Safe storage for warehousing and logistics

Physical shop closures after the Covid pandemic and increased costs of retail premises, created rapid growth in ecommerce. Hence a surge in demand for warehousing and logistics centres then occurred.

The expectation of faster delivery times, casual staff recruitment and the need to be sustainable and save costs, all contribute to the added pressures of safe storage in warehousing and logistics.

15 fatal injuries occurred in 2022/23 in the UK transportation and storage industry. Forklift injuries were the highest contributor, but 16% of fatal injuries were caused due to being struck by a moving, including flying/falling object. 11% were due to something collapsing or overturning (source RIDDOR: 22/23). Falling materials and collapsing loads can crush or immobilise workers, which causes injury or even death. Warehouses can be hazardous workplaces and safety is an ongoing challenge.

In this blog we will tackle one of the crucial safety risks. Proper storage and the hazards that occur due to poor, unsafe storage, such as unstable or overloaded shelves. We will help you tackle these challenges to ensure your employees’ wellbeing.

Some of the hazards associated with storage:

1. Stock falling from shelving or racking due to poor stacking
2. Increased manual-handling injuries, e.g. lifting boxes up high, back injuries, lack of mechanical assistance
3. Exposure to badly stored hazardous substances/contamination
4. Chance of falling if climbing to reach goods
5. Risk of fire, if flammable goods not stored appropriately
6. Spillages increasing slips and potential environmental damage
7. Trips from rubbish or lack of appropriate storage
8. Goods blocking fire exits
9. Shelving/racking not appropriate for requirements, potential collapse if overstocked
10. Damage to goods that will cause financial impact.

Creating a safe storage environment

With such a dynamic working environment of constant refilling and shipping stock, moving machinery and lots of people, there is a high level of health and safety risk.

Proper storage solutions and best practice minimise the risks associated with storage facilities.

Below are a few guidelines to follow.

Your compliance requirements

You should carry out a risk assessment on your storage/warehouse facilities, as well as workplace transport under health & safety legislation.   A fire risk assessment should also be conducted, taking account of the nature and quantity of stored products. This will identify foreseeable risks and how they can be reduced or mitigated.

Some areas of storage for example for a factory, warehouse, food business or shop are going to be much larger areas than for example an office, however proper storage is imperative, whatever the size of the area. The profitability of the company can depend on having the correct storage solution installed for their specific needs. If goods are not stored correctly hazards can occur.

Shelving and racking

A conventional pallet racking system is the most common in warehousing and storage facilities, but they can pose a risk if not managed correctly.

The HSE states that ‘The layout of storage and handling areas should avoid tight corners, awkwardly placed doors, pillars, uneven surfaces and changes of gradient.’ Shelving and racking must be installed correctly and fit for purpose, and continually maintained as this all reduces potential incidents.

The following must be adhered to:

• Flooring must be suitable and level – prevents items toppling.
• Check the load bearing wall is adequate.
• Racking to be installed by a competent person, so it is fitted correctly and firmly secured, with no risk of falling or collapsing.
• Do not store materials within 18 inches of sprinkler heads, in case of fire.
• Racking should be arranged to allow enough space, for safe access for vehicles and people.
• Install fall protection netting – to prevent goods from inadvertently falling.
• Use suitable guards on racking uprights and vulnerable parts such as corners to protect against impact damage.
• Use visual indicators of maximum stacking heights, so employees can easily see the height and clearance limits. (16 feet high, without using a machine, otherwise 20 feet)
• Do not exceed the safe working load of the storage racking/shelving, which should be clearly labelled.  
• Do not make any modifications to the racking without prior consultation with the suppliers.
• Stack in interlocking blocks to prevent sliding and falling (taking into consideration weight and height) with blocks or pallets in between.
• Align goods with the racking, no overhang to prevent falling objects.
• Proper stacking techniques, put heaviest items at the lower/middle shelves as this minimizes upper body risk of stacking/unstacking.
• Use ladders and stools, do not climb on the racking, or lean on it.
• Most frequently used items in easy reach.
• Ensure the facility is well-lit  

Pallets

If pallets are being used, they must be good quality. The correct pallet should be used for the racking system, with the correct load bearing. Incorrectly loaded or damaged pallets can lead to collapse.  Pallets should be inspected each time they are used to ensure they are in a safe condition. Pallets should not be walked over, dragged, or thrown. More information on pallets is available from the HSE here Pallet safety PM15 (hse.gov.uk)

Hazardous materials

Chemicals and dangerous substances need to be handled and stored correctly as per the Control of Substances Hazardous to Health Regulations (COSHH). Each hazardous substance  should have a safety data sheet and where appropriate, a COSHH assessment.

Layout and good housekeeping

A well-organised warehouse with an efficient layout, not only improves productivity but also improves safety. Keeping walkways clean and clear from rubbish, helps prevent slips and trips, lowers fire risk and pest infestation. Having easy access to stock, proper labelling of stock storage areas, or separating into category areas, makes it easier and quicker for employees to find, increasing efficiency. Clearly differentiated pathways for forklifts and pedestrians, to prevent incidents.

Training

Training on correct storage practices, highlighting height and weight restrictions and emphasising the dangers of incorrect stacking is a necessity.

Manual handling should be avoided in favour of suitable lifting or moving equipment where possible. If manual handling is unavoidable then employees should be trained on safe lifting techniques through competent manual handling training to prevent injuries. If a mechanical lifting aid is required, then this should not be operated unless the employee has been correctly trained and have the relevant certification to do so. Correct PPE should also be provided, including hard hats, protective gloves, goggles, and safety footwear etc.

Training for working at height should also be provided, so employees are fully aware of the dangers of falls and selecting the right equipment for their task.

Regular inspections

The Storage Equipment Manufacturers Association (SEMA) recommends that your racking is inspected weekly by a competently trained person, to check for damage or wear and make sure it is still functional, checking for missing safety pins, overloading etc. It is recommended that this is recorded in a log book. In addition, regular inspection and maintenance on lifting equipment and fork lift trucks is also required.

It is important to record all inspection and maintenance schedules. Also have a clear process for employees to report maintenance issues or near misses as well as actual incidents.

Importance of safe storage for warehousing and logistics

Multiple factors play a role, with training being key, to maintaining proper material storage. Each sector will also have specific guidelines for stacking their specific materials e.g. drums, kegs, paper, waste etc. and their storage facilities should be chosen specifically for their individual needs. If done correctly it can drastically reduce the number of risks to your business and your employees, improve inventory management and increase operational efficiencies.

If you would like assistance with risk assessments Risk Assessment – do I need one? | Sentinel Safety Solutions Ltd, manual handing training, COSHH assessments or racking awareness training, please email info@sentinelsafety.co.uk or call us on 01527 833834.