Health Safety-guidance 2.0(1)

8/18/2019 Health Safety-guidance 2.0(1)

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HEALTH AND SAFETY


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Warehousing

A guide to health and safety

This short guide is to help those involved in warehousing and storage to reduce

the number of injuries and cases of occupational ill health. It contains simple advice

that you should be able to apply.

Causes of accidents.

The main causes of accidents in warehousing and storage are:

manual handling;

slips and trips;

work at height;

vehicles in and around the warehouse; and

moving or falling objects.

Manual handling

People suffer from work-related aches and pains in the warehousing and storage

industry, including problems such as lower back pain and neck pain. The biggest cause of

back injury at work is lifting or handling objects incorrectly. There are some steps that must

be followed in order to prevent injury and avoid back pain.

1.The lift must be planned and assessed in advance in case you require help from acolleague not to injure yourself. The necessity of resting the load mid-way can also present

itself in which case you need to ensure you have a bench or a table nearby.

2.Keep the load close to your body for as long as possible while lifting so you can see

over it and since the distance of the load from the body increases considerably the effort put

on your spine and could have severe consequences.

3.Make sure the position you are in the moment of the lift is a stable one. Your feet

should be apart with one leg slightly forward to maintain balance (alongside the load if it's on

the ground).

4.Do not bend your back while lifting and avoid twisting your body in any way.

5.Keep your head up and look ahead when handling the load.

6.Try to move as smoothly as possible and know what your limits are.

The activities that involve manual handling are picking up and

putting down objects, pushing and pulling objects and carrying

objects.

You must always remember that you need to keep the loads close

to your body at all times.

The main purpose of a manual handling risk assessment is to

reduce or even eliminate the risk of hazard.

If a load is to heavy or bulky you must always get a mechanical help or somebody to help

you. You should not always pull a trolley and when it comes to team lifts, one person should be in charge.


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People suffer from work-related aches and pains in the warehousing and storage industry,

including problems such as lower back pain and neck pain.

If there is a risk from a manual handling task, try to avoid the task first. If the task cannot be

avoided, the risk of injury occurring must be minimised.

Carry out a manual handling assessment for manual handling operations and tasks that present a risk of injury. Consider:

■ the task;

■ the load;

■ the working environment;

■ individual capability; and

■ other factors.

Good handling technique for lifting

Here are some practical tips, suitable for use in training people in safe manual

handling. In the following section a basic lifting operation is taken as an example.

■ Think before lifting/handling. Plan the lift. Can handling aids be used? Where

is the load going to be placed? Will help be needed with the load? Remove

obstructions such as discarded wrapping materials. For a long lift, consider

resting the load midway on a table or bench to change grip. By using the natural pivot points

when lifting and lowering you are only taking the weight of an item when you have to, this

makes the task safer and easier.

■ Keep the load close to the waist. Keep the load close to the body for as long

as possible while lifting. Keep the heaviest side of the load next to the body. If a

close approach to the load is not possible, try to slide it towards the body

before attempting to lift it.


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■ Adopt a stable position. The feet should be apart with one leg slightly forward

to maintain balance (alongside the load, if it is on the ground). The worker

should be prepared to move their feet during the lift to maintain their stability.Avoid tight clothing or unsuitable footwear, which may make this difficult.

■ Get a good hold. Where possible the load should be hugged as close as

possible to the body. This may be better than gripping it tightly with hands only.

■ Start in a good posture. At the start of the lift, slight bending of the back, hips

and knees is preferable to fully flexing the back (stooping) or fully flexing the

hips and knees (squatting).

■ Don’t flex the back any further while lifting. This can happen if the legs begin to straighten

before starting to raise the load.

■ Avoid twisting the back or leaning sideways, especially while the back is bent. Shoulders

should be kept level and facing in the same direction as the hips. Turning by moving the feet

is better than twisting and lifting at the same time.

■ Keep the head up when handling. Look ahead, not down at the load, once it has been held

securely.

■ Move smoothly. The load should not be jerked or snatched as this can make it harder to

keep control and can increase the risk of injury.


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■ Don’t lift or handle more than can be easily managed. There is a difference between what

people can lift and what they can safely lift. If in doubt, seek advice or get help. To reach

items above head height use the correct access equipment and always try to work at shoulder

height.

■ Put down, then adjust. If precise positioning of the load is necessary, put it

down first, then slide it into the desired position.

Good handling technique for pushing and pulling

Here are some practical points to remember when loads are pushed or pulled.

