Example risk assessment for a warehouse

Setting the scene

The warehouse manager carried out a risk 3 For each hazard identified, the manager recorded what
assessment of the warehouse. controls, if any, were in place to manage these. Important reminder

The warehouse employed 12 staff, some Where existing controls did not meet good practice, This example risk assessment shows the kind
the manager wrote down what further actions were of approach a small business can take.
were part of a union.
needed to manage the risk.
Use it as a guide to think through some of
How was the risk assessment done? 4 Putting the findings of the risk assessment into the hazards in your business and the steps
practice, the warehouse manager decided who was you need to take to control the risks.
The manager followed the guidance in Five steps to risk responsible for implementing the further actions and
assessment: when it should be done. She wrote this down and Please note that it is not a generic
when each action was completed it was ticked off risk assessment that you can just put
1 To identify the hazards, the manager: and the date recorded. your company name on and adopt
wholesale without any thought. This would not
• walked around the warehouse, noting activities that 5 The warehouse manager discussed the findings with satisfy the law – and would not be
might pose a risk and taking into consideration what the safety representative. They decided to review and effective in protecting people.
she learnt from our guidance; update the assessment at least annually, or at any
time when major changes to the workplace occurred. Every business is different – you need to
• Talked through the issues with the union safety The warehouse manager gave out copies of the risk think through the hazards and controls required
representative and asked about concerns that staff assessment to all members of staff.
had on health and safety; in your business for yourself.

• Talked to supervisors to learn from their detailed

knowledge of particular jobs and areas; and
Download now the templates
• Looked at the accident book to gather information available in our FREE resources
on past problems.
area
2 The manager then wrote down who could be harmed
by the hazards and how. www.chemsafe.ie
061 - 523 444

Example risk assessment: A warehouse 1 of 6 pages

 Date of risk assessment: 10/1/06

What are the hazards? Who might be harmed and What are you already doing? What further action is necessary? Action by Action by Done
how? who? when?

Falls from height Staff could suffer severe or ■ All staff are given strict instructions never to climb racking –
even fatal injuries if they fell monitored by supervisors.
whilst climbing racking.

Staff could suffer severe or ■ Proprietary forklift cage used by maintenance worker for ■ Train maintenance worker to check cage RB 17/1/06 20/1/06
even fatal injuries if they fell changing bulbs. Cage supplier’s information shows it is is in good condition and properly secured
whilst changing light bulbs manufactured to standard. before each use.
etc in the high ceiling.

Staff or contractor could ■ No controls in place. ■ Put up ‘fragile roof’ signs, one on each side RB 13/1/06 14/1/006
suffer severe or fatal injuries of the building and at access points to roof.
falling through fragile roof ■ Agree with maintenance worker that a SP 28/2/06 28/2/06
lights when looking for/ contractor will be used for any access to the
repairing leaks. roof.
■ Require contractor to provide an assessment SP 15/3/06
before access is allowed if any roof work is
required.

Worker falling from roof of ■ The internal warehouse roof is load bearing, has full rails and ■ No further action required.
internal warehouse office boards around its edge. It has adequate lighting and access is
used for storage. by permanent steps with a handrail.

Manual handling All warehouse staff could ■ Conveyor system used to reduce manual handling materials in ■ Manual handling training to be given to all SP 6/2/06 1/2/06
Regular movement of suffer from back pain if and out of delivery trucks. warehouse staff.
cartons to pallets. regularly lifting/carrying ■ Lift trucks used for most manual handling. ■ Remaining manual handling tasks to be JB 20/1/06 20/1/06
Rolls of stretch-wrap heavy or awkward objects. ■ A range of manual handling tasks still required. risk assessed using HSE’s Manual handling
and flat pallets assessment charts INDG383.

Example risk assessment: A warehouse 2 of 6 pages

What are the hazards? Who might be harmed and What are you already doing? What further action is necessary? Action by Action by Done
how? who? when?

