Warehouse Health and Safety: 7 Common Mistakes Ecommerce Businesses Make

Warehouse health and safety is about more than simply complying with regulations. Effective health and safety management protects warehouse workers from injury, improves operational efficiency and helps businesses maintain productivity.

Many warehouses contain a combination of moving vehicles, heavy objects, hazardous materials, high shelving and storage equipment. Without proper planning, these hazards can quickly lead to accidents.

A safe warehouse environment helps:

• Protect worker safety
• Reduce accidents
• Improve warehouse health
• Ensure compliance
• Reduce operational disruption
• Support long-term business growth

Risk should be carefully considered throughout every warehouse environment. From unloading goods and operating forklift trucks to storing hazardous substances and managing workplace traffic routes, every activity carries potential risks that require appropriate control measures.

One of the most common warehouse health and safety mistakes is failing to complete regular risk assessments.

Risk assessments help identify hazards, assess risk levels and implement appropriate control measures before incidents occur. Employers are legally required to conduct risk assessments and maintain records to demonstrate compliance with health and safety legislation.

Common hazards found within warehouses include:

• Falling objects
• Uneven surfaces
• Moving vehicle activity
• Hazardous materials
• Poor storage practices
• Damaged equipment
• Slippery floors
• High shelving risks

Risk assessments should cover all storage facilities, work areas, loading bays, traffic routes and operational processes.

Warehouse workers should also be encouraged to report hazards and potential dangers so they can be addressed quickly.

Regular risk assessments help businesses:

• Identify specific risks
• Reduce accidents
• Protect workers
• Improve warehouse health
• Support legal requirements
• Strengthen safety management

Health and safety regulations place significant emphasis on risk assessments because they provide the foundation for all other safety measures.

Manual handling injuries remain one of the leading causes of workplace accidents in warehouses.

Warehouse workers often spend long periods moving stock, unloading goods and lifting heavy objects. Without proper training and safe lifting techniques, employees face a significantly higher risk of injury.

Common manual handling injuries include:

• Back injuries
• Muscle strains
• Sprains
• Broken bones
• Repetitive strain injuries

Manual handling techniques should be taught during induction and reinforced through ongoing training courses.

Businesses should provide:

• Proper training
• Safe lifting techniques
• Mechanical aids
• Suitable equipment
• Regular supervision

Mechanical aids such as pallet trucks, lifting tables and handling equipment reduce the demands associated with heavy lifting.

Physical health standards relating to ergonomics and workstation design also play an important role in improving warehouse health. Ergonomics and musculoskeletal health regulations encourage businesses to minimise physical strain while maintaining productivity.

Load capacities should always be respected and workers should never attempt to move heavy objects without appropriate support.

A competent person should regularly review manual handling procedures to ensure warehouse staff are following best practices and that safe systems remain effective.

Forklift trucks are among the most important pieces of equipment found within warehouses. However, they are also responsible for a significant number of workplace accidents.

Industry figures indicate that forklift trucks are involved in more than a quarter of workplace transport accidents, highlighting the importance of operator training and traffic management.

Potential hazards include:

• Falling objects
• Falling loads
• Collisions
• Structural damage
• Pedestrian injuries
• Serious injury incidents

A safe warehouse environment requires clear workplace traffic routes that separate vehicles and pedestrians wherever possible.

Workers should never share the same traffic route as a moving vehicle unless adequate separation measures are implemented.

Businesses should introduce:

• Vehicle-pedestrian segregation
• Speed limits
• Clearly marked traffic route systems
• Equipment inspections
• Forklift operator training
• Site safety rules for visiting drivers

Equipment should also be regularly maintained to ensure faults are identified before they become safety risks.

Proper training helps operators understand load capacities, safe operating procedures and the importance of maintaining awareness throughout the warehouse environment.

Fire safety remains one of the most critical areas of warehouse health and safety.

Many warehouses contain flammable materials, packaging products, fuel sources and other hazardous substances that can increase fire risk.

Effective fire safety planning should include:

• Fire risk assessments
• Fire extinguishers
• Alarm systems
• Emergency procedures
• Evacuation plans
• Staff training

Storage facilities should be carefully organised to minimise hazards and reduce the spread of fire.

Businesses should also ensure fire doors remain compliant and receive regular fire door inspections and maintenance as part of their wider fire safety strategy.

Emergency procedures should not simply exist on paper. Regular drills help warehouse employees understand evacuation routes, assembly points and reporting procedures.

Well-prepared workers are more likely to respond effectively during fires and other emergencies, helping prevent accidents and reduce the risk of serious injury.

Storage and racking issues contribute to a significant number of warehouse accidents every year.

Poorly organised storage facilities increase risk, create hazards and make it more difficult for workers to operate safely. High shelving systems, overloaded racking and unstable stock can all result in falling objects that place workers at risk.

Common storage hazards include:

• High shelving failures
• Overloaded racking
• Unstable loads
• Poor aisle management
• Unsafe stacking methods
• Damaged storage equipment

Warehouse workers should never be required to access stock from unsafe positions or use unsuitable equipment when retrieving goods.

Storage facilities should be inspected regularly to identify structural damage, overloaded shelving and other potential hazards.

Load capacities must always be respected. Exceeding manufacturer limits can significantly increase the likelihood of accidents and create serious risks for warehouse staff.

Many warehouses now conduct scheduled storage audits to identify hazards before incidents occur. This proactive approach improves warehouse health while reducing the risk associated with daily operations.

Many warehouses store or handle hazardous substances as part of normal operations.

These may include cleaning chemicals, fuels, solvents and other hazardous materials that can affect worker health if appropriate control measures are not implemented.

