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OSHA 3220-10N 2004 WORKER SERIES WAREHOUSING 11 Think Safety & • More than 145,000 people work in over 7,000 warehouses. Warehouse operations can present a wide variety of potential hazards for • The fatal injury rate for the warehousing the worker. industry is higher than the national average for all industries. For warehousing establishments, the • Potential hazards for workers in warehousing: 10 OSHA standards most frequently • Unsafe use of forklifts; included in the agency’s citations • Improper stacking of products; were: • Failure to use proper personal protective 1 . Forklifts equipment; 2. communication • Failure to follow proper lockout/tagout 3. Electrical, wiring methods procedures; 4. Electrical, system design • Inadequate provisions; or 5. Guarding floor & wall openings • Repetitive motion injuries. and holes 6. Exits 7 . Mechanical power transmission 8. Respiratory protection 9. Lockout/tagout 10. Portable fire extinguishers

Occupational Safety and Health Administration U.S. Department of Labor www.osha.gov

Occupational Safety and Health Administration 2 WORKER SAFETY SERIES WAREHOUSING 3 Docks Forklifts Hazard: Injuries happen here when forklifts Hazard: About 100 employees are killed and run off the dock, products fall on employees 95,000 injured every year while operating or equipment strikes a person. forklifts in all industries. Forklift turnovers account for a significant percentage of these Solutions: fatalities. • Drive forklifts slowly on docks and dock Solutions: plates; • Train, evaluate and certify all operators to • Secure dock plates and check to see if the ensure that they can operate forklifts safely; plate can safely support the load; • Do not allow anyone under 18 years old to • Keep clear of dock edges and never back operate a forklift; up forklifts to the dock’s edge; • Properly maintain haulage equipment, • Provide visual warnings near dock edges; including tires; • Prohibit “dock jumping” by employees; • Before using a forklift, examine it for haz- • Make sure that dock ladders and stairs meet ardous conditions which would make it OSHA specifications. unsafe to operate; • Follow safe procedures for picking up, putting down and stacking loads; • Drive safely, never exceeding 5 mph and slow down in congested areas or those with slippery surfaces;

Occupational Safety and Occupational Safety and Health Administration Health Administration 4 WORKER SAFETY SERIES WAREHOUSING 5 • Ensure that the operator wears a seatbelt Conveyors installed by the manufacturer; Hazard: Workers can be injured when they • Never drive up to a person standing in front are caught in pinch points or in the in-going of a fixed object such as a wall or stacked nip points, are hit by falling products or materials; develop musculoskeletal disorders associated • Prohibit stunt driving and horseplay; with awkward postures or repetitive motions. • Do not handle loads that are heavier than Solutions: the capacity of the forklift; • Inspect conveyors regularly; • Remove unsafe or defective trucks from • Ensure that pinch points are adequately service until the defect is properly repaired; guarded; • Maintain sufficiently safe clearances for • Develop ways of locking out conveyors and aisles and at loading docks or passages train employees in these procedures; where forklifts are used; • Provide proper lighting and working sur- • Ensure adequate ventilation either by faces in the area surrounding the conveyor. opened doors/windows or using a ventila- tion system to provide enough fresh air to keep of noxious gases from engine exhaust below acceptable limits; • Provide covers and/or guardrails to protect workers from the hazards of open pits, tanks, vats and ditches; • Train employees on the hazards associated with the combustion byproducts of forklift operation, such as .

Materials Storage Hazard: Improperly stored materials may fall and injure workers. Solutions: • Stack loads evenly and straight; • Place heavier loads on lower or middle shelves; • Remove one object at a time from shelves; • Keep aisles and passageways clear and in good repair.