Slips, trips and falls All staff may suffer sprains ■ Flooring kept dry and quality maintained. ■ Suitable absorber to be made available for RB 18/1/06 16/1/06
or fractures if they trip over ■ All staff trained to maintain good housekeeping standards and liquid spills.
debris or slip on spillages. ensure stock does not project into gangways. ■ Staff to be trained to clean and dry any JB 11/1/06 11/1/06
■ Cleaner empties bins and removes loose debris daily. spillages immediately.
■ Pallets stored safely in designated area. ■ Extra bins to be provided for waste material RB 12/1/06 12/1/06
■ Protective non-slip footwear supplied and worn. near loading bays.

Falling objects A member of staff or any ■ Racking is designed to be suitable for the loads carried and has ■ Sign fixed to racking stating maximum loads/ RB 14/7/06
From racking and other person in the warehouse not been modified. configuration.
during movement may suffer serious injury if ■ Staff report any damage to racking immediately.
struck by a falling object. ■ System in place to make sure defective pallets withdrawn from
use immediately.
■ Protective footwear used by all entering warehouse.
■ Protective gloves provided to handle pallets.

Operation of lift trucks Injuries such as fractures ■ All operators trained and competent for use of the lift truck. ■ Supervisor to ensure truck drivers check JB 10/1/06 10/1/06
or, at worst, fatalities can be ■ Trucks serviced regularly and examined by suppliers every six trucks each day before starting.
caused as a result of: months. ■ Separate pedestrian entrance(s) with RB 20/6/06
■ the vehicle crashing into ■ Drivers instructed to keep keys with them at all times. protective barrier rail to be provided next to
other vehicles and/or ■ System in place for refresher training of drivers. roller-shutter doors.
other objects; ■ Gangways and aisles of sufficient space to enable lift trucks to ■ Housekeeping standards and floor condition SP 27/1/06 27/1/06
■ staff and visitors being hit load and unload from the racking safely. to be covered by a monthly inspection by
by lift trucks; ■ System in place to keep vehicles and pedestrians separated. manager and brief record kept.
■ objects falling from lift ■ Access to warehouse restricted to staff. ■ Strict requirement that only competent SP 23/1/06 23/1/06
trucks onto staff and ■ Floor condition maintained on a regular basis, housekeeping drivers may operate lift trucks to be
visitors; standards maintained by cleaner and workforce. explained to all staff. Disciplinary action to
■ lift trucks toppling over; ■ Warning signs located around the traffic route. be taken against anyone involved in breaking
■ people falling from the ■ Trucks have seat belts and roll cages. this rule.
vehicle or parts of the
vehicle; and
■ being crushed by the mast.

Example risk assessment: A warehouse 3 of 6 pages

What are the hazards? Who might be harmed and What are you already doing? What further action is necessary? Action by Action by Done
how? who? when?

Traffic movements Injuries such as fractures ■ Floor and traffic routes suitable for the vehicles using them. ■ Anyone working in the vicinity of moving SP 20/1/06 20/1/06
(deliveries etc) or, at worst, fatalities can be ■ Vehicle routes kept free of obstructions (with spillages being vehicles should be given training and high-
caused by: cleaned up promptly). visibility clothing.
■ staff and visitors being hit ■ Parking of cars and vans only allowed in marked spaces well
by vehicle; away from external delivery/dispatch area.
■ people falling from a ■ Outside area gritted when frosty, snow cleared.
vehicle or parts of a ■ Sensible speed limits imposed and adhered to.
vehicle; and ■ Adequate signage to warn of hazards.
■ objects falling from vehicle ■ Reversing of delivery vehicles should be avoided unless
onto staff and visitors. absolutely necessary.
■ Any reversing that is necessary should be overseen by a trained
reversing assistant (banksman).

Machinery All staff using the machine. ■ Only standard palletised loads wrapped. ■ Area around machine to be kept JB 18/1/06 18/1/06
Stretch-wrap machine Moving parts can trap parts ■ Machine is relatively new and instructions show it meets the unobstructed at all times.
of the body (eg fingers/hand/ relevant guarding standard. ■ Area around machine to be indicated by use RB 28/4/06
arm) causing crush injuries. ■ Emergency stop button provided. of markings in fluorescent orange-red.
The whole body may also ■ Fixed guards on moving parts. ■ Weekly check on guarding and condition of JB 18/1/06 18/1/06
get trapped between moving ■ Mechanical parts maintained regularly. machine.
pallet load and fixed structure. ■ Staff trained to use correctly.

