Warehouse Health & Safety STUDENT GUIDE LEARNING ACADEMY BUILDING SUSTAINABLE SAFETY EXCELLENCE
2014Trucking Safety Council of BC 210 20111 93A Avenue Langley, BC V1M 4A9 Tel: 604-888-2242 Toll Free: 1-877-414-8001 Fax: 604-888-2243 www.safetydriven.ca info@safetydriven.ca 2
Warehouse Health & Safety STUDENT GUIDE All or portions of these materials may be reproduced without permission for educational purposes with appropriate credit to SafetyDriven the Trucking Safety Council of BC (TSCBC). LEARNING ACADEMY Warehouse Health & Safety 3
Contents Module 1 Legal Rights and Responsibilities 1.1. Introduction...10 1.2. Learning Outcomes...10 1.3. Basic Rights to Health and Safety...10 1.4. Guided Activity Basic Rights... 11 1.5. Responsibilities... 11 1.6. Orientations... 12 1.7. Guided Activity Site Specific Information... 15 1.8. Truck Stop... 17 Module 2 - Hazard Assessment and Control 2.1. Introduction...20 2.2. Learning Outcomes... 21 2.3. Identify Hazards... 21 2.4. Guided Activity Identify Hazards...24 2.5. Assessment of Risk...25 2.6. Guided Activity Assessment of Risk...29 2.7. Mitigating Risk using Controls...29 2.8. Guided Activity Mitigating Risk through controls...32 2.9. Truck Stop...33 Module 3 Common Hazards in a Warehouse 3.1. Introduction...36 3.2. Learning Outcomes...36 3.3. Physical Hazards... 37 3.4. Chemical and Biological Hazards... 41 3.4. Psychological Hazards...43 3.5. Truck Stop...43 4
Appendix 1 Identification Practice 4.1. Identify Hazards Guided Activity... 46 Appendix 2 Assessment and Mitigation Practice 5.1. Part 1 - Assessment of Risk Guided Activity... 54 5.2. Part 2 - Mitigating Control Guided Activity... 58 LEARNING ACADEMY Warehouse Health & Safety 5
Preface The Trucking Safety Council of British Columbia (TSCBC) is the certifying partner for the Certificate of Recognition (COR) program for the General Trucking and Moving and Storage industries. As part of this program, TSC- BC offers Occupational Health & Safety training courses, including this one. Welcome to Working Safely in Warehouses. Course Description Warehouses can be busy places in which to work and the conditions of work can change quickly. As a result, warehouses contain many different kinds of hazards. It can be challenging for workers to be aware of these hazards, especially if they are new to the work site. This course will help you to become familiar with common hazards and other safety challenges in the warehouse environment. But more than that, this course will give you some tools for controlling safety hazards in your workplace on a day to day basis, regardless of where you might be working. All workers needs the tools necessary to identify hazards, assess the risks of those hazards, and mitigate those risks in the work place. When you can do this, you are more able to control safety in your own workplace. As you work through this course, remember: I Identify hazards A Assess risks M Mitigate risks Module 1 of this course provides an overview of your legal rights and responsibilities for safety. 6
Module 2 introduces the I AM Safety Driven method for hazard identification and control, with specific applications to the warehouse environment. Module 3 extends this topic with a review of common warehouse hazards and resulting controls and safety practices. Course Goals The course is organized around three modules which cover the three core goals. By the end of the course, participants should be able to: 1. Explain their legal rights and responsibilities for safety, particularly in the context of contract workers in a warehouse environment 2. Conduct hazard identification, assessment of risk, and risk mitigation through controls, applied specifically in the context of the warehouse environment. 3. Discuss common hazards and safe work practices in the warehouse environment. Evaluation Self-evaluation with module quizzes (Truck Stops) and a final quiz at the completion of the course. How to Use this Guide As a learning guide: During the course, follow along through each module as the facilitator covers the course material. As a review tool: During and after the course, use the quiz questions (Truck Stop) at the end of each module to measure what you have learned. As a reference: Use this book as a source of information when you are on the job. LEARNING ACADEMY Warehouse Health & Safety 7
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Module 1 Legal Rights and Responsibilities
