.
• Jam clearing.
• Lockout/tagout.

Employees should not ride or climb conveyors unless specifically designed and authorized for that purpose.

Conveyor Guarding

Hazardous conveyor components should be appropriately guarded.

Potential hazards may include:

• Nip points.
• Rollers.
• Belts.
• Chains.
• Sprockets.
• Transfer points.
• Drive mechanisms.

Missing or damaged required guards should be reported and corrected.

Conveyor Lockout/Tagout

Clearing jams, cleaning, servicing, or repairing conveyors may expose employees to hazardous energy.

When applicable, employees should follow the facility’s Lockout/Tagout Program before entering hazardous areas or performing covered servicing activities.

Operating controls or emergency stops should not be treated as substitutes for energy isolation when lockout/tagout is required.

Machine Guarding — When Applicable

Warehouses may use stretch wrappers, packaging machines, labelers, compactors, balers, conveyors, automated systems, and other machinery.

Hazardous moving parts should be appropriately guarded.

Employees should not remove or bypass guards or safety devices.

Lockout/Tagout — When Applicable

Warehouse equipment may contain electrical, mechanical, hydraulic, pneumatic, gravity, or other hazardous energy.

Covered servicing and maintenance should be performed under appropriate energy-control procedures.

Equipment may include:

• Conveyors.
• Compactors.
• Balers.
• Dock equipment.
• Automated storage systems.
• Packaging machinery.
• Stretch wrappers.

Employees should receive training appropriate to their responsibilities.

Compactors and Balers — When Applicable

Compactors and balers can expose employees to crushing, caught-in, and hazardous-energy hazards.

Employees should:

• Follow operating procedures.
• Maintain guards and interlocks.
• Keep body parts out of hazardous areas.
• Avoid reaching into equipment.
• Follow lockout/tagout procedures for covered servicing.

Only trained and authorized employees should operate this equipment.

Hand and Power Tools

Warehouse employees may use knives, cutters, drills, saws, strapping tools, and other hand or power tools.

Tools should be appropriate for the task and maintained in safe condition.

Employees should use cutting tools away from the body and store them safely when not in use.

Defective tools should be removed from service.

Ladders and Mobile Ladder Stands

Employees should use ladders and mobile ladder stands appropriate to the work.

Equipment should be inspected and used on stable surfaces.

Employees should not place ladders on pallets, boxes, barrels, or other unstable surfaces to gain additional height.

Mobile ladder stands should be secured against unintended movement while occupied as required.

Walking-Working Surfaces

Warehouse floors, docks, stairs, platforms, aisles, and elevated areas should be maintained in safe condition.

Hazards may include:

• Damaged floors.
• Wet surfaces.
• Debris.
• Packaging materials.
• Dock edges.
• Changes in elevation.
• Floor openings.

Hazards should be corrected or appropriately controlled.

Slips, Trips and Falls

Warehouse operations continually move products, pallets, packaging, and equipment, creating changing walking-surface conditions.

Employees should report and correct hazards such as:

• Spills.
• Shrink wrap.
• Strapping.
• Broken pallets.
• Loose packaging.
• Cords.
• Debris.
• Damaged flooring.

Travel routes and exits should remain clear.

Housekeeping

Good housekeeping is essential to warehouse safety.

Facilities should control accumulations of:

• Cardboard.
• Plastic wrap.
• Pallets.
• Strapping.
• Trash.
• Damaged products.
• Spilled materials.

Housekeeping should prevent trip hazards, fire hazards, pest problems, and obstruction of aisles or emergency equipment.

Personal Protective Equipment

PPE should be selected according to the hazards identified at the facility.

Depending on operations, PPE may include:

• Safety footwear.
• Safety glasses.
• Gloves.
• High-visibility apparel.
• Hearing protection.
• Head protection.
• Face protection.
• Chemical-resistant PPE.

Employees should inspect and properly use assigned PPE.

Hazard Communication

Warehouses that use or store hazardous chemicals should maintain an applicable Hazard Communication Program.

The program should address:

• Chemical inventory.
• Container labeling.
• Safety Data Sheets.
• Employee information and training.
• Non-routine tasks.
• Contractor communication where applicable.