Occupational Safety and Occupational Safety and Health Administration Health Administration 6 WORKER SAFETY SERIES WAREHOUSING 7 Manual Lifting/Handling Hazard Communication Hazard: Back injuries may occur from Hazard: Chemical burns are possible if spills improper lifting or overexertion. of hazardous materials occur. Solutions: Solutions: • Provide general ergonomics training and • Maintain a Material task-specific training; (MSDS) for each chemical to which workers are exposed in the facility; • Minimize the need for lifting by using good design and engineering techniques; • Follow instructions on the MSDS for han- dling chemical products; • Lift properly and get a coworker to help if a product is too heavy. • Train employees on the risks of each chemical being stored; • Provide spill cleanup kits in any area where chemicals are stored; • Have a written spill plan; • Train employees to clean up spills, protect themselves and properly dispose of used materials; • Provide proper personal protective equipment and enforce its use; • Store all chemicals safely and securely; • Store chemicals away from forklift traffic areas.

Occupational Safety and Occupational Safety and Health Administration Health Administration 8 WORKER SAFETY SERIES WAREHOUSING 9 Charging Stations Poor Ergonomics Hazard: Fires and explosion risks are possible Hazard: Improper lifting, repetitive motion or unless proper guidelines are followed. poor design of operations can to muscu- loskeletal disorders in workers. Solutions: • Prohibit smoking and open flames in and Solutions: around charging stations; • If possible, use powered equipment instead • Provide adequate ventilation to disperse of requiring a manual lift for heavy materials; fumes from gassing batteries; • Reduce lifts from shoulder height and from • Ensure that fire extinguishers are available floor height by repositioning the shelf or bin; and fully charged; • Ensure overhead lighting is adequate for • Provide proper personal protective the task at hand; equipment such as rubber gloves and eye • Provide employees with task-oriented and face protection; ergonomic training; • Properly position forklifts and apply brakes • Use your legs and keep your back in a natu- before attempting to change or charge ral position while lifting; batteries; follow required procedures when • Test the load to be lifted to estimate its refueling gas or fueled forklifts; weight, size and bulk, and to determine the • Provide conveyors, overhead hoists or proper lifting method; equivalent materials handling equipment • Get help if the load exceeds the maximum for servicing batteries; weight a person can lift safely without • Provide an eyewashing and safety shower assistance; facility for employees exposed to battery • Don’t twist while carrying a load, but shift acids. your feet and take small steps in the direc- tion you want to turn; • Keep floors clean and free of slip and trip hazards.

Occupational Safety and Occupational Safety and Health Administration Health Administration 10 WORKER SAFETY SERIES WAREHOUSING 11 Other Hazards Think Safety Inadequate fire safety provisions, improper use of lockout procedures and failure to wear The following checklists may help personal protective equipment also create you take steps to avoid hazards that hazards in the warehouse workplace. cause injuries, illnesses and fatalities. Employers should have an emergency plan As always, be cautious and seek help that describes what is expected of employees if you are concerned about a poten- in the event of an emergency, including: tial hazard. • Provisions for emergency exit locations and evacuation procedures; General Safety • Procedures for accounting for all employees ❏ Exposed or open loading dock doors and and visitors; other areas that employees could fall 4 feet or more or walk off should be chained • Location and use of fire extinguishers and off, roped off or otherwise blocked. other emergency equipment. ❏ Floors and aisles are clear of clutter, Warehouse operations need a lockout/tagout electrical cords, hoses, spills and other program to prevent equipment from being hazards that could cause employees to accidentally energized and injuring employees. slip, trip or fall. Employees required to perform these opera- ❏ Proper work practices are factored into tions should be trained and all employees determining the time requirements for an should have a working knowledge of the employee to perform a task. program. ❏ Employees performing physical work Finally, at warehouse operations have adequate periodic rest breaks needs to conduct a site hazard assessment to to avoid fatigue levels that could result in determine what personal protective equipment greater risk of and reduced (PPE) must be worn based on the hazards quality of work. present and train warehouse employees on proper PPE selection, use and maintenance. ❏ Newly-hired employees receive general ergonomics training and task-specific training. ❏ The warehouse is well ventilated. ❏ Employees are instructed on how to avoid heat stress in hot, humid environments. ❏ Employees are instructed on how to work in cold environments. ❏ The facility has lockout/tagout procedures.

