Warehouse Safety Checklist – Free PDF Download

Warehouse safety checklist template

The warehouse safety checklist is a comprehensive tool for conducting thorough safety inspections while ensuring compliance with industry regulations. With this template, you can identify hazards, streamline routine inspections, and maintain a safer work environment for your team. According to the US Bureau of Labor Statistics, nearly 30% of all injuries in transportation and warehousing are caused by overexertion and same-level falls, emphasizing the need for robust safety protocols.

This template stands out by offering customizable fields tailored to your warehouse operations, from equipment checks to worker safety protocols. It complements our other templates, such as the OSHA Warehouse Safety Checklist and Warehouse Fire Safety Checklist, by focusing on holistic safety management. Use it to reduce risks, improve compliance, and optimize your operational workflows.

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General Inspection

General Information

Nature of business

Materials and Products Stored

Procurement Manager

General Warehouse Areas

Are aisles clear and open for material transfers? • No product shall be stored in aisles where it blocks equipment maneuvering.

REFERENCE: Clean aisles. No materials are stored in walkways. [This is an example of how you can use Lumiform to include best practice reference images in your templates to assist with inspections]

Are floor and rack storage limits properly posted? • One sign near the entrance of the warehouse should indicate the floor rating. • All racks should be labeled with load ratings.

Are rack uprights and beams in good condition? • Bent racks and beams must be repaired or replaced. • All racks should be bolted to the floor.

Are designated open areas clear of blockage? • Such areas include 18 inch perimeters along interior walls as well as electrical panels and eye wash units.

Are fire extinguishers and overhead fire sprinklers up to date for inspections and in good condition? • Verify employees have received appropriate training and education.

Are all emergency exits clear of blockage and are the exit signs in good condition? • Inspect both inside and outside for blockage of the exits. • All exit signs should be lit & all emergency lights tested.

Are all pallets in good condition? • Empty pallets must be stored properly. • No broken or protruding wood or nails. • No pallets on edge. • Avoid storing empty pallets in quantities or densities in excess of O.H. fire sprinkler combustible load ratings.

Are overhead lighting, skylights, and roofs in good condition? • Check for leaks, broken panels/light bulbs, and missing bulb shields.

Are loose/unboxed materials stacked properly? • Properly stored by blocking, interlocking or limiting the height of the pile. • Insure product stack heights are inforced to prevent container crushing and falling materials.

Are all bags, containers, bundles, etc. stored in tiers that are stacked, blocked, interlocked and limited in height? • Stable and secure to prevent sliding or collapse.

Are Derail and/or bumper blocks provided on spur railroad tracks where a rolling car could contact other cars being worked on or roll out into entrances to buildings, work or traffic areas?

Are all employees use proper personal protective equipment when handling chemicals?

Are guardrails and/or covers provided to protect personnel from the hazards of open sides of stairs, platforms, floor openings, floor holes, mezzanines, equipment pits, and other possible fall hazards?

Are elevators and hoists for lifting items properly used? • Have adequate/safe clearances, no obstructions, appropriate signals and directional warning signs. • Documented annual inspections by licensed inspector are posted on the equipment and on file.

All hazardous materials' containers are properly labeled? • Indicated chemical’s identity, the manufacturer’s name and address, and appropriate hazard warnings.

Are all chemicals stored according to the manufacturer’s recommendations and local or national fire codes. (i.e. flammable cabinets, cans, etc.)?

Are all employees use the proper lifting technique for the materials being handled?

Products and containers that are most frequently moved by hand are stored at rack heights that minimize bending / stooping or excess reach to pick up or place?

Dock Areas (Exterior and Interior)

Dock Areas (Exterior)

Are approach roads and staging areas (yard) clear for maneuvering, well drained, free of potholes and are all signs in place and legible?

Is the approach to the dock well drained and free from potholes or other obstructions? • Pay particular attention to snow, ice, storm water and debris build up.

Are dock positions clearly marked with painted lines that the drivers can see to help them spot their trailer accurately?

Are all exterior lights working properly? • This item will need to be inspected during the evening when lights are functioning.

Are wheel chocks and/or trailer restraint systems working properly? • If trailer restraint systems are in use remember to inspect for proper locking and indicator light function both inside and outside. • Ensure tractors are disconnected from trailer.

Are "attractive nuisances" controlled or removed from around the facility? • An attractive nuisance is any feature that might attract children, vandals, vagrants or other undesirable activities (i.e. concrete culverts, stacks of pallets, etc.).

Dock Areas (Interior)

Are visitors and drivers remaining in designated safe areas and walkways?

Are all interior overhead lights and trailer lights in the dock area operating properly? • Test all lights that might be off at time of inspection to be sure they work properly

Do dock doors work properly and close completely? • Ensure that all doors in use open and close smoothly. • Inspect automatic stops and auto-reversing functions on powered doors

Are dock doors closed when not in use? • Closed doors should seal well with the floor and dock leveling plate.

Is there sufficient room to maneuver materials? • Dock area floors should be clean and free of trash, debris, or stored items that block the safe passage of loaded equipment

Are there sufficient waste cans for the area and are those cans properly labeled and emptied on a regular basis? • In general, floors, ceilings, and exhaust fans are clean and free of cobwebs and dust buildup.

Is there adequate natural or mechanical ventilation to control any potential atmospheric hazards? • Where propane-powered equipment is in use, the ventilation must be tested to rule out excess carbon dioxide/monoxide. An Industrial Hygienist may need to do testing.

Equipment Check

Equipment Checks

Are all ladders and hand tools are in good condition? • Remove any unsafe equipment from service while awaiting repair.

Are forklifts being operated safely and inspected at the start of every shift? • Observe powered industrial truck operations and review training certifications to confirm operators have been adequately trained and evaluated.