Employees should understand how to obtain hazard information for chemicals they handle.

Chemical Safety

Warehouse chemicals may include:

• Cleaning products.
• Battery electrolyte.
• Fuels.
• Maintenance chemicals.
• Aerosols.
• Stored hazardous products.

Chemicals should be stored and handled according to their hazards and applicable requirements.

Leaks or damaged containers should be reported promptly.

Fire Prevention

Warehouses can contain substantial quantities of cardboard, pallets, plastics, packaging, stored products, and other combustible materials.

Fire-prevention procedures should address:

• Housekeeping.
• Storage.
• Ignition sources.
• Flammable materials.
• Battery charging.
• Hot work where applicable.
• Electrical hazards.
• Emergency exits.
• Fire-protection equipment.

Storage should not interfere with required fire-protection systems or emergency access.

Flammable and Combustible Liquids — When Applicable

Warehouses storing or using flammable and combustible liquids should establish appropriate storage and handling procedures.

Controls may address:

• Approved containers.
• Storage areas.
• Ignition sources.
• Dispensing.
• Spill control.
• Fire protection.

Quantities and storage arrangements should comply with applicable requirements.

Emergency Action Plan

Warehouse facilities should establish emergency procedures appropriate to their operations.

Potential emergencies may include:

• Fire.
• Severe injury.
• Chemical release.
• Equipment incident.
• Power failure.
• Severe weather.
• Medical emergency.

Employees should understand alarm systems, evacuation procedures, emergency responsibilities, and assembly locations.

First Aid

Appropriate first-aid arrangements and supplies should be maintained according to workplace hazards and applicable requirements.

Employees should know how to summon emergency medical assistance.

First-aid supplies should remain readily accessible.

Emergency Eyewash and Shower — When Applicable

Where employees may be exposed to corrosive materials, appropriate emergency washing facilities should be available as required.

Battery-charging and chemical-handling areas should be evaluated to determine whether eyewash or emergency shower equipment is necessary.

Required emergency washing equipment should remain accessible and be maintained in usable condition.

Heat Stress

Warehouse employees may be exposed to high temperatures, particularly in facilities without climate control, loading areas, trailers, or other hot work environments.

Heat-illness prevention measures may include:

• Drinking water.
• Rest.
• Acclimatization.
• Ventilation or cooling.
• Work practices.
• Employee monitoring.
• Emergency response.

Supervisors should consider workload and environmental conditions when evaluating heat exposure.

Cold Storage / Cold Stress — When Applicable

Employees working in refrigerated warehouses, freezers, or other cold environments may be exposed to cold stress.

Controls may include:

• Appropriate clothing.
• Gloves.
• Footwear.
• Warming opportunities.
• Work practices.
• Employee monitoring.

Employees should understand the signs and symptoms of cold-related illness.

Working Alone

Warehouse employees may work alone during nights, weekends, maintenance periods, or low-staffing operations.

Where applicable, procedures should address:

• Communication.
• Emergency contact.
• Check-in procedures.
• Restricted tasks.
• Access control.

Certain hazardous tasks should not be performed alone when assistance is necessary for safe work or emergency response.

Visitors, Drivers and Contractors

Warehouse facilities frequently receive truck drivers, delivery personnel, vendors, visitors, and contractors.

These individuals should be informed of applicable facility requirements.

Controls may include:

• Designated waiting areas.
• Restricted access.
• PPE.
• Traffic instructions.
• Dock procedures.
• Emergency procedures.

Visitors should not enter hazardous operating areas without authorization.

Facility Security

Warehouse security procedures may address:

• Access control.
• Restricted areas.
• Visitors.
• Deliveries.
• After-hours access.
• Suspicious activity.
• Emergency communication.

Security procedures should complement rather than interfere with emergency evacuation requirements.

Warehouse Safety Training

Employees should receive training appropriate to their responsibilities and workplace hazards.

Training may include:

• Forklift safety.
• Powered pallet jacks.
• Material handling.
• Loading docks.
• Warehouse traffic.
• PPE.
• Hazard Communication.
• Emergency procedures.
• Ergonomics.
• Conveyor safety.
• Lockout/tagout.
• Fire prevention.