Occupational Safety and Occupational Safety and Health Administration Health Administration 12 WORKER SAFETY SERIES WAREHOUSING 13 Materials Handling Safety Hazard Communication Safety ❏ There are appropriately marked and ❏ All hazardous materials containers sufficiently safe clearances for aisles and are properly labeled, indicating the at loading docks or passageways where chemical’s identity, the manufacturer’s mechanical handling equipment is used. name and address, and appropriate hazard warnings. ❏ Loose/unboxed materials which might fall from a pile are properly stacked by block- ❏ There is an updated list of hazardous ing, interlocking or limiting the height of chemicals. the pile to prevent falling hazards. ❏ The facility has a written program that ❏ Bags, containers, bundles, etc. are stored covers hazard determination, including in tiers that are stacked, blocked, inter- Material Safety Data Sheets (MSDSs), locked and limited in height so that they labeling and training. are stable and secure to prevent sliding There is a system to check that each or collapse. ❏ incoming chemical is accompanied by ❏ Storage areas are kept free from accumu- a MSDS. lation of materials that could lead to trip- All employees are trained in the require- ping, fire, explosion or pest infestations. ❏ ments of the hazard communication ❏ Excessive vegetation is removed from standard, the chemical hazards to which building entrances, work or traffic areas they are exposed, how to read and to prevent possible trip or fall hazards understand a MSDS and chemical labels, due to visual obstructions. and on what precautions to take to prevent exposure. ❏ Derail and/or bumper blocks are provided on spur railroad tracks where a rolling car ❏ All employee training is documented. could contact other cars being worked on All outside contractors are given a com- and at entrances to buildings, work or ❏ plete list of chemical products, hazards traffic areas. and precautions. Covers and/or guardrails are provided to ❏ Procedures have been established to protect personnel from the hazards of ❏ maintain and evaluate the effectiveness stair openings in floors, meter or equip- of the program. ment pits and similar hazards. Employees use proper personal protective Personnel use proper lifting techniques. ❏ ❏ equipment when handling chemicals. Elevators and hoists for lifting materials/ ❏ All chemicals are stored according to the containers are properly used with ade- ❏ manufacturer’s recommendations and quate safe clearances, no obstructions, local or national fire codes. appropriate signals and directional warn- ing signs.

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Forklift Safety ❏ Forklifts are properly positioned and brakes applied before workers start to Powered industrial trucks (forklifts) meet ❏ change or charge batteries. the design and construction requirements established in American National ❏ Vent caps are properly functioning. Standard for Powered Industrial Trucks, Precautions are taken to prevent smoking, Part II ANSI B56.1-1969. ❏ open flames, sparks or electric arcs in ❏ Written approval from the truck battery charging areas and during stor- manufacturer has been obtained for any age/changing of propane fuel tanks. modifications or additions that affect Tools and other metallic objects are kept the capacity and safe operation of the ❏ away from the top of uncovered batteries. vehicle. Concentrations of noxious gases and Capacity, operation and maintenance ❏ ❏ fumes are kept below acceptable levels. instruction plates, tags or decals are changed to specify any modifications or ❏ Forklift operators are competent to oper- additions to the vehicle. ate a vehicle safely as demonstrated by successful completion of training and Nameplates and markings are in place ❏ evaluation conducted and certified by and maintained in a legible condition. persons with the knowledge, training and ❏ Forklifts that are used in hazardous loca- experience to train operators and evalu- tions are appropriately marked/approved ate their performance. for such use. ❏ The training program content includes ❏ Battery charging is conducted only in all truck-related topics, workplace-related designated areas. topics and the requirements of 29 CFR 1910.178 for safe truck operation. ❏ Appropriate facilities are provided for flushing and neutralizing spilled ❏ Refresher training and evaluation is electrolytes, for fire extinguishing, for conducted whenever an operator has protecting charging apparatus from been observed operating the vehicle in damage by trucks and for adequate an unsafe manner or has been involved ventilation to disperse fumes from in an or a near-miss incident. gassing batteries. ❏ Refresher training and evaluation is ❏ Conveyors, overhead hoists or equivalent conducted whenever an operator is materials handling equipment are provided assigned to drive a different type of truck for handling batteries. or whenever a condition in the workplace changes in a manner that could affect Reinstalled batteries are properly ❏ safe operation of the truck. positioned and secured. Evaluations of each operator’s perfor- Carboy tilters or siphons are used for ❏ ❏ mance are conducted at least once every handling electrolytes. three years.

