Handling product in and out of storage shelving or racking

Use solutions with the least risk

Most workplaces have a large variety of products that are stored on shelves. Heavy or hard-to-reach products can create a risk of a musculoskeletal disorder (MSD) occurring, particularly if they are stored above shoulder height or below mid-thigh height. Product is often also double-handled, both in and out of shelves or on and off low trolleys. As well as being inefficient, this can increase the risk of injury to employees. The following solutions can help employers control risks to employees handling products in and out of storage shelving or racking. These solutions may help eliminate or reduce the risk of employees developing an MSD.

Solutions are listed in order, from those considered most effective to those considered less effective.

Employers should make sure employees use the handling solutions with the least risk, so far as reasonably practicable.

Solutions with reduced risks are an alternative only if least-risk methods are not reasonably practicable.

Employers should start implementing risk controls for the heaviest or highest-volume products first.

The following guidance also describes high-risk actions that can cause an MSD. Employers have a duty to eliminate or reduce the risk of MSDs, so far as reasonably practicable and should make sure employees do not perform high-risk actions, if practicable.

Consultation

So far as reasonably practicable, employers must consult with employees and any health and safety representatives (HSRs) when identifying hazards and providing risk control measures. Consultation should include discussions about how employees will handle product in and out of storage shelving or racking, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Handling product stored above shoulder height and below mid-thigh height

High-risk actions that can cause an MSD

• Bending the back forwards or sideways more than 20 degrees, working with one or both hands above shoulder height, reaching forwards or sideways more than 30 cm from the body, lifting and lowering and exerting force while in an awkward posture:
  • more than twice per minute for more than 30 minutes continuously or
  • more than 2 hours over the whole shift

  These actions may occur in the situations listed or in combination with other work activities.

Potential source of risk

• Product is stored above employees' shoulder height and below mid-thigh height.

Handling solutions

Preferred solutions with the least risk

• Provide high-volume stock in bulk. Use a hopper or silo system with inbuilt weighing or dosing system if required.
• Store product in a carousel.
• Use hydraulic lifters or order pickers to raise the person.

Solutions with a reduced risk

• Use height-adjustable trolleys to transfer product.
• Provide order-picking trolleys.
• Put the whole pallet in the rack to eliminate double-handling.
• Organise shelves with heavier and more frequently used stock between mid-thigh and shoulder height.
  • Place lighter, less frequently used stock above and below the heavier, more frequently used stock.
  • See WorkSafe's Manual order picking guide for further information.

Handling heavy products in and out of storage shelving or racking

High-risk actions that can cause an MSD

• Using high force lifting, lowering or carrying heavy loads.
• High force using a finger-grip, a pinch-grip or an open-handed grip to handle a heavy or large load.
• Exerting high force while in an awkward posture.

Potential source of risk

• Weight of product.

Handling solutions

Preferred solution with the least risk

• Obtain frequently used or high-volume stock in bulk and use a hopper or silo system with inbuilt weighing or dosing system if required.

Solution with a reduced risk

• Contact supplier to reduce weight of product.
  • For example, have 12.5 kg bags delivered instead of 25 kg bags.

  Note: This will usually increase the frequency of the handling, so ensure that this is done in combination with other risk controls which improve postures and movements.

Handling product stored below mid-thigh height or above shoulder height

High-risk actions that can cause an MSD

• Bending the back forwards or sideways more than 20 degrees, working with one or both hands above shoulder height, reaching forwards or sideways more than 30 cm from the body, lifting and lowering and exerting force while in an awkward posture:
  • more than twice per minute for more than 30 minutes continuously or
  • more than 2 hours over the whole shift

  These actions may occur in the situations listed or in combination with other work activities.

• Using high force lifting, lowering or carrying heavy loads.

Potential source of risk

• Product is stored below employees' mid-thigh height or above shoulder height.