Staff can also cut themselves

on sharp edges or scald
themselves on hot parts.

Conveyor belt for As above, particularly where ■ Guards provided for moving parts. ■ Weekly check on guarding and condition of JB 18/1/06 18/1/06
unloading from lorries the belt meets rollers. ■ Conveyor instructions show it meets guarding standards. conveyor.
■ Emergency stop button provided.
■ Regular maintenance.

Portable electrical All staff could receive ■ Fixed electrical installations are maintained to a suitable ■ Manager to arrange and record the six- SP 1/5/06
equipment potentially fatal electrical standard and inspected every five years. monthly inspection and testing of portable
Mess room: industrial shocks or burns if they use equipment.
cleaner, kettle and heater faulty electrical equipment. ■ Instruct staff to report faults immediately. JB 13/1/06 13/1/06

Example risk assessment: A warehouse 4 of 6 pages

What are the hazards? Who might be harmed and What are you already doing? What further action is necessary? Action by Action by Done
how? who? when?

Fire If trapped in the warehouse, ■ Building designed with fire-resisting materials. ■ Discussions with insurer on the provision SP 25/8/06
■ Bulk storage all staff and visitors could ■ Exits and fire exits marked and kept clear. of automatic closing of roller-shutter doors
of easily burnt suffer from smoke inhalation ■ Fire extinguishers located throughout warehouse. linked to fire alarm to be decided upon.
materials or burns which could ■ Access to all exits and fire extinguishers kept clear at all times.
■ Ignited through potentially kill. ■ Fire detection and alarm system in place.
electrical fault, ■ Fire evacuation procedures displayed at each fire alarm point.
smoking materials, ■ Maintenance contracts for extinguishers and detection/alarm
battery recharging system.
etc ■ 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.

Hazardous The fumes may cause staff ■ Number of vehicles delivering materials is relatively low and ■ No further action required.
substances eye irritation and respiratory exposure very limited; this prevents build-up of fumes.
Vehicle exhaust fumes irritation. ■ Drivers not allowed to leave vehicles’ engines running in
warehouse.
■ Roller shutter doors and warehouse windows open, where
practicable, to assist ventilation.

Bleach and cleaning Direct skin contact could lead ■ Cleaner made aware of safe procedures. Rubber gloves used. ■ Investigate availability of safer alternatives RB 17/2/06 28/2/06
fluids to the cleaner getting skin ■ First-aid facilities (including eye wash) are readily available. for cleaner.
irritation. The vapour may cause
the cleaner to have eye irritation
or breathing difficulties.

Recharging of forklift Burns or fractures from ■ Batteries charged in designated bay that is well ventilated. ■ Supervisor to monitor and ensure protective JB 13/1/06 13/1/06
truck batteries – material ejected could affect Safe system of work used which includes provision and use of equipment is being worn.
potential explosion by any worker nearby at the goggles and gloves. Potential sources of ignition controlled.
release of hydrogen, time.
spillage of acid

Example risk assessment: A warehouse 5 of 6 pages

 What are the hazards? Who might be harmed and What are you already doing? What further action is necessary? Action by Action by Done
how? who? when?

Lighting Poor lighting is likely to result in ■ Good quality lighting provided throughout the warehouse. ■ No further action required.
higher levels of work error and ■ Stacking of materials in warehouse on top of racking is
accidents. 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.

Hygiene/comfort All staff could suffer varied ■ Heated mess room provided with hot and cold water and water ■ No further action required.
discomfort, eg being too hot/ for beverages.
cold. ■ Area kept clean.Lockers available for staff members’ belongings.
■ Toilets a short walk away, cleaned daily.

Assessment review date: 26/2/07

Example risk assessment: A warehouse 6 of 6 pages