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❏ Load engaging means are fully lowered, Warehouse Safety & with controls neutralized, power shut off and brakes set when a forklift is left Health Resources unattended. Most resource materials can be found ❏ Operators maintain a safe distance from on the OSHA website: www.osha.gov the edge of ramps or platforms while using forklifts on any elevated dock, Materials Handling platform or freight car. Materials Handling and Storage ❏ There is sufficient headroom for the fork- OSHA Publication 2236 (Revised 2002). lift and operator under overhead installa- 559KB PDF, 40 pages. tions, lights, pipes, sprinkler systems, etc. A comprehensive guide to hazards and safe work practices in handling materials. ❏ Overhead guards are provided in good http://www.osha.gov/Publications/osha2236.pdf condition to protect forklift operators from falling objects. Electrical Hazards ❏ Operators observe all traffic regulations, Control of Hazardous Energy (Lockout/Tagout) including authorized plant speed limits. OSHA Publication 3120 (Revised 2002). ❏ Drivers are required to look in the direc- 174 KB PDF, 45 pages. tion of and keep a clear view of the path This booklet presents OSHA’s general require- of travel. ments for controlling hazardous energy during service or maintenance of machines or equipment. ❏ Operators run their trucks at a speed that http://www.osha.gov/Publications/osha3120.pdf will permit the vehicle to stop in a safe manner. Controlling Electrical Hazards OSHA Publication 3075 (Revised 2002). ❏ Dock boards (bridge plates) are properly 349KB PDF, 71 pages. secured when loading or unloading from This publication provides an overview of basic dock to truck. electrical safety on the job. ❏ Stunt driving and horseplay are prohibited. http://www.osha.gov/Publications/osha3075.pdf ❏ All loads are stable, safely arranged and Safety and Health Topics: Lockout/Tagout fit within the rated capacity of the truck. OSHA website index to information about lockout/tagout, including hazard recognition, ❏ Operators fill fuel tanks only when the compliance, standards and directives, Review engine is not running. Commission and Administrative Law Judge ❏ Replacement parts of trucks are equivalent Decisions, standard interpretations and in terms of safety with those used in the Compliance Letters, compliance assistance original design. and training. http://www.osha.gov/SLTC/controlhazardous Trucks are examined for safety before ❏ energy/index.html being placed into service and unsafe or defective trucks are removed from service.