Employees should receive required training before performing work that requires specific knowledge, qualification, or authorization.

New and Short-Service Employees

New, temporary, seasonal, and inexperienced employees may be unfamiliar with warehouse traffic, equipment, storage systems, emergency procedures, and facility rules.

Orientation should address applicable hazards before employees begin work.

Employees should not operate forklifts or other equipment requiring training and authorization until those requirements have been completed.

Supervision should reflect the employee’s experience and familiarity with the facility.

Warehouse JSA/JHA

JSAs/JHAs can be developed for recurring or higher-hazard warehouse tasks.

Useful topics may include:

• Forklift operation.
• Powered pallet jack operation.
• Loading and unloading trailers.
• Dock operations.
• Order picking.
• Pallet handling.
• Battery charging.
• Conveyor operation.
• Compactor or baler operation.
• Manual material handling.
• Rack loading.
• Shipping and receiving.

The JSA/JHA should reflect the actual equipment, facility, employees, and work conditions.

Warehouse Toolbox Talks

Toolbox talks and short safety meetings can reinforce hazards associated with current warehouse operations.

Useful topics may include:

• Forklift and pedestrian safety.
• Loading docks.
• Pallet racks.
• Material stacking.
• Manual lifting.
• Ergonomics.
• Housekeeping.
• Slips and trips.
• PPE.
• Battery charging.
• Conveyor safety.
• Emergency procedures.

Toolbox talks supplement formal safety training but should not replace training required for specific equipment or operations.

Additional Warehouse Safety Programs

Depending on the facility’s operations, equipment, materials, and employee exposures, additional programs may include:

• Battery Charging Safety.
• Bloodborne Pathogens.
• Cold Stress.
• Conveyor Safety.
• Driving and Fleet Safety.
• Electrical Safety.
• Emergency Action Plan.
• Ergonomics.
• Fall Protection.
• Fire Prevention.
• First Aid.
• Flammable and Combustible Liquids.
• Forklift / Powered Industrial Trucks.
• Hand and Power Tools.
• Hazard Communication.
• Heat Stress Prevention.
• Housekeeping.
• Loading and Unloading.
• Loading Dock Safety.
• Lockout/Tagout.
• Machine Guarding.
• Manual Lifting and Material Handling.
• Personal Protective Equipment.
• Spill Prevention and Response.
• Slips, Trips and Falls.
• Walking-Working Surfaces.
• Working Alone.
• Workplace Security.
• Workplace Visitors Security.

Programs should be selected according to the warehouse’s actual operations rather than automatically included simply because the company operates a warehouse.

Building a Warehouse Safety Manual

The most useful Warehouse Safety Manual is based on how materials actually move through the facility.

Consider whether employees:

• Operate forklifts.
• Operate powered pallet jacks.
• Work around pedestrian and equipment traffic.
• Load or unload trailers.
• Work on loading docks.
• Store products on pallet racks.
• Perform elevated order picking.
• Manually pick and pack products.
• Perform frequent lifting.
• Work around conveyors.
• Operate compactors or balers.
• Charge forklift batteries.
• Handle hazardous chemicals.
• Work in cold-storage areas.
• Perform equipment maintenance.
• Work alone or after hours.

These activities help determine which individual safety programs should be included.

A small storage warehouse should not receive a manual filled with programs for conveyors, automated equipment, cold storage, or battery charging if those hazards do not exist. Likewise, a large distribution or fulfillment center may require numerous specialized programs in addition to core workplace safety procedures.

Customized Warehouse Safety Manuals

Companies can request a customized Warehouse Safety Manual containing programs selected according to the facility’s equipment, storage systems, materials, work processes, and employee exposures.

Manuals can be developed for warehouses, distribution centers, fulfillment operations, shipping and receiving facilities, storage operations, wholesalers, and other material-storage and distribution businesses.

Applicable programs can be selected for forklifts, loading docks, pallet racks, material handling, conveyors, ergonomics, battery charging, fire prevention, chemicals, emergency procedures, and other warehouse hazards.

Individual safety programs can also be selected when a company needs to add or update a particular program within an existing safety manual.