Write a risk assessment for warehouse

A warehouse risk assessment should be documented as a task-based assessment that identifies hazards by area, job step, hazard source, body part at risk, severity, probability, risk code, required controls, responsible person, and review date. A suitable method is to carry out a walk-through survey, break each job into steps, identify hazard types and sources, assign a risk priority code, implement controls, and certify the assessment. Employees should be involved in the process, and the assessment should be reviewed periodically and whenever tasks, equipment, or incidents change. [9] [12] [9]

• Hazard identification: inspect each warehouse area for vehicle movement, manual handling, storage stability, slips/trips, fire risks, electrical hazards, poor lighting, noise, chemicals, and emergency access issues.
• Task-based risk evaluation: assess receiving, unloading, palletizing, picking, packing, charging batteries, waste handling, cleaning, maintenance, and loading operations step by step.
• Risk rating and action: use severity and probability to assign a risk code. High-risk tasks must stop until controlled; medium-risk tasks require prompt controls; low-risk tasks still need review against legal requirements.
• Control measures: apply the hierarchy of controls first—elimination, substitution, engineering controls, safe systems of work, supervision, training, and then PPE.
• Manual handling: reduce lifting by redesigning tasks, using pallet trucks, conveyors, lift tables, hoists, team lifts, weight limits, and training on stable loads and neutral postures.
• Forklift and pedestrian segregation: provide marked walkways, physical barriers where practicable, one-way traffic systems, crossing points, speed limits, warning signage, lighting, horns, and trained authorized operators only.
• Storage and racking safety: ensure racks are suitable for load, protected from impact, inspected routinely, damaged components taken out of service, loads kept stable, aisles clear, and heavier items stored lower where practicable.
• Slips, trips, and falls: maintain housekeeping, remove debris, clean spills immediately, secure cables and mats, repair floor defects, improve lighting, and require slip-resistant footwear where needed.
• Fire safety: maintain extinguishers and alarms, control ignition sources, manage flammables, keep exits and aisles clear, post evacuation routes, and train staff in alarm raising and evacuation.
• Emergency procedures: establish emergency action and fire prevention plans, first-aid arrangements, spill response, evacuation assembly points, rescue contacts, and drills.
• PPE: select PPE only after other controls are considered; typical warehouse PPE may include safety footwear, hi-vis clothing, gloves, eye protection, hearing protection, and task-specific respiratory protection.
• Incident reporting and compliance: report injuries, near misses, property damage, and unsafe conditions promptly; investigate root causes; maintain OSHA injury records where required; and keep training, inspections, and hazard assessment documentation available.

[15] [6] [1] For manual handling, the assessment should identify lifting, lowering, carrying, pushing, pulling, twisting, repetitive handling, and awkward postures. Controls should prioritize mechanical assistance and task redesign over reliance on technique alone. Where loads are heavy or unstable, use hoists, pallet jacks, lift tables, conveyors, or team handling, and set clear rules for maximum load size, route condition, and stacking stability. Manual handling risks should also consider slips and visibility while carrying loads. [15] [5] [14]

Forklift and pedestrian segregation is a critical warehouse control. The risk assessment should identify all vehicle routes, reversing areas, dock edges, blind corners, charging areas, and pedestrian crossings. Controls should include separate pedestrian walkways, barriers or guardrails where feasible, designated crossing points, mirrors at blind spots, traffic management rules, speed control, exclusion zones during loading, and pre-use checks for powered industrial trucks. Only trained and authorized operators should use forklifts, and pedestrians should wear high-visibility clothing where vehicle interaction exists. [12] [1] [15]

Storage and racking safety documentation should cover rack load limits, pallet condition, stacking methods, aisle widths, impact protection, inspection frequency, and defect reporting. The assessment should verify that materials are stored in an organized manner, that employees understand storage and placement rules, and that damaged racks, pallets, or guards are remedied immediately. Loads should not protrude into aisles, and unstable or damaged pallets should be removed from use. [2] [2] [1]

Slips, trips, and falls should be assessed in all aisles, docks, stairs, mezzanines, entrances, and outdoor loading areas. Common controls include housekeeping standards, immediate spill cleanup, floor maintenance, cable management, adequate lighting, marked changes in level, suitable footwear, and routine inspections. Conditions such as poor lighting, glare, shadows, bulky PPE, noise, clutter, loose mats, wet floors, and improper mounting or dismounting of equipment all increase risk and should be specifically addressed in the assessment. [3] [14] [14]

Fire safety and emergency procedures should be documented together. The warehouse assessment should confirm that alarms and extinguishers are available, exits are clearly marked and accessible, evacuation routes are maintained, and employees are trained in emergency response. Emergency arrangements should include alarm activation, evacuation, roll call, first aid, spill response, fire warden responsibilities, emergency contacts, and periodic drills. Battery charging, hot work, flammable storage, and waste accumulation should be included where relevant. [2] [2] [1] [1]

PPE requirements should be based on the hazard assessment and matched to the task. The documentation should state what PPE is required, where it is required, limitations, inspection and replacement rules, training records, and supervisory enforcement. In warehouses, common PPE includes safety footwear with slip-resistant soles, high-visibility garments around vehicles, gloves for handling materials, eye protection where there is flying debris or strap tension, hearing protection in noisy areas, and head protection where overhead hazards exist. PPE must not be the first or only control where engineering or administrative controls are feasible. [10] [10] [13] [7]

Incident reporting and legal compliance should require prompt reporting of injuries, near misses, unsafe conditions, equipment damage, racking strikes, spills, and fires. Investigations should identify immediate and root causes, corrective actions, responsible persons, and completion dates. For OSHA-aligned compliance, maintain required injury and illness records, including the OSHA 300 log and 300A summary where applicable, and ensure hazard assessments, PPE training, inspections, and emergency procedures are documented and available. For HSE-style compliance, the same principles apply: suitable and sufficient risk assessment, preventive and protective measures, employee information and training, consultation, monitoring, and periodic review. [1] [1] [11]

• Warehouse/activity covered and assessment date.
• Assessor name, competent reviewer, and approval/sign-off.
• Area/task/step being assessed.
• Hazard type, hazard source, persons at risk, and existing controls.
• Severity, probability, and risk code.
• Further controls required using the hierarchy of controls.
• PPE required, issue arrangements, training, inspection, and replacement.
• Emergency arrangements relevant to the task or area.
• Inspection frequencies for racking, forklifts, fire equipment, exits, and housekeeping.
• Incident and near-miss reporting route.
• Legal references used by the site, including OSHA requirements and applicable HSE duties.
• Review trigger dates: after incidents, layout changes, new equipment, new substances, or process changes.

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