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Protecting Young Workers: Prohibition Evacuation Plans and Procedures Against Young Workers Operating Forklifts An eTool designed to help small, low-hazard OSHA Safety and Health Bulletin (2003), 4 service or retail businesses implement an emer- pages. Available as a PDF document, 109 KB. gency action plan and comply with OSHA's http://www.osha.gov/dts/shib/shib093003.html emergency standards. http://www.osha.gov/SLTC/etools/evacuation/ Hazard Communication index.html OSHA’s website index for resources on hazard communication. Fire Safety http://www.osha.gov/SLTC/hazardcommunica- Safety and Health Topics: Fire Safety tions/index.html OSHA website index to information on fire safety. http://www.osha.gov/SLTC/firesafety/index.html More Hazard Communication Frequently Asked Questions for Hazard Fire Safety Advisor Communication. OSHA, 6 pages. OSHA's Fire Safety Advisor is an interactive http://www.osha.gov/html/faq-hazcom.html expert software. It will help explain and apply OSHA's Fire Safety-related standards. It can Hazard Communication Standard. be used online or is available for download. OSHA Fact Sheet (1993), 3 pages. http://www.osha.gov/dts/osta/oshasoft/ http://www.osha.gov/pls/oshaweb/owadisp.shw softfirex.html _document?p_table=FACT_SHEETS&p_id=151 Hazard Communication Guidelines for Forklift Safety Compliance. OSHA Publication 3111 (2000), 112 Safety and Health Topics: Powered KB PDF, 33 pages. Industrial Trucks This document aids employers in understanding OSHA website index links to specific require- the Hazard Communication standard and in ments and other Federal agency requirements. implementing a hazard communication program. http://www.osha.gov/SLTC/poweredindustrial- http://www.osha.gov/Publications/osha3111.pdf trucks/index.html Communication. OSHA Sample Daily Checklists for Powered Industrial Trucks Publication 3084 (1998), 248 KB PDF, 31 pages. http://www.osha.gov/dcsp/ote/trng-materials/pit/daily_pit_checklist.html This booklet answers several basic questions Preventing Injuries and Deaths of Workers about chemical hazard communication. Who Work Near Forklifts http://www.osha.gov/Publications/osha3084.pdf NIOSH Alert Pub. No. 2001-109 (June 2001). NIOSH Pocket Guide to Chemical Hazards. This alert instructs workers in the steps they can Handy source of general industrial hygiene take to protect themselves near forklifts. It is also information on several hundred chemicals/ available as a downloadable PDF document. classes for workers, employers and occupa- http://www.cdc.gov/niosh/2001-109.html tional health professionals. http://www.cdc.gov/niosh/npg/npg.html

Occupational Safety and Occupational Safety and Health Administration Health Administration 20 WORKER SAFETY SERIES WAREHOUSING 21 Ergonomics Warehouse Industry Safety and Health Topics: Ergonomics OSHA website index to resources and publica- Cooperative Programs tions on ergonomics. http://www.osha.gov/SLTC/ergonomics/index.html Grocery Warehousing – Ergonomics An e-tool specific for warehousing operations in the grocery industry. http://www.osha.gov/SLTC/etools/grocery warehousing/index.html Personal Protective Equipment Voluntary Protection Programs Numerous VPP worksites that OSHA Safety and Health Topics: recognizes for their excellent safety and health Personal Protective Equipment management systems deal with the hazards OSHA’s website index to hazard recognition, of warehousing and storage. These model control and training related to personal protec- worksites are willing to share their expertise tive equipment. and many are available to mentor other http://www.osha.gov/SLTC/personalprotective businesses. For further information on how equipment/index.html VPP participants can help you, contact the VPP Personal Protective Equipment. OSHA Manager in your OSHA Regional Office or the Publication 3151 (2004), 695KB PDF, 44 pages. Voluntary Protection Programs Participants’ Discusses equipment most commonly used for Association, 7600-E Leesburg Pike, Suite 440, protection for the head, including eyes and face, Falls Church, VA 22043, telephone (703) 761- and the torso, arms, hands and feet. The use of 1146. equipment to protect against life-threatening hazards is also discussed. http://www.osha.gov/Publications/OSHA3151/ osha3151.html

Alliance Program Alliances enable organizations committed to workplace safety and health to collaborate with OSHA to prevent injuries and illnesses in the workplace. A number of Alliances have an impact on the warehousing industry, including the following: Retail Industry Leaders Association The OSHA Alliance with the Retail Industry Leaders Association (RILA) is focused on