1.1. Introduction Health and Safety in the workplace is everyone s right. And everyone s responsibility. This module will review these rights and responsibilities, looking carefully at the challenges of contract workers who are often moving to new work sites. Contract workers need important site specific information to ensure that they can protect the health and safety of themselves and others while working. 1.2. Learning Outcomes 1. By the end of this module, participants should be able to: 2. Explain a worker s legal rights and responsibilities for safety. 3. Explain a contractor s legal rights and responsibilities for safety on another employer s site. 4. Describe reasonable expectations for onsite safety and hazard orientation for contract workers starting at a job site. 1.3. Basic Rights to Health and Safety All workers in Canada have 3 basic rights to safety. These rights are legally guaranteed. They apply to both provincial and federal jurisdictions. Right to Know Workers have the right to be made aware of hazards, procedures, training and legislation that affect their workplace. Right to Participate Workers have the right to participate in safety management in the workplace. Participation can include policy development, inspections, incident investigations and any other activities related to safety. Right to Refuse Unsafe Work Workers have the right to refuse work they feel they cannot perform safely. Legislation ensures there cannot be redress by the employer for refusing unsafe work. 10
1.4. Guided Activity Basic Rights 1.4.1. Introduction To be able to protect your health and safety at work, you need to be aware of and comfortable standing up for your rights. Part of this is being able to understand when these rights have not been met in the workplace. 1.4.2. Instructions 1. Together, discuss examples of each of the three Worker Rights defined above. 2. Have you or anyone in your group ever had an experience when these rights were not honoured or when you had to assert these rights? 3. Discuss what could have been done in such circumstances to ensure rights were being met? Note your examples here: Right to Know Examples/Personal Experience Right to Participate Right to Refuse Unsafe Work 1.5. Responsibilities With rights come responsibilities. According to law, workers must take reasonable steps to protect their own health and safety while at work. Also, workers must take care to protect the health and safety of others who may be affected by what they do or what they fail to do while working. LEARNING ACADEMY Warehouse Health & Safety 11
These reasonable steps include, but are not limited to: Following safe work procedures Using specified Personal Protective Gear (PPE) Avoiding horseplay or other dangerous behavior Ensuring no impairment by alcohol, drugs, or any other cause Reporting any failure to take these reasonable steps to a supervisor Reporting any hazards or injuries to a supervisor It s the law! You have to take these reasonable steps towards a healthy and safe workplace. Employers and Supervisors Generally, employers and supervisors have a special role to play in creating a culture of safety. They must provide workers with information necessary to protect their health and safety. This would include, for example, providing clear safe work procedures and instructions regarding PPE, as well as tools for reporting safety problems. Employees often get this information in a safety orientation. 1.6. Orientations Good orientations provide workers with the information they need to protect the health and safety of themselves and others on the worksite. Workers can and should expect to be given information about the layout and hazards of a specific worksite, about health and safety procedures, and about how to ask for help and report problems. 12
Site Specific Information Checklist For a variety of reasons, workers often find themselves on a work site, perhaps doing a new task, without enough information to manage the situation safely. Workers have the right and the responsibility to ask for site specific health and safety information to ensure they can protect their health and safety and that of those they work with. Workers should not begin work at a new worksite until they have been provided with the following: Table 1: Site Information Checklist Site Specific Information Checklist Basic site rules and policies such as entry / exit procedures, smoking areas, what you can t do and what you must do Emergency response procedures How to obtain first aid and first aid location Introduction to the supervisor Incident reporting requirements Clear explanation and demonstration of your task and duties Personal protective equipment required Known and foreseeable hazards Any specific written procedures, such as lock-out Anything else that is not clear LEARNING ACADEMY Warehouse Health & Safety 13
Remember You can and should request this information before You start work at a new site Who is responsible? Who is responsible for providing this information in a site-specific safety orientation? The challenge for contract workers is that they are often employed by one company, but work at the job site of a second company. This can make it difficult to ensure that the worker always has enough information to work safely at a specific job location. Your employer and the site employer are both responsible for ensuring the health and safety of workers on the job site. This works differently in different situation. Consider these two examples: Example A Your Employer is hired as a Site Employer and so you go to work at the site. In this case, your employer is the Prime Contractor and so has control of the work site. Responsibility: Your Employer, as the Prime Contractor, is responsible for coordinating safety on the site. For you: As a worker, you will have 1 working relationship with your Employer. Your employer is directly responsible for providing both general and site specific orientation. This site specific orientation should include the information listed earlier in the checklist. 14
