Warehouse Safety Inspection Checklist | Free PDF Template

Warehouse safety inspection checklist

The warehouse safety inspection checklist enables you to identify hazards, ensure compliance with safety regulations, and maintain a secure working environment for your team. It streamlines inspections, focusing on critical areas like equipment safety, fire prevention, and employee practices. The US Bureau of Labor Statistics found that there are around 4.5 injuries per 100 full-time workers annually in warehousing and transportation. This underscores the importance of regular safety inspections to minimize risks and improve operational efficiency.

This template is tailored for warehouse managers and safety officers tackling the challenges of maintaining compliance and reducing incident rates. Unlike general safety checklists, it’s customizable to your warehouse layout and processes. Looking for more? Explore our OSHA Warehouse Safety Checklist for regulatory compliance or the Warehouse Racking Safety Checklist for structural inspections.

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Audit

Aisles

Are aisles properly marked?

Do you maintain the standard width of aisles?

Are aisles clear of obstructions?

Do you maintain cleanliness?

Is there adequate housekeeping?

Is there adequate drainage?

Are floors and surfaces clean, free of obstruction and slippery materials?

Racks

Safe working limits

Rack load signs posted

Racks conform to these signs

Uprights and footplates

Uprights not damaged, i.e not twisted/no splits or cracks

If an upright was replaced due to damage, the footplate is replaced; and splices in good condition

Splices in accordance with the manufacturer’s technical specifications

Racks stable, i.e., on a flat, level foundation

Braces

Racking braces not damaged/bent

Floor anchors installed and not damaged

Footplate replaced if a floor anchor was replaced due to damage

Beams

Beams not overloaded

Beams show no sign of deflection

Beams connect at an upright and beam connectors reasonably parallel

Beams not damaged

Beam connectors and safety clips are complete

Beam connectors and safety clips are undamaged

No beams pop out of their upright

Welds are undamaged

Forklift

Signage and stickers are legible/capacity plate present

Wheels and tires are not worn and good air pressure

Forks/backrest/mast/chains/rollers: no damage, good working condition

Battery: charge is good, connections not loose

Engine; not rough, no noise or leaks

Fluid levels good: oil, fuel and radiator

Lights: headlights and warning lights working

Horn: loud and working

Fluid leaks: no damp spots or drips on ground

Seatbelt: good working condition, no damage

Steering; good working condition

Tilt/sideshift: loose, no leaks, doesn’t stick

Propane tank (if applicable): secured, connections tight, hose in good condition

Brakes: foot, parking in good working condition

Gauges working

Stairs

Are stair railings in good condition?

Are hand rail provided on stairs with 4 or more risers?

Are risers in proper and uniform height?

Are standard railings provided on stairway floor opening?

Are railings in place and secured?

Exits

Are there enough building exits?

Are there signs posted on exits?

Are there power supplies for emergency use?

Are exit signs and hallways well lighted and in proper standards?

Are exits unlocked?

Ladders

Are fixed ladders enclosed with cage or basket guard?

Are ladders equipped with safety shoes?

Are there no splinters or sharp edges on ladders?

Are step ladders not longer than 20’?

Scaffolding can carry the maximum intended load safely

Air Emissions

Are warning signs posted in areas where carbon monoxide might be present?

Work Environment

Are lightings adequate on all work areas?

Are acceptable noise levels maintained?

Are exhaust stacks and air intakes located away from potential sources of contamination?

Material Handling

Are safe clearances from equipments maintained?

Are passages marked and clear of obstructions?

Are daily inspection maintained for mechanical equipments or vehicles?

Are vehicles inspected/turned on-off before and after use/loading?

Are materials stored securely and in stable condition?

Ensure that bridge plates are used for vehicles and docks operations

Ensure that movements of trucks and trailers are secured during operations

Fire Protection

Are fire extinguishers accessible?

Are fire extinguishers in good condition and inspected regularly?

Are emergency numbers posted on the phone?

Are there adequate containers for flammable materials, rags and wastes disposal?

Are sprinkler heads clearance maintained according to fire security policies?

Personal Protective Equipment

Are hard hats provided and worn when necessary?

Are hard hats in good condition?

Is foot protection provided when necessary?

Completion

Additional recommendation

Full Name & Signature of Inspector

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Frequently asked questions

What are the most common safety hazards in warehouses?

Common hazards include forklift accidents, improper stacking of materials, blocked emergency exits, damaged racking systems, and poor lighting. Addressing these issues proactively can significantly reduce injury risks and ensure compliance with safety standards.

What are the key OSHA standards for warehouse safety?

OSHA standards for warehouses include requirements for safe forklift operation, proper material storage, clear marking of hazards, and accessible emergency exits. Employers must also provide training on hazard communication and ensure that all equipment meets safety standards.

How can you reduce forklift-related accidents in your warehouse?

To reduce forklift accidents, train operators thoroughly, enforce speed limits, mark pedestrian pathways, and conduct regular equipment maintenance. Make sure operators follow OSHA forklift safety guidelines and use a checklist to inspect forklifts daily before use.

What are some ways to prevent slips, trips, and falls in the warehouse?

Keep floors clean and dry, repair damaged flooring, and mark uneven surfaces. Use anti-slip mats in high-risk areas and ensure proper lighting throughout the warehouse to reduce the risk of falls.

This template, developed by Lumiform employees, serves as a starting point for businesses using the Lumiform platform and is intended as a hypothetical example only. It does not replace professional advice. Companies should consult qualified professionals to assess the suitability and legality of using this template in their specific workplace or jurisdiction. Lumiform is not liable for any errors or omissions in this template or for any actions taken based on its content.