Handling solutions

Preferred solutions with the least risk

• Provide high-volume stock in bulk. Use a hopper or silo system with inbuilt weighing or dosing system if required.
• Store product in a carousel.
• Use hydraulic lifters or order pickers to raise the person.

Solutions with a reduced risk

• Use height-adjustable trolleys to transfer product.
• Provide order-picking trolleys.
• Put the whole pallet in the rack to eliminate double-handling.
• Organise shelves with heavier and more frequently used stock between mid-thigh and shoulder height.
  • Place lighter, less frequently used stock above and below the heavier, more frequently used stock.
  • See WorkSafe's Manual order picking guide for further information.

Handling products stored at long reach distance

High-risk actions that can cause an MSD

• Bending the back forwards or sideways more than 20 degrees, working with one or both hands above shoulder height, reaching forwards or sideways more than 30 cm from the body, lifting and lowering and exerting force while in an awkward posture:
  • more than twice per minute for more than 30 minutes continuously or
  • more than 2 hours over the whole shift

  These actions may occur in the situations listed or in combination with other work activities.

• Using high force lifting, lowering or carrying heavy loads.
• High force using a finger-grip, a pinch-grip or an open-handed grip to handle a heavy or large load.
• Exerting high force while in an awkward posture.

Potential source of risk

• Product stored at long reach distance. For example, in deep shelves.
• Product unable to be slid closer before lifting.

Handling solutions

Preferred solution with the least risk

• Reduce depth of shelving.

Solutions with a reduced risk

• Only stock front part of shelving for heavier products.
• Rotate pallets using mechanical aids to ensure manual handling is only from the front half of the pallet.

Handling products in close-shelf racking, forcing back bending to reach in

High-risk actions that can cause an MSD

• Bending the back forwards or sideways more than 20 degrees, working with one or both hands above shoulder height, reaching forwards or sideways more than 30 cm from the body, lifting and lowering and exerting force while in an awkward posture:
  • more than twice per minute for more than 30 minutes continuously or
  • more than 2 hours over the whole shift

  These actions may occur in the situations listed or in combination with other work activities.

• Using high force lifting, lowering or carrying heavy loads.
• High force using a finger-grip, a pinch-grip or an open-handed grip to handle a heavy or large load.
• Exerting high force while in an awkward posture.

Potential source of risk

• Shelf racking is close together, forcing employees to bend their backs to reach in between shelves.

Handling solutions

Preferred solution with the least risk

• Provide walk-in storage bays within pallet racking.

Solution with a reduced risk

• Raise shelf racking to allow access without bending.

Your legal duties

Employers

The Occupational Health and Safety Act 2004 (OHS Act) requires employers to provide and maintain a working environment that is safe and without risks to health, so far as reasonably practicable. An employer contravenes this duty if they fail to:

• provide or maintain plant or systems of work that are, so far as reasonably practicable, safe and without risks to health
• make arrangements for ensuring, so far as reasonably practicable, safety and the absence of risks to health in connection with the use, handling, storage or transport of plant or substances
• maintain, so far as is reasonably practicable, each workplace under the employer's management and control in a condition that is safe and without risks to health
• provide, so far as is reasonably practicable, adequate facilities for the welfare of employees at any workplace under the management and control of the employer
• provide information, instruction, training or supervision to employees of the employer as is necessary to enable those employees to perform their work in a way that is safe and without risks to health

Employers also have an obligation to consult, so far as is reasonably practicable, with employees and any HSRs on matters related to health and safety that directly affect them, or that are likely to directly affect them. This duty to consult also extends to independent contractors, including employees of the independent contractor, engaged by the employer in relation to matters over which the employer has control.

Employees

While at work, employees also have duties under the OHS Act to take reasonable care for their own health and safety and the health and safety of others who may be affected by their acts or omissions in the workplace. Employees must also co-operate with their employer's actions to make the workplace safe and comply with the OHS Act and Regulations.

The WorkSafe website has guidance about the occupational health and safety (OHS) responsibilities of employers and employees.