Example: Risk assessment in a warehouse - Forktruck Solutions Ltd.

Company’s Name: GHI Warehouse Date of Risk Assessment: 10-01-06 

What are the 

hazards 

Falls from height 

Who might be harmed 

and how 

Staff could suffer severe or 

even fatal injuries if they fell 

whilst climbing racking. 

What are you already doing What further action is necessary Action 

by whom 

• All staff are given strict 

instructions never to climb 

racking – monitored by 

supervisors. 

Action 

by when 

Done 

Staff could suffer severe or 

even fatal injuries if they fell 

whilst changing light bulbs 

etc in the high ceiling. 

• Proprietary forklift cage used 

by maintenance worker for 

changing bulbs. Cage 

supplier’s information shows it 

is manufactured to standard. 

• Train maintenance worker to check 

cage is in good condition and 

properly secured before each use. 

RB 

17-01-06 

20-01-06 

Staff or contractor could 

suffer severe or fatal injuries 

falling through fragile roof 

lights when looking 

for/repairing leaks. 

• No controls in place. 

• Put up “fragile roof” signs, one on 

each side of the building and at 

access points to roof. 

• Agree with maintenance worker that 

a contractor will be used for any 

access to the roof. 

• Require contractor to provide an 

assessment before access is 

allowed if any roof work is required. 

RB 

SP 

SP 

13-01-06 

28-02-06 

15-03-06 

14-01-06 

28-02-06 

Manual handling 

Regular movement of 

cartons to pallets. 

Rolls of stretch wrap and 

flat pallets. 

Slips, trips and falls 

Worker falling from roof of 

internal warehouse office 

used for storage. 

All warehouse staff could 

suffer from back pain if 

regularly lifting/carrying 

heavy or awkward objects. 

All staff may suffer sprains 

or fractures if they trip over 

debris or slip on spillages. 

• The internal warehouse roof 

is load bearing, has full rails 

and boards around its edge, 

adequate lighting and access 

is by permanent steps with a 

handrail. 

• Conveyor system used to 

reduce manual handling 

materials in and out of 

delivery trucks. 

• Lift trucks used for most 

manual handling. 

• A range of manual handling 

tasks still required. 

• Flooring kept dry and quality 

maintained. 

• All staff trained to maintain 

good housekeeping standards 

and ensure stock does not 

project into gangways. 

• No further action required. 

• Manual handling training to be given 

to all warehouse staff. 

• Remaining manual handling tasks to 

be risk assessed using HSE’s 

Manual Handling Assessment Chart. 

• Suitable absorber to be made 

available for liquid spills. 

• Staff to be trained to clean and dry 

any spillages immediately. 

• Extra bins to be provided for waste 

material near loading bays. 

SP 

JB 

RB 

JB 

RB 

06-02-06 

20-01-06 

18-01-06 

11-01-06 

12-01-06 

01-02-06 

20-01-06 

16-01-06 

11-01-06 

12-01-06

Falling objects 

From racking and during 

movement 

Operation of lift trucks 

A member of staff or any 

other person in the 

warehouse may suffer 

serious injury if struck by a 

falling object. 

Injuries such as fractures or 

at worse fatalities can be 

caused as a result of: 

• the vehicle crashing into 

other vehicles and/or 

other objects; 

• staff and visitors being 

hit by lift trucks; 

• objects falling from lift 

trucks on to staff and 

visitors; 

• lift trucks toppling over; 

• people falling from the 

vehicle or parts of the 

vehicle, and 

• being crushed by the 

mast. 

• Cleaner empties bins and 

removes loose debris daily. 

• Pallets stored safely in 

designated area. 

• Protective non-slip footwear 

supplied and worn. 

• Racking is designed to be 

suitable for the loads carried 

and has not been modified. 

• Staff report any damage to 

racking immediately. 

• System in place to make sure 

defective pallets withdrawn 

from use immediately. 

• Protective footwear used by 

all entering warehouse. 

• Protective gloves provide to 

handle pallets. 

• All operators trained and 

competent for use of the lift 

truck. 

• Trucks serviced regularly and 

examined by suppliers every 

six months. 

• Drivers instructed to keep 

keys with them at all times. 

• System in place for refresher 

training of drivers. 

• Gangways and aisles of 

sufficient space to enable lift 

trucks to load and unload 

from the racking safely. 

• System in place to keep 

vehicles and pedestrians 

separated. 

• Access to warehouse 

restricted to staff. 

• Floor condition maintained on 

a regular basis, housekeeping 

standards maintained by 

cleaner and workforce. 

• Warning signs located around 

the traffic route. 

• Trucks have seat belts and 

• Sign fixed to racking stating 

maximum loads/configuration. 

• Supervisor to ensure truck drivers 

check trucks each day before 

starting. 

• Separate pedestrian entrance(s) 

with protective barrier rail to be 

provided next to roller-shutter doors. 

• Housekeeping standards and floor 

condition to be covered by a 

monthly inspection by manager and 

brief record kept. 

• Strict requirement that only 

competent drivers may operate lift 

trucks to be explained to all staff. 

Disciplinary action to be taken 

against anyone involved in breaking 

this rule. 

RB 14-07-06 

JB 10-01-06 

RB 20-06-06 

SP 27-01-06 

SP 23-01-06 

10-01-06 

27-01-06 

23-01-06

Traffic movements 

(deliveries etc) 

Machinery 

Stretch-wrap machine 

Injuries such as fractures or 

at worse fatalities can be 

incurred by 

• staff and visitors being 

hit by vehicle; 

• people falling from a 

vehicle or parts of a 

vehicle; and 

• objects falling from 

vehicle on to staff and 

visitors. 

All staff using the machine. 