■ Handling devices. Aids such as barrows and trolleys should have handle heights that are between the shoulder and waist. Devices should be well maintained with wheels that run smoothly

(the law requires that equipment is maintained). When purchasing new trolleys etc, ensure they are

of good quality with large diameter wheels made of suitable material and with castors,

bearings etc which will last with minimum maintenance. Consultation with your

employees and safety representatives will help, as they know what works and what doesn’t.

The SOP, Risk Assessment and Trolley Code have the information on how to safely move a

trolley.

■ Force. As a rough guide the amount of force that needs to be applied to move a load over a flat,

level surface using a well-maintained handling aid is at least 2% of the load weight. For example,

if the load weight is 400 kg, then the force needed to move the load is 8 kg. The force needed will

be larger, perhaps a lot larger, if conditions are not perfect (e.g. wheels not in the right position ora device that is poorly maintained).


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The operator should try to push rather than pull when moving a load, provided they can see over it

and control steering and stopping.

■ Slopes. Employees should enlist help from another worker whenever necessary if they have to

negotiate a slope or ramp, as pushing and pulling forces can be very high. For example, if a load

of 400 kg is moved up a slope of 1 in 12 (about 5°), the required force is over 30 kg even in ideal

conditions - good wheels and a smooth slope. This is above the guideline weight for men and wellabove the guideline weight for women.

■ Uneven surfaces. Moving an object over soft or uneven surfaces requires higher forces. On an

uneven surface, the force needed to start the load moving could increase to 10% of the load

weight, although this might be offset to some extent by using larger wheels. Soft ground may be

even worse.

■ Stance and pace. To make it easier to push or pull, employees should keep their feet well away

from the load and go no faster than walking speed. This will stop them becoming too tired too

quickly.

If a tracker coach will observe that you are using incorrect manual handling techniques, he

will stop you, demonstrate the correct technique to you and ask you to demonstrate it back to

them and to ensure you are competent in the technique.

General risk assessment guidelines

General risk assessment guidelines.

There is no such thing as a completely ‘safe’ manual handling operation. But working within

the following guidelines will cut the risk and reduce the need for a more detailed assessment.

Figure 2 Lifting and lowering

■ Use Figure 2 to make a quick and easy assessment. Each box contains a guideline weight

for lifting and lowering in that zone. (As you can see, the guideline weights are reduced if

handling is done with arms extended, or at high or low levels, as that is where injuries are

most likely to occur.)

■ Observe the work activity you are assessing and compare it to the diagram. First, decide

which box or boxes the lifter’s hands pass through when moving the load. Then, assess the

maximum weight being handled. If it is less than the figure given in the box, the operation is

within the guidelines.


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■ If the lifter’s hands enter more than one box during the operation, use the smallest weight.

Use an in-between weight if the hands are close to a boundary between boxes.

■ The guideline weights assume that the load is readily grasped with both hands and that the

operation takes place in reasonable working conditions, with the lifter in a stable body

position.

TwistingReduce the guideline weights if the handler twists to the side during the operation.

As a rough guide, reduce them by 10% if the handler twists beyond 45°, and by 20% if the

handler twists beyond 90°.

Frequent lifting and lowering

The guideline weights are for infrequent operations - up to about 30 operations per hour -

where the pace of work is not forced, adequate pauses to rest or use different muscles are

possible, and the load is not supported by the handler for any length of time. Reduce theweights if the operation is repeated more often. As a rough guide, reduce the weights by 30%

if the operation is repeated once or twice per minute, by 50% if the operation is repeated five

to eight times a minute, and by 80% where the operation is repeated more than 12 times a

minute.

The right order in which you need to lift a load is to assess the weight of the load being lifted,

bend at the knees, maintaining the back`s natural posture and hold the load close to your body

at all times.


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Slips and trips

Slips and trips can be a problem in the warehouse environment that can happen at any

time but that can also be easily avoided.

A contaminated floor must be dealt with immediately. Also the recommendedfootwear should help reduce slips that is why you must follow the dress code the warehouse

is enforcing.

Trips are usually caused by what is called a trip hazard that happens when the floors

and the traffic routes are not free from obstructions. Good housekeeping is important and by

paying attention and inspecting the workplace regularly you can also make it happen; this

way you avoid any kind of tripping hazard.

Slip and trip accidents are a serious problem in warehousing and storage and can happen

anywhere. They are often seen as trivial and ‘just one of those things’, but most slip and trip

accidents can be avoided.

Slips

Slips usually happen because the floor is wet or contaminated. Within warehouses,

water, oil, cleaning products, dry powders and foodstuffs can all make the floor more

slippery. Other items, like stretch wrapping, label backing and plastic bags, can also cause

slips. Try to stop the floor getting contaminated, eg by maintaining equipment properly.

