The Top Ten Hazards for Warehouse Workers

The warehousing and storage industry employs more than 1.7 million workers across more than 22,000 private companies. According to the U.S. Bureau of Labor Statistics, work–related injuries and illnesses affect 5.5% of the truck and tractor operators, laborers and material movers, shipping and receiving clerks, stock clerks, and managers who work in the industry. In 2022, 50 warehouse employees were killed in a work–related incident.

Here are the top ten hazards warehouse workers face while on the job:

1. Automation and Robotics

   Heavy machinery can pose a risk to employees who maintain and operate it. Companies must ensure that all employees are trained in operating such machines. Continued maintenance, safety setting checks, and performance monitoring are important steps to keep robotic systems performing as expected.
   
   Lockout/Tagout: Before performing any servicing or maintenance, an employee should disconnect the equipment from its energy source. This ensures that the worker is not injured due to the machine turning on or releasing heat or electricity during maintenance.

2. Electrical Hazards

   Electricity can be dangerous to people who work directly on machines, cables, and circuits and those who are indirectly exposed through their day–to–day tasks. Warehouses should use insulation, guarding, grounding, protective devices, and safe work practices to reduce electrical hazards. Additionally, basic electrical safety knowledge and housekeeping techniques can help keep employees safe.

3. Hazardous Chemicals

   When chemicals are present, businesses must follow OSHA’s Hazard Communication Standard. Maintain labels and Safety Data Sheets (SDSs) for all chemical containers that enter the workplace. Workers must be trained in how to read an SDS and what to do if a chemical spill or leak happens.
   
   Process Safety Management: When hazardous and flammable chemicals are present at or above specific quantities, the business must implement safety programs to prevent fires, explosions, spills, toxic gas releases, chemical reactions, and other incidents.

4. Heat Illness

   When a facility is humid or has no climate control, workers can suffer from heat illness. Ventilation, water, and rest stations can help improve the environment. In addition, workers should be given the opportunity to safely acclimatize to the heat, learn how to recognize the symptoms of heat illness, and access first aid when needed.

5. Materials Handling

   Correctly store materials to prevent collapse, sliding, and falling. For example, use interlocking and blocking techniques to stack items, place heavier items on lower shelves, and restrict the height of stacked items and the load capacity for shelving units. At conveyors, install proper lighting, adequate guarding around pinch points, and work surfaces.

6. Musculoskeletal Disorders

   Tasks such as lifting, pushing, and pulling heavy items can increase the risk of musculoskeletal disorders in warehouse employees. Warehouses can reduce these hazards by changing the environment to meet workers’ ergonomic needs, reducing case weights, and using equipment like dock levelers and mechanical stretch wrappers. Additionally, train workers in safe lifting techniques.

7. Powered Industrial Trucks (Forklifts)

   In 2022, 14 workers were killed in warehouses, and 231 across all industries, by off–road and industrial vehicles. Ensure safe clearances when using pallet jacks, forklifts, and any other equipment. Keep passageways clear, surfaces well–maintained, and equipment operating correctly with minimal employee force. Require caution when forklifts are operated near docks and prohibit drivers from backing up forklifts to a dock edge. The only workers who may operate a forklift are those who are trained, certified, and over the age of 18.

8. Refrigerated Warehousing

   Cold conditions can increase the risk of musculoskeletal disorders, hypothermia, and frostbite in workers. Protective clothing, acclimatization, regular breaks in warm areas, and training can help keep workers safe. Cold storage areas must contain an inside release for exiting without any keys, tools, or special knowledge.

9. Slips, Trips, and Falls

   In 2022, slips, trips, and falls accounted for 8 fatal injuries in warehouses and 865 across all industries. Train workers in ladder safety, a “clean–as–you–go” discipline, and fall protection systems. Control the environment to reduce wet or slippery floors, keep walkways clear of clutter, and provide fall protection at dock doors and on dockboards.

10. Stress and Fatigue

    Worker stress and fatigue can lead to an increase in mistakes and injuries. Make staffing decisions that allow a safe and healthy work pace for employees. Allow plenty of rest breaks and provide resources for maintaining healthy diets, exercise levels, and stress management strategies. Increase alertness with adjustments to the lighting and temperature in work areas.

Keeping employees safe is the responsibility of every business owner. An effective safety program can help reduce the number of injuries in your workplace and control the cost of insurance.

NJM was established more than 100 years ago and has remained committed to providing reliable, cost–effective, and safety–focused insurance. All NJM business policyholders receive access to loss prevention resources to help reduce injuries and illnesses in the workplace. Connect with an agent today to get a quote for NJM Business Insurance.

Sources
Occupational Injuries/Illnesses and Fatal Injuries Profiles (2022). U.S. Bureau of Labor Statistics. data.bls.gov
“Warehousing.” Occupational Health and Safety Administration. osha.gov
“Industries at a Glance: Warehousing and Storage: NAICS 493” (Feb. 21, 2024). U.S. Bureau of Labor Statistics. bls.gov
“Worker Safety Series: Warehousing” (2004). Occupational Safety and Health Administration. osha.gov