Warehouses are structures that serve as storage areas for goods. The Occupational Health and Safety Administration (OSHA) estimated that over 145,000 people are employed in more than 7,000 warehouses across the U.S. (OSHA, 2010). There are aspects of the warehouse environment that present health and safety hazards including layout, floors, noise, heating, housekeeping, and fire. However, proactively managing these hazards reduce the risk for injury. The warehouse must be assessed for existing health and safety risks to identify appropriate interventions.
Health and Safety Risks
The warehouse layout contributes to health and safety risks. When storage areas are not designated in a safe place, goods can be stored even in areas with uneven surfaces and gradient changes that reduce the stability of stacked items (Jones, 2010). Racking systems with blind corners, sharp bends, narrow isles, and dead ends also present hazards when fork lift trucks or manual trucks are used. Studies show that layouts where traffic routes for fork lift trucks and manual handling are the same and where fork lift trucks need to reverse increases the likelihood of accidental collisions (de Koster, Stam & Balk, 2011). In addition, storage areas that block entrances and exits also constitute hazards as does the proximity of traffic routes to stairways, holes, pits, ladders, and doors.
Another health and safety risk is slippery stairs or floors that cause slipping, falling, or tripping identified as the causes of about 25% of major injuries among warehouse workers (HSE, 2007). Loose flooring and protruding nails are tripping hazards while potholes can cause fork lift trucks, manual trucks, and workers to lose balance. Unstable floors also constitute a danger when racks are bolted to them. On the other hand, smooth floors and stairs can be slippery and more so when cleanliness is not maintained. Poor housekeeping, such as when there is clutter, hoses, and electrical cables lying on the floor, increase the risk of slips and trips (HSE, 2012). Water and oil spills, foodstuffs, and powders also increase friction that can cause slipping (Jones, 2010). Accumulated rubbish including packaging materials, strappings, and damaged pallets can become a fire hazard.
The heating system in a warehouse constitutes a health risk when inadequate during the cold months. Discomfort and shivering from insufficient heating negatively affects the performance of tasks that can precipitate injury. Heating systems such as propane heaters also emit carbon monoxide as a by-product of combustion (Jones, 2010). The lack of ventilation systems lead to the accumulation of carbon monoxide, a toxic gas, inside an enclosed warehouse.
Noise can be generated by compressors, conveyors, compactors, fork lift trucks, radios, and other equipment. The general rule is that, if two people are two meters apart and speaking in a normal voice but have difficulty hearing each other clearly, a noise assessment is warranted (HSE, 2012). The results will indicate if the noise level is hazardous. Using noisy tools or machines for more than 30 minutes each day exposes the worker to noise-related injury where excessive noise can damage the eardrums leading to hearing loss (OSHA, 2014). Loud noise also contributes to workplace stress and to injury when the worker fails to hear alarms.
U.S. fire department investigations reveal that 13% of warehouse fires are caused by lighting equipment or electrical distribution and 9% by heating equipment (Campbell, 2013). Ignition most commonly occurred by arcing but also by sparks, embers, and flame. Sixteen-percent of fires relate to the latter heat sources produced by various types of equipment including shop tools, burners, torches, soldering iron, and industrial equipment (Campbell, 2013). Thus, substandard electrical wiring and distribution systems as well as machines that generate heat increase the risk of fire. This is especially so when equipment is used near easily combustible materials such as processed paper or wood, fabric or textiles, plastics, and flammable solids or gases (Campbell, 2013).
Risk Assessment
In a sorting and packaging warehouse for apples, one area was designated for sorting the fruits, one for packing, and one for storage prior to shipping. A conveyor system connects the packing and storage areas. There are no markings or signage clearly delineating the areas of work. There are no railings to protect workers from vehicle traffic in the sorting and packing areas. The packing area is at the end of the warehouse and the storage area is nearer the door. Forklift trucks need to reverse to get the boxes to the storage area. Workers use the same routes as the trucks. Housekeeping is poor with damaged boxes and packaging material piled in one corner.
Recommendations
Conclusion
Warehouses are useful structures for storage purposes. Just like any workplace, however, there are associated health and safety hazards. A risk assessment determines the specific hazards present inside the warehouse environment. Identification followed by the implementation of corrective actions prevents the negative health outcomes brought on by hazards. A proactive rather than reactive approach promotes the health and safety of workers that enhances productivity as well.
References
Campbell, R. (2013). Structure fires in U.S. warehouses. Retrieved from http://www.nfpa.org/~/media/files/research/nfpa%20reports/occupancies/oswarehouse .pdf
de Koster, R.B.M., Stam, D., & Balk, B.M. (2011). Accidents happen: The influence of safety-specific transformational leadership, safety consciousness, and hazard reducing systems on warehouse accidents. Journals of Operations Management, 29(7-8), 753- 765. doi:10.1016/j.jom.2011.06.005.
Health and Safety Executive (2007). Warehousing and storage: A guide to health and safety. Retrieved from http://search.searchimprove.com/search.aspx?pckid=1775564886&aid=470651&sw= Warehousing+and+storage
Health and Safety Executive (2012). Safety in warehouses. Retrieved from http://www.hse.gov.uk/pubns/indg412.pdf
Jones, T. (2010). Warehousing and storage safety: Establishing a comprehensive safety approach. Professional Safety, June (2010), 34-36. Retrieved from http://www.asse.org/professionalsafety/indexes/2010.php