The Control of Substances Hazardous to Health (COSHH) Regulations require businesses to identify hazardous substances, assess exposure risks and introduce suitable control measures.

Businesses should:

• Conduct risk assessments
• Identify hazardous materials
• Provide protective clothing
• Supply personal protective equipment
• Deliver proper training
• Store substances safely
• Monitor exposure risks

Warehouse employees should understand the specific risks associated with any hazardous substances they may encounter.

Control measures should be reviewed regularly to ensure they remain effective.

Failure to manage hazardous materials correctly can result in accidents, health issues, enforcement action and long-term operational disruption.

Even the strongest health and safety procedures can fail without effective training.

Training remains one of the most important investments businesses can make when improving warehouse health and safety.

Warehouse workers should receive training covering:

• Manual handling techniques
• Safe lifting techniques
• Fire safety
• Emergency procedures
• Forklift awareness
• Hazard reporting
• Equipment operation
• Risk assessments
• Personal protective equipment requirements

Providing appropriate training helps workers identify hazards before incidents occur and supports a stronger safety culture throughout the organisation.

Warehouse staff should feel comfortable reporting hazards, potential dangers and near misses without fear of blame.

Regular refresher training courses help ensure workers remain aware of changing risks, updated procedures and new equipment.

Proper training not only protects workers but also supports productivity, operational efficiency and long-term compliance.

Slips, trips and falls are among the top causes of non-fatal injuries within warehouses and continue to account for thousands of preventable accidents every year.

These incidents frequently result in fractures, sprains, broken bones and lost working time.

Common causes include:

• Uneven surfaces
• Spillages
• Damaged flooring
• Poor housekeeping
• Obstructed walkways
• Inadequate lighting

Maintaining a clean and organised warehouse environment significantly reduces these risks.

Warehouse workers should be encouraged to report hazards immediately, while management teams should conduct routine inspections to identify problems before accidents occur.

Preventive measures such as housekeeping programmes, routine inspections and clearly marked walkways help improve worker safety while supporting overall warehouse health.

Technology is playing an increasingly important role in warehouse health and safety.

Automation equipment such as Automated Storage and Retrieval Systems (AS/RS), Automated Guided Vehicles (AGVs), robotic piece-picking systems and conveyor belts can perform repetitive, physically demanding or hazardous tasks.

By reducing manual handling requirements, these technologies help lower the risk of strains, sprains and other injuries.

Modern warehouse environments are also benefiting from advanced monitoring systems.

Automated systems can monitor warehouse conditions and identify potential hazards before incidents occur. Examples include:

• Bin jams
• Equipment failures
• Robot malfunctions
• Unsafe storage conditions
• Traffic management issues

Businesses are increasingly integrating:

• Sensors
• Alarm systems
• Surveillance cameras
• Digital inspections
• Incident reporting systems

These tools improve hazard detection, strengthen safety management and support faster incident response.

Technology also helps businesses maintain detailed information relating to inspections, corrective actions, incidents and compliance activities.

As warehouses continue to evolve, digital tools will play an increasingly important role in improving warehouse health and reducing risk.

Health and safety regulations are critical because warehouses remain inherently high-risk environments with elevated rates of workplace accidents.

Historical warehousing data has highlighted the significant dangers associated with storage facilities and distribution environments. In one reported year, 157 major injuries were recorded across warehousing and storage facilities, demonstrating why effective safety management remains essential.

The Health and Safety at Work etc. Act 1974 (HASWA) remains the primary legislation governing workplace health and safety in the UK.

Under HASWA, employers have a duty to protect the health, safety and welfare of workers.

Additional legal requirements include:

• COSHH Regulations
• Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)
• Workplace safety regulations
• Fire safety legislation

LOLER requires lifting operations involving equipment to be properly planned, supervised and completed by a competent person.

Environmental standards also help maintain a safe warehouse environment by reducing exposure to issues that may affect worker health, including poor ventilation and other workplace conditions.

Ensuring compliance helps businesses avoid penalties, improve worker safety and reduce operational risk.

Businesses looking to improve warehouse health and safety should focus on creating a comprehensive framework that combines training, technology, inspections and risk management.

Best practices include:

• Regular risk assessments
• Proper training
• Fire safety planning
• Equipment inspections
• Hazard reporting
• Emergency response planning
• Storage audits
• Worker engagement
• Preventive measures
• Ongoing compliance reviews

Health and safety should be carefully considered throughout every stage of warehouse operations.

The most successful organisations view safety as an ongoing process rather than a one-time exercise.

1. Why is warehouse health and safety important?

Warehouse health and safety helps minimise risk, prevent accidents and improve operational efficiency. Effective safety measures protect workers from injuries while supporting compliance and productivity.

2. What are the biggest warehouse safety risks?

Common risks include slips, trips and falls, forklift truck incidents, falling objects, manual handling injuries, hazardous substances and poor storage practices.

3. How can technology improve warehouse health and safety?

Technology can support safety management through sensors, alarms, surveillance cameras, automated inspections and incident reporting systems that help identify hazards earlier.

4. What role does training play in warehouse safety?

Training helps workers understand hazards, operate equipment safely, follow emergency procedures and reduce accidents throughout the warehouse environment.

5. Which regulations apply to warehouse health and safety?

Key regulations include Health and Safety at Work etc. Act 1974, COSHH Regulations and LOLER requirements governing lifting equipment and workplace safety.

6. How often should risk assessments be carried out?

Risk assessments should be reviewed regularly and whenever there are significant changes to equipment, warehouse layouts, storage facilities or working practices.