When contamination does happen, deal with it immediately, eg by cleaning. Most floors have

good slip resistance when they are clean, dry and level. However, smooth floors that become

even a tiny bit wet or contaminated will be slippery; the rougher the floor, the better it will

cope with water and other contamination and the less likely someone is to slip.The right footwear can help reduce slips but only consider issuing footwear to control slip

risks as a last resort – try to eliminate the root of the problem first.

Trips

Objects on the floor or uneven surfaces are usually the cause of trips. Trip hazards

can include items like goods, waste packaging, banded strapping loops and pallets.

Plan workflows and storage to make sure that goods, equipment and waste do not

cause obstructions or project into places where people may walk. Keep floors andtraffic routes free from obstructions. Check that floor surfaces are even both inside

and outside buildings and fill in any holes. Provide good lighting. Good housekeeping is

important; if items fall onto traffic routes, clear them as soon aspossible.

Also inspect the workplace regularly to make sure that there are no trip hazards.


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Moving objects

Mechanical handling

Mechanical handling equipment (eg a fork-lift truck) should be suitable for the job

it is used for. All industrial truck operating areas should be suitably designed and properlymaintained.

When working on site with Mechanical Handling Equipment, never walk under or over the

forks, always keep the safe designated distance away from operating MHE and never walk

past a piece of MHE in use without the permission from the driver.

Industrial truck operators need to be trained by a competent person. Operator

training should include the following three stages:

■ basic training;

■ specific job training; and

■ familiarisation training.

Storage systems

Storage areas should be properly designated and clearly marked. The layout of

storage and handling areas should avoid tight corners, awkwardly placed doors, pillars,

uneven surfaces and changes of gradient.

Inspect pallets each time before use to make sure that they are in a safe condition.

Take damaged pallets out of use for repair or destruction. Handle empty pallets carefully – do

not drag or throw them about. Pallets should be loaded correctly to ensure load stability;

banding, shrink or stretch wrap can help with this.

If you use pallet racking in your warehouse, make sure the pallets you use are suitable for

the type of racking you have. Racking systems should be properly designed and installed, this

includes being able to safely take the load of the goods being stored. Protect racking if it is

likely to be struck by lift trucks and other vehicles.

Inspect racking regularly to make sure it is repaired and maintained properly and is

safe.

You should use three types of inspection:

■ immediate reporting of damage and defects; ■ visual inspections at regular intervals; and

■ ‘expert’ inspections car ried out at intervals by a competent person.

Where you find damage that affects the safety of the racking system, offload the racking

and introduce controls to prevent it being used until remedial work has been carried out.


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Reporting accidents and incidents at work

RIDDOR is the law that requires employees and other people in control of work premises

to report and keep records of:

work-related accidents which cause death;

work-related accidents which cause certain serious injuries (reportable injuries); diagnosed cases of certain industrial diseases; and

certain ‘dangerous occurrences’ (incidents with the potential to cause harm).

Reporting certain incidents is a legal requirement. The report informs the enforcing

authorities (HSE, local authorities and the Office for Rail Regulation (ORR)) about injuries,

occupational diseases and dangerous occurrences, so they can identify where and how risks

arise, and whether they need to be investigated. This allows the enforcing authorities to target

their work and provide advice about how to avoid work-related deaths, injuries, ill health and

accidental loss.

Dangerous occurrences are certain, specified ‘near -miss’ events (incidents with the potential

to cause harm.) Not all such events require reporting. For example: the collapse, overturning or failure of load-bearing parts of lifts and lifting equipment;

plant or equipment coming into contact with overhead power lines;

explosions or fires causing work to be stopped for more than 24 hours.

Boxes that are stacked safely on a pallet will never be a near miss.

At work everybody is responsible for Health and Safety. The first thing you need to do if

there was an accident and someone was injured is to report it immediately to a First Aider.

Employers must report diagnoses of certain occupational diseases, where these are

likely to have been caused or made worse by their work.

These diseases include :

carpal tunnel syndrome;

severe cramp of the hand or forearm;

occupational dermatitis;

hand-arm vibration syndrome;

occupational asthma;

tendinitis or tenosynovitis of the hand or forearm;

any occupational cancer;

any disease attributed to an occupational exposure to a biological agent.

To help prevent accidents you should see the Risk Assessments and Standard Operation

Procedures. In that way you ensure that you`re working in a safe manner.

Employers are responsible for ensuring that employees receive immediate attention if they

are taken ill or are injured at work. Accidents and illness can happen at any time and first aid

can save lives and prevent minor injuries from becoming major ones. Employers must report

all the accidents. A Safety Rep or a Team Leader will always be prepared to assess your

concerns about health and safety.