Do forklifts have functioning warning devices such as back-up alarms, strobes, or horns? • Test equipment as needed, report repairs,and tag out equipment that is unsafe until repairs are made.

Are battery charging/changing areas designated for that purpose and contain appropriate emergency flushing facilities (i.e. eyewash and shower)?

Are guards in place for any hazard points on moving equipment such as belt guards on compressors or conveyors? • Inspect all powered work tools as well (i.e. cords, insulation, shrouds, casing, guards, etc.).

Are propane tanks stored correctly and are the tank exchange and/or tank filling areas properly maintained? • Appropriate signs are in place and area is free of trash.

Are all fire sprinkler control valves in their open position? • Do a visual check to insure the valves are fully open.

Are all powered industrial trucks (i.e. forklifts) meet the design and construction requirements established in regulatory standards?

Are the original capacity, operation and maintenance instruction plates, tags or decals on powered industrial trucks in place and legible? • All authorized equipment and accessory modifications are also identified on those labels/tags/decals.

Forklifts are used in hazardous locations (i.e. around flammable materials) are properly marked / labeled / tagged for the specific hazardous location?

Are battery exchange conveyors, overhead hoists or equivalent materials handling equipment in use provided and reinstalled? • Batteries are properly positioned and secured. • The forklift is properly positioned with brakes applied prior to battery exchange.

Are carboy tilters or siphons rated for the specific corrosive material used for handling electrolytes? • Stored in an approproate area (i.e. corrrosvies cabinet or other protected, designated and segregated area).

Are battery vent caps in place, in good working condition with vents open and clear?

Hot Work Permit process or other documented/dedicated processes are in place? • To prevent smoking, welding, grinding or other ignition sources from battery charging functions and other flammable materials areas.

Are tools and other spark producing metallic objects kept away from the top of uncovered batteries?

Sanitation (For food storage facilities)

Sanitation Inspection

Are rodent and other pest control devices in place and in proper working condition? • Look for missing or damaged traps and check fly zappers as well.

Are aisles, wall perimeters, exterior areas near the building, trash cans and dumpsters free of loose trash and debris?

Are stored products in good condition and free of spillage / breakage?

Are stocks properly dated and documented for best rotation control? • First In First Out.

Are products which are broken, damaged or otherwise removed from distribution properly labeled, segregated (if required), disposed of or recouped?

Are the storage areas free of pests? • Look for signs of pests such as dead insects, container damage caused by feeding, droppings, feathers, etc.

Training & General Safety

Training and General Safety

Are all employees properly trained and is training and certification up to date? • Inspect records to verify training is documented and up to date.

Are emergency evacuation routes and guidelines posted?

Are the appropriate posters posted in a conspicuous place?

Are your employees actively and meaningfully involved in workplace safety programs? (i.e. participate in accident investigations, self inspection, committees, etc.)

Are accidents, near misses and injuries being investigated and are unsafe conditions being corrected, reported/documented in a timely manner?

Are MSDS available to employees and are they up to date and complete?

Are location security process and equipment in place and operating well? • Inspect identification badges, uniforms, and intrusion alarms. • Verify monitoring services and equipment tests.

Are proper and safe work practices factored in when determining the appropriate time requirements to perform tasks?

Are all employees properly trained and outfitted for weather/temperature extremes? (i.e. heat stress, cold weather, refrigerated storage areas, etc.)

Are newly-hired employees receive documented general material handling and task-specific ergonomics training? • Verify through observations that employees practice safe lifting techniques on the job.

Are all employees trained in the requirements of the hazard communication standard? • Including a review of each MSDS and the specifics of existing and potential hazards of chemicals in the work place, precautions and safe work practices.

Is employee training documented?

Is a documented pre-work program for review of all outside contractor activities in place to ensure the work they will perform and the materials they will use are compatible with the activities and materials in use in the area of their work?

Is refresher training and evaluation conducted and documented whenever a powered industrial truck operator has been observed operating a vehicle in an unsafe manner or has been involved in an accident or a near-miss incident?

Is refresher training and evaluation conducted and documented whenever a powered industrial truck operator is assigned to drive a different piece of equipment, attachment, or the nature of the employee's duties change in any way that might impact safety?

Are evaluations of each powered industrial truck operator's performance conducted at least once every three years to verify they are working in accordance with established safety practices? • Records are on file to document the evaluations.

Completion

Recommendation

Write recommendations here

Completion

Full Name and Signature of Inspector

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Frequently asked questions

What are the most common safety hazards in a warehouse?

The most common warehouse safety hazards include overexertion from lifting heavy objects, slips and falls on wet or uneven surfaces, improper forklift operation, and poorly stored materials. These risks can lead to injuries, downtime, and compliance failures if not addressed with proper protocols and regular safety inspections.

How can you reduce workplace injuries in your warehouse?

Focus on proper employee training, ensuring clear walkways, maintaining equipment, and implementing regular safety inspections. Encourage reporting of hazards and provide ergonomic tools for lifting. OSHA-compliant safety programs and checklists can also help identify and mitigate risks effectively.

What are the best practices for warehouse safety inspections?

Effective warehouse safety inspections involve using a detailed checklist to assess areas like equipment, fire safety, and employee workstations. Schedule inspections regularly, involve trained personnel, and document findings to track improvements. Address hazards immediately to prevent accidents and maintain compliance.

How do overexertion injuries happen in warehouses?

Overexertion injuries often occur when workers lift or move heavy objects without proper techniques or tools. Repetitive tasks, awkward postures, and insufficient breaks can also contribute. These injuries commonly affect the back and shoulders, and ergonomic training and equipment can mitigate them.

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.