Example B Your Employer is hired by a Site Employer and so you go to work at the site. In this case, your employer provides only labour and does not have any control of the work site. Responsibility: Your Employer has no control over the work site and the Site Employer has the responsibility for coordinating safety on the site. For you: As a worker, this means you will have 2 working relationships: Your Employer must provide you with a full orientation relevant to your role as an employee. The Site Employer must also provide you with a site specific orientation before you start work at the site. This site specific orientation should include the information listed in the checklist. 1.7. Guided Activity Site Specific Information 1.7.1. Introduction Being safe at a new worksite depends on being able to get important safety information about that worksite. In this activity, you are asked to use your own experiences to reflect on why this information is so important. LEARNING ACADEMY Warehouse Health & Safety 15
1.7.2. Instructions As a group, share your experiences with receiving orientation at a new work site. Use the Information Checklist to guide your discussion. 1. Do you have examples of when you were provided with a clear and complete site specific safety orientation? 2. Do you have examples of when this information was not provided? 3. Can you think of a time when you might have needed some of the information that is listed on the checklist but did not have it? What happened? 4. Discuss examples of different work sites you have been on. Do you know who is responsible for providing this kind of information? Table 1: Site Specific Information Checklist Site Specific Information Checklist Basic site rules and policies such as entry / exit procedures, smoking areas, what you can t do and what you must do Emergency response procedures How to obtain first aid and first aid location Introduction to the supervisor Incident reporting requirements Clear explanation and demonstration of your task and duties Personal protective equipment required Known and foreseeable hazards Any specific written procedures, such as lock-out Anything else that is not clear. 16
1.8. Truck Stop Use your course book and any notes you have taken to answer the following questions. When everyone is finished, the instructor will review the answers. # Question Answer Space 1. What are everyone s 3 basic rights for safety? 2. List at least three reasonable steps workers legally have to take to protect their own health and safety and the health and safety of others. 3. What should every employee receive before they start work at a new site? 4. Who is legally responsible for ensuring the safety of yourself and other workers on site? 5. List at least three examples of information workers should have before starting work at a new site. LEARNING ACADEMY Warehouse Health & Safety 17
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Module 2 - Hazard Assessment and Control
2.1. Introduction The warehouse environment can be very hazardous. And workers who are around these hazards are at risk of injury. All workers need to be able to identify the hazards around their job site before they begin work and do what is necessary to control those hazards and reduce risk of injury. What workers do when they spot a hazard is important for everyone s safety. Figure 1: Stop. Think. Act. Graphic Source: TSCBC. https://www.safetydriven.ca/stop-think-act/ 20
This module will give you the tools you need to think about the hazards in the workplace and to act appropriately to reduce risk. In this module, you will learn how to identify common warehouse hazards, assess how much risk is involved, and decide how to mitigate or control the hazard to reduce the risk. This module covers the three main components of the I Am Safety Driven method promoted by the TSCBC. Figure 2: I AM Safety Driven I Identify hazards A Assess risks M Mitigate risks 2.2. Learning Outcomes By the end of this module, participants should be able to: 1. Identify workplace hazards 2. Name the 4 categories of hazards 3. Understand risk 4. Assess risk using a risk assessment tool 5. Understand a range of hazard controls for mitigation of risk 6. Mitigate risk by employing hazard controls 2.3. Identify Hazards Workers must take an active role in protecting their own health and safety at work. The first step is being able to identify hazards in the work environment. Hazards are anything or any experience that might put you or others at risk of injury or disease. LEARNING ACADEMY Warehouse Health & Safety 21
