Warehousing and storage

A snapshot of how people employed in the warehousing and storage industry get injured at work, and tips to help prevent these types of injuries from occurring.

Injury hotspots pages contain helpful information for

training and induction materials
occupational health and safety content
preventing injuries in the workplace.

Warehousing and storage

Hazards

Hazard 1
Accidents caused by mobile plant
Implement appropriate traffic management plans (eg design all new workplaces to ensure pedestrians and forklifts are completely separated, establish appropriately sized pedestrian exclusion zones).

Ensure ride-on mobile plant has curtain / barrier foot protection and automatically stops when operator dismounts.

Ensure all operators of mobile plant have appropriate licences.

7 per cent of the injuries were to a persons hand / fingers.
Hazard 2
Falling objects
Use appropriate wrapping and stillages to prevent objects falling from containment.

Stack heaviest items at the base of the load.

14 per cent of the injuries were to a persons shoulder.
Hazard 3
Lifting and repetitive bending (order picking replenishing container packing and unpacking)
Provide appropriate mechanical aids and equipment (eg four-wheel trolleys and lifters to lift heavy weights, height-adjustable reach conveyor) and ensure they are used properly and maintained in accordance with manufacturer specifications. Eliminate manual lifting of hardwood pallets.

Ensure employees are not exposed to repetitive work for long periods (eg by using job rotation, work variation, providing sit-stand stools and anti-fatigue mats) or work that requires a significant amount of high force.

Train employees in the selection and use of any mechanical equipment and aids and safe handling methods (eg that the best working zone is when work is between shoulder and knee (preferably mid-thigh) height and with the elbows close to the body, work upright where possible).

6 per cent of the injuries were to a persons arm.

7 per cent of the injuries were to a persons hand / fingers.

14 per cent of the injuries were to a persons shoulder.

28 per cent of the injuries were to a persons back.
Hazard 4
Pushing and pulling trolleys and packages (eg loading freezers)
Use plate freezers or trolley systems wherever possible. If this isn't practicable, ensure freezer frame load / unloading is always done between mid-thigh and shoulder height, using aids such as height adjustable racking and trolleys, pallet lift tables and vacuum lifters.

6 per cent of the injuries were to a persons arm.

7 per cent of the injuries were to a persons hand / fingers.

14 per cent of the injuries were to a persons shoulder.

28 per cent of the injuries were to a persons back.

5 per cent of the injuries were to a persons abdomen.
Hazard 5
Slips trips and falls
Ensure work areas and access areas are free of debris, level, well-lit and in good condition, and walkways are clearly defined.

Use barriers for loading bays that are not in use.

Ensure fences and barriers at finger docks remain in place until truck acts as a barrier.

Apply good housekeeping practise (eg remove unnecessary items, provide sufficient storage, ensure items are put away, doors and drawers closed after use).

Ensure employees wear appropriate footwear (eg non-slip).

Develop and implement appropriate policies and procedures (eg don't stand on pallets, no climbing on shelves, drivers not to drive away during loading / unloading process).

6 per cent of the injuries were to a persons arm.

6 per cent of the injuries were to a persons forearm / wrist.

9 per cent of the injuries were to a persons knee.

28 per cent of the injuries were to a persons back.
Hazard 6
Work-related stress fatigue bullying and harassment
Develop and implement appropriate policies and procedures for workplace bullying and harassment.

Encourage a positive workplace culture, including reporting of bullying and harassment.

Ensure all employees understand what bullying and harassment is, and the procedures for reporting incidents (eg policies and procedures should be promoted during employee induction and workplace bullying prevention or training).

Provide access and encourage employees to use employee counselling / support services, where possible.

Develop strategies for managing the impact of fatigue (eg develop a fatigue management system and train managers/team leaders how to effectively implement it).

Train employees how to recognise fatigue signs and symptoms.

Encourage employees to report any workplace stress factors (eg work demand, low control, poor support, lack of role clarity, organisational culture) and control appropriately.

5 per cent of the injuries were to a persons psychological system.

Injury hotspots disclaimer

This information does not give rise to any liability of, or claim against, WorkSafe Victoria. It does not give rise to any right, expectation, duty or obligation that a person may not otherwise have. It does not give rise to any defence that would not otherwise be available to a person.

This information does not affect the operation of the Occupational Health and Safety Act 2004 or the Occupational Health and Safety Regulations 2017.

Please note these injuries and hazards are based on historical claims data. There may also be new common injuries and hazards emerging at your workplace which will need to be addressed.

Warehousing and storage

Injury hotspots pages contain helpful information for

Warehousing and storage

Hazards

Accidents caused by mobile plant

Falling objects

Lifting and repetitive bending (order picking replenishing container packing and unpacking)

Pushing and pulling trolleys and packages (eg loading freezers)

Slips trips and falls

Work-related stress fatigue bullying and harassment

Injury hotspots disclaimer

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