Moving parts can trap parts 

of the body (e.g. 

fingers/hand/arm) causing 

crush injuries. The whole 

body may also get trapped 

between moving pallet load 

and fixed structure. 

Staff can also cut 

themselves on sharp edges 

or scald themselves on hot 

parts. 

roll cages. 

• Floor and traffic routes 

suitable for the vehicles using 

them. 

• Vehicle routes kept free of 

obstructions (with spillages 

being cleaned up promptly). 

• Parking of cars and vans only 

allowed in marked spaces 

well away from external 

delivery/dispatch area. 

• Outside area gritted when 

frosty, snow cleared. 

• Sensible speed limits 

imposed and adhered to. 

• Adequate signage to warn of 

hazards 

• Reversing of delivery vehicles 

should be avoided unless 

absolutely necessary. 

• Any reversing that is 

necessary should be 

overseen by a trained 

reversing assistant 

(Banksman). 

• Only standard palletised loads 

wrapped. 

• Machine is relatively new and 

instructions show it meets the 

relevant guarding standard. 

• Emergency stop button 

provided. 

• Fixed guards on moving parts 

• Mechanical parts maintained 

regularly. 

• Staff trained to use correctly. 

• Anyone working in the vicinity of 

moving vehicles should be given 

high visibility clothing and training. 

• Area around machine to be kept 

unobstructed at all times. 

• Area around machine to be 

indicated by use of markings in 

fluorescent orange-red. 

• Weekly check on guarding and 

condition of machine. 

SP 20-01-06 20-01-06 

JB 18-01-06 18-01-06 

RB 28-04-06 

JB 18-01-06 18-01-06 

Conveyor belt for 

unloading from lorries 

As above, particularly where 

the belt meets rollers. 

• Guards provided for moving 

parts. 

• Conveyor instructions show it 

meets guarding standards. 

• Emergency stop button 

• Weekly check on guarding and 

condition of conveyor. 

JB 

18-01-06 

18-01-06

Portable electrical 

equipment 

Mess room: Industrial 

cleaner, kettle and 

heater. 

Fire 

• Bulk storage of 

easily burnt 

materials. 

• Ignited through 

electrical fault, 

smoking materials, 

battery recharging 

etc. 

Hazardous substances 

Vehicle exhaust fumes 

All staff could incur 

potentially fatal electrical 

shocks or burns if they use 

faulty electrical equipment. 

If trapped in the warehouse 

all staff and visitors could 

suffer from smoke inhalation 

or burns which could 

potentially kill. 

The fumes may cause staff 

eye irritation and respiratory 

irritation. 

provided. 

• Regular maintenance. 

• Fixed electrical installations 

are maintained to a suitable 

standard and inspected every 

five years. 

• Building designed with fireresisting 

materials. 

• Exits and fire exits marked 

and kept clear. 

• Fire extinguishers located 

throughout warehouse. 

• Access to all exits and fire 

extinguishers kept clear at all 

times. 

• Fire detection and alarm 

system in place. 

• Fire evacuation procedures 

displayed at each fire alarm 

point. 

• Maintenance contracts for 

extinguishers and 

detection/alarm system. 

• Fire drill and training in use of 

extinguishers held once a 

year. 

• Smoking prohibited in the 

warehouse. 

• Cleaner ensures no debris left 

around warehouse. 

• All staff trained in good 

housekeeping during 

induction. 

• Number of vehicles delivering 

materials is relatively low and 

exposure very limited this 

prevents build-up of fumes. 

• Drivers not allowed to leave 

vehicles engines running in 

warehouse. 

• Roller shutter doors and 

warehouse windows open 

• Manager to arrange and record the 

six monthly inspection and testing of 

portable equipment. 

• Instruct staff to report faults 

immediately. 

• Discussions with insurer on the 

provision of automatic closing of 

roller-shutter doors linked to fire 

alarm to be decided upon. 


SP 01-05-06 

JB 13-01-06 13-01-06 

SP 25-08-06

where practicable to assist 

ventilation. 

Bleach and cleaning 

fluids 

Direct skin contact could 

lead to the cleaner getting 

skin irritation. The vapour 

may cause the cleaner to 

have eye irritation or 

breathing difficulties. 

• Cleaner made aware of safe 

procedures. Rubber gloves 

used. 

• First aid facilities (inc. eye 

wash) are readily available. 

• Investigate availability of safer 

alternatives for cleaner. 

RB 

17-02-06 

28-02-06 

Recharging of fork lift 

truck batteries – 

potential explosion by 

release of hydrogen, 

spillage of acid 

Lighting 

Hygiene/comfort 

Burns or fractures from 

material ejected could affect 

any worker nearby at the 

time. 

Poor lighting is likely to 

result in higher levels of 

work error and accidents. 

All staff could suffer varied 

discomfort eg being too 

hot/cold. 

• Batteries charged in 

designated bay that is well 

ventilated. Safe system of 

work used which includes 

provision and use of goggles 

and gloves. Potential sources 

of ignition controlled 

• Good quality lighting provided 

throughout the warehouse. 

• Stacking of materials in 

warehouse on top of racking 

is restricted in order to avoid 

blocking light and creating 

shadows. 

• Cleaner checks that light units 

are operating and are 

replaced by electrician when 

necessary. 

• Floodlighting in the external 

area. 

• Heated mess room provided 

with hot and cold water and 

water for beverages. 

• Area kept clean. 

• Lockers available for staff’ 

belongings. 

• Toilets a short walk away, 

cleaned daily. 

• Supervisor to monitor and ensure 

protective equipment is being worn. 



JB 

13-01-06 

13-01-06 

Review Date: 26-02-07

Example: Risk assessment in a warehouse - Forktruck Solutions Ltd.

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