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sharing safety and health best practices and technical knowledge, including ergonomics in NJ Warehouse retail warehousing and distribution facilities. Operation - Industrial Truck Association The Industrial Truck Association (ITA) and A Success Story OSHA also have an Alliance to promote the safe operation of powered industrial trucks OSHA recommendations result in through training and outreach. The goal of the immediate, high payoff for an East Alliance is to assist employers and employees Coast warehouse operation. in reducing and preventing exposure to potential hazards associated with the use of Injury Reduction powered industrial trucks in general, and in Recently, a New Jersey warehouse operation warehouses in particular. had been averaging two back injuries a month. After adopting several OSHA International Warehouse Association recommendations for reducing ergonomic OSHA and the International Warehouse risk factors specific to their operations, the Logistics Association (IWLA) work together company reported zero back injuries. to protect employees’ safety and health, including hard-to-reach youth workers. The Boosting Morale & Productivity Alliance addresses materials handling, forklift And there was another benefit from adopting safety, hazard communication and other OSHA’s recommendations. According to the issues unique to the public warehouse industry. Marlton, NJ OSHA area office, company National Lumber and Building Material sources reported that both the morale and Dealers Association productivity of the company’s 50 warehouse OSHA has an Alliance with the National employees had subsequently increased. Lumber and Building Material Dealers Association (NLBMDA) to increase overall Ongoing Help safety awareness in that industry while As part of OSHA’s ongoing efforts to do a specifically addressing recordkeeping issues, better job in promoting workers’ safety and preventing forklift accidents and avoiding health, the agency has developed a program lifting strains. to help identify certain industries that have exceptionally high injury rates. One of these industries is warehousing. By identifying these workplaces, OSHA is better able to assist businesses in reducing their high injury rates. Through the Site Specific Targeting Plan, OSHA performs a comprehensive evaluation of a workplace and, with the help of its technical experts, helps the employer develop a plan for improving its employees’ safety and health.

Occupational Safety and Occupational Safety and Health Administration Health Administration 24 WORKER SAFETY SERIES WAREHOUSING 25 Specific Recommendations Feasible Controls OSHA’s recommendations were developed In OSHA’s detailed evaluation, each hazard specifically for this New Jersey warehouse was carefully described, including photo- operation by OSHA’s Salt Lake City Technical graphs illustrating the task to help clearly Support Center following an inspection of the show the hazard. For each hazard, OSHA 186,000 square foot facility under the specialists detailed several feasible controls. agency’s Site Specific Targeting Plan which These were straightforward, easy-to-imple- included a comprehensive walkaround of the ment actions such as: workplace and a review of its injury records. • Adjusting the height of shelves; Avoiding MSDs • Providing stools or ladders to employees; OSHA compliance officers worked with • Reducing the depth of shelving; experts at the Salt Lake City Center to tailor • Raising loading heights; specific recommendations to address the potential ergonomic risk factors they • Evaluating the flow and volume of orders observed. Specialists at Salt Lake City so faster-moving products are placed on analyzed the warehouse’s various operations easier-to-reach shelves. and recommended 19 steps, known as “feasible controls,” that the employer could Also, OSHA’s evaluation report detailed a list take to help employees to avoid muscu- of available resources, including on-site losketal disorders (MSDs). consultation visits, that the company could use in developing improved ways to prevent Hazards Identified injuries. Some of the hazards identified by OSHA included: The company adopted 13 of the 19 feasible controls that OSHA recommended. And the • Employees had to reach elevated and result, thus far, speaks for itself: a perfect zero distant locations in storage shelves to for back injuries, improved productivity and access materials; higher employee morale. • Workers had to repeatedly bend to reach low-level locations at floor level to access materials; • Employees were lifting and placing heavy boxes onto pallets placed on the floor; • Employees were performing forceful finger tasks with their wrists in bent postures while pricing products at poorly designed workstations.

Occupational Safety and Occupational Safety and Health Administration Health Administration Occupational Safety and Health Administration U.S. Department of Labor www.osha.gov

OSHA’s role is to assure the safety and health of America’s workers by setting and enforcing stan- dards; providing training, outreach and education; establishing partnerships; and encouraging con- tinual improvement in workplace safety and health.

This informational booklet provides a general overview of a particular topic related to OSHA standards. It does not alter or determine compli- ance responsibilities in OSHA standards or the Occupational Safety and Health Act of 1970. Because interpretations and enforcement policy may change over time, you should consult current OSHA administrative interpretations and decisions by the Occupational Safety and Health Review Commission and the Courts for additional guid- ance on OSHA compliance requirements.

This publication is in the public domain and may be reproduced, fully or partially, without permis- sion. Source credit is requested but not required.

This information is available to sensory impaired individuals upon request. Voice phone: (202) 693- 1999; teletypewriter (TTY) number: (877) 889-5627.