How to Use: Walk the warehouse from a safe distance—never touch stored goods or equipment. Use a flashlight to check for dust or leaks. Ask the warehouse manager: “Last safety check? Forklift logs?” Mark High (overloaded shelves, blocked exits), Medium (clutter, old tags), or Low (stable, clear, trained) risk. Warehousing causes about 95,000 injuries each year in the United States (Occupational Safety and Health Administration 2024 data); falls from height and forklift crashes make up 40% of them. Average fire claim: $75,000+. Prevent with Occupational Safety and Health Administration storage rules and National Fire Protection Association warehouse standards.
THE BASICS: HOW WAREHOUSING FACILITIES WORK
Warehousing facilities store goods on shelves or pallets until shipped. Forklifts move heavy loads, workers pick items, and trucks load at docks.
Simple Types of Work:
- Storage: Goods stacked on racks or floors.
- Forklifts: Lift and carry boxes.
- Loading Docks: Trucks back in to load/unload.
Other Tasks: Packing makes trash, inventory counts clutter.
Key Tools:
- Racks: Tall shelves for boxes.
- Forklifts: Powered trucks for lifting.
Docks: Platforms for trucks.
Why Inspect: Overloaded racks collapse, forklifts tip, clutter trips—most problems from poor stacking or missing guards.
Easy Fact: Warehouses hold everything from food to tools—safe with clear paths and stable stacks, risky without.
INSPECTION CHECKLIST STORAGE RACKS
o Racks straight, anchored to floor, no bends Why: Weak racks fall over.
o Load signs posted: “Max 2,000 pounds per level” Why: Stops overload crashes. o Items stable, not leaning or over edges Why: Falling boxes hurt people.
FORKLIFTS
o Tires good, no leaks, seatbelts work Why: Bad tires cause tips.
o Horn and lights working, mirrors clean Why: Warns walkers nearby. o Drivers trained, no speeding Why: Cuts crash risk.
LOADING DOCKS
o Dock edges marked, bumpers good Why: Stops trucks from falling off. o Wheel chocks used for parked trucks Why: Keeps trucks from rolling. o Doors close tight, no gaps Why: Stops cold air or pests in.
FLOORS & PATHS
o Floors clean, no spills or loose pallets Why: Slips happen on mess. o Paths at least 3 feet wide, marked lines Why: Room for safe walking. o No cords or hoses across paths Why: Trips over them hurt.
FIRE PREVENTION
o Fire extinguishers near doors, current tags Why: Puts out small fires fast. o No smoking near stored goods Why: Sparks start box fires.
o Flammable items in locked cabinets Why: Keeps fire risk low.
FACILITY FIRE ALARMS & SPRINKLERS
o Fire alarm system serviced – annual tag current (last 12 months)Why: Proves full test and battery check.
o Smoke alarms beep when tested, no dust Why: Warns of fire early.
o Sprinkler system serviced – annual tag current (last 12 months)Why: Proves flow test and no clogs.
o Sprinkler heads clean, nothing within 18 inches Why: Water sprays free in fire. o Alarm panel green light, no trouble beeps Why: System ready to call help.
o Fire doors close tight, no props Why: Stops smoke spread.
SPRINKLER RISER & FIRE DEPARTMENT CONNECTION
o Riser room door unlocked, area clear of storage Why: Firefighters need fast access.
o Siamese caps on tight, no missing or painted Why: Lets fire trucks pump water in.
o Fire department connection sign visible: “Sprinkler Connection” Why: Guides fire crew quickly.
GENERAL SAFETY
o Lights bright, no dark corners Why: Stops trips in shadows. o Staff trained yearly on safe lifting Why: Cuts back injuries.
QUESTIONS TO ASK MANAGER
1. “When was the last full safety check? Can I see the log?”
2. “Racks—load limits posted? Anchored?”
3. “Forklifts—driver strained? Daily checks?”
4. “Docks—chocks used? Edges marked?”
5. “Fire alarms and sprinklers—annual service tags?”
6. “Riser room clear? Fire department connection caps on and signed?”
RISK LEVELS
- High = Bent racks, unsteady shelving, blocked riser, no service tags → Suggest attention immediately, fix now
- Medium = Clutter, dim lights → Clean in 30 days
Low = Stable, clear, trained → Best practice
LCA Certified Inspector “Stack it. Clear it. Service it.” Resources:
- Occupational Safety and Health Administration Storage Rules
- National Fire Protection Association Warehouse Standard
- National Institute for Occupational Safety and Health Lifting Guide
Safety by Design Warehouse Checklist
Disclosure: This guide highlights common risks but is not exhaustive. Always verify local codes and carrier guidelines.