Upon hearing the fire alarm first you should do is evacuate immediately via the nearest fire

exit. If the fire exit is blocked, unblock it, if possible, and then report it to your Line Manager.

Fire fighting equipment on site (E.g. Fire extinguishers) can be used only by trained people

and authorised to do so.


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Safety Attitude

We've talked about many different safety procedures that can prevent injury and accidents

in a warehouse. There's one more, which is all-important. That's your attitude. No matter how

good the protective equipment and how strict the rules, you can't be safe unless you make

safety a priority. You should always make sure your PPE(Personal Protective Equipment) is properly maintained, report faulty equipment to a team leader and wear it where and when

you are supposed to.

You have to take it seriously and use the equipment and procedures. You also have to use

your common sense. For example:

Pay attention to warning signs and signals — and obey them.

Watch where you're going; work is no place for daydreaming.

Walk, don't run. You'll get there almost as quickly — and more importantly, you'll get

there.

Hand tools and materials to other people; don't throw them.

Don't fool around; there are too many potential hazards here to allow horseplay.

If you have an accident / near miss / see a potentially dangerous Health & Safety hazard on

site you must report it immediately to your Line Manager.

Under health and safety law, employers are required to report and keep a record of certain

injuries, incidents and cases of work-related disease. Keeping records helps employers

improve the quality of the first aid provided to you and it is also necessary for the insurance

company in case of a work-related claim.

Packing and Unpacking

You also have to be aware of hazards and safety procedures when you pack and unpack

containers. Any cutting tool demands caution. Hold and use it in a manner that won't cut you

or someone else. On site or in the warehouse the type of knife should only be used is a safety

knife.

Don't leave an open blade on the floor or any surface where it creates a hazard.

Take care with metal and plastic strapping, too. If it whacks you in the face or eyes — or

anywhere else, for that matter — you'll regret it. Always wear heavy gloves and goggles when

you attach or remove strapping.

Use cutting tools that don't leave sharp edges. If you're doing packing, be sure to put the

straps on with just the right tension — not too loose or too tight. Don't lift by the strap unless

it's designed for that purpose. When you remove the straps, use one hand to hold down the

strapping and one to cut. Make sure that the sharp strapping end will go away from you when

you cut. Once the straps are cut, place them immediately in a trash container so they don't

hurt someone while lying on the floor. All the waste packaging should be disposed of

immediately in the correct way.


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Wrap-up

The warehouse is not a dangerous place, but it does contain many potential hazards. We

don't want to get so caught up in getting materials moved in and out that we forget to do it

safely. Fortunately, the safe way to run a warehouse is also the most efficient way. So

following safety rules and guidelines isn't just a legal requirement — it's good sense.Good housekeeping is one of the best ways to assure warehouse safety. We have to keep

the entire warehouse clean and neat, with everything in its place. The housekeeping on your

site is everyone’s responsibility.

Don't block aisles or leave materials around for someone to trip or fall over. Don't place

items on shelves or racks or ladders so unsteadily that they might fall on someone below.

Wear necessary protective gear and pay attention to warning signs and to the work that's

going on around you. Give the right of way to forklift trucks and even hand trucks. Operate

material handling equipment carefully; watch where you're going and keep your loads stable

and secure. When you lift and carry, do it properly so your legs do the work — not your back.

Preview every job before you start to make sure your equipment is in good condition and

that you are properly protected. Don't forget to alert others around you to tasks that could putthem in danger.

In other words, every day, all day, pay attention to what's going on around you and

precautions that will keep you and others safe.

Assessment guide for lifting operations

Load weight/frequency


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Hand distance from the lower back

Observe the task and examine the horizontal distance between the operative’s

hands and their lower back.

Vertical lift region

Observe the position of the operative’s hands at the start of the lift and as the lift progresses.


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Torso twisting and sideways bending

Observe the operative’s torso as the load is lifted.

Assessment guide for carrying operations


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Observe the task and examine the horizontal distance between the operative’s


Asymmetrical torso/load

The operative’s posture and the stability of the load are risk factors associated with

musculoskeletal injury.


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Assessment guide for team handling operations

Load weight


Observe the task and examine the horizontal distance between each operative’s


Vertical lift region

Observe the position of the operatives’ hands at the start of the lift and as the lift

progresses.


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Warehouse Signs


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MANDATORY SIGNS:


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PROHIBITION SIGNS:


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FIRE SIGNS:


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WARNING SIGNS:


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SAFE SIGNS:

Health Safety-guidance 2.0(1)

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