To be effective at identifying hazards in at the worksite, try the following: Be familiar with the four different types of hazards listed below. This will help you to consider all of them when your check your work site. Imagine yourself moving through the work site and consider what might be a problem for you in that space. 2.3.1. Types of Hazards Physical Physical hazards are those that can come in contact with an employee. Below are some examples. Slips, Trips and Falls Mobile Equipment, Vehicles, and Moving Machinery Freight stacking, Lifting and Heights Noise, Temperature and Vibration Figure 3: Physical Hazards Chemical Chemical hazards can come from multiple sources in the warehouse. Below are some examples. Fumes Liquids Dust Gases Vehicle exhaust or smoke Herbicides, Pesticides Asbestos, silica, wood dust Chlorine, Ammonia, Flammable Figure 4: Chemical Hazards 22
Biological Biological hazards can be present after an incident has occurred or from natural sources. Below are some examples. Bodily Fluids Used medical Equipment Molds Animal Waste Blood, vomit, urine Figure 5: Biological Hazards Psychological Psychological hazards can exist outside of working hours and the workplace. Below are some examples. Working Conditions Stress Tired Harassment Workplace Violence Not valued at work Too much overtime Problems at home Figure 6: Psychological Hazards LEARNING ACADEMY Warehouse Health & Safety 23
2.4. Guided Activity Identify Hazards 2.4.1. Introduction This activity has two parts. In part one you are asked to share your experiences with different kinds of hazards in the workplace. In part two, you will practice identifying hazards common to the warehouse environment using photos. Later in the course, you will have a chance to determine how risks some of those hazards are and decide the best ways to control them to lower the risk of injury. 2.4.2. Instructions Part one As a group, make a list of specific hazards you have experienced or might expect to experience in a warehouse environment. Use the table above, and write the hazards into the appropriate category box. Physical Chemical Biological Psychological 24
Now, while looking at your list, consider: What are the most common types of hazards? In your experience, are these hazards often recognized or ignored on the job? Part two Appendix 1 WorkSafeBC offers a What s Wrong with this Photo challenge to encourage workers and employers to develop their ability to identify hazards in the workplace. These photos are staged to show multiple hazards and dangerous work activities. Working in groups, identify all the hazards in the WorkSafeBC Photos provided. You will find the photos and a table to record your answers in appendix 1 of this course book. Go to appendix 1 now for further instructions. 2.5. Assessment of Risk We all participate in risky behavior in our everyday lives. We go through our day making choices about how much risk we are willing to take. Should we eat that fast food? Should we run that yellow light? Should we make a call while driving? Usually, we make these decisions based on experience, a kind of gut feel about what will be ok and what won t. Some of these decisions are good and realistic, and some are not. When working, our assessment of risk must be systematic and informed. Gut feel is not enough to keep you, and those around you, safe. You must be able to make accurate decisions about the chance of injury and how serious that injury might be. Understanding risk means making careful decisions about how likely it is that an incident will occur and, if it does occur, how severe that incident will be. LEARNING ACADEMY Warehouse Health & Safety 25
Let s consider Lottery Tickets: When you buy a lottery ticket: You have a chance of winning! 2 factors influence your lottery experience: A) How many tickets are sold? (How likely is it that you will win?) The less tickets sold, the more likely you will win! B) How much can you win? The larger the prize, the more you win! (How significant will winning be?) Every time you buy a ticket, you could win it all. You can learn to assess how likely and how significant that win might be. Now let s apply the same thinking to doing an unsafe act: Unlike winning the lottery, winning with safety can have dire consequences. When you do an unsafe act: You have a chance of injury to yourself or someone else. 2 factors influence the consequences of an unsafe act: A) How likely is it that an injury will occur? The more likely an injury, the more risky the unsafe act is. B) How severe will that injury be? The more severe an injury, the more risky the unsafe act is. Every time you do something unsafe, you could win a severe injury. You can learn to assess how likely and how severe the consequences of an unsafe act might be. We call this assessing the risk. Risk = How Likely + How Severe 26
Assessing Risk Figure 7 provides a tool for risk assessment. After identifying a hazard at the work site, workers must assess the risk this hazard represents. This assessment helps to caution the workers about the hazard and helps them to determine how to control the risks. Figure 7 identifies three zones of risk. Cool zone. Here are risks that are unlikely to occur and, if they do occur, would have minimal consequences or limited severity. Warm zone. Here are risks that are unlikely to occur, but, if they do occur, would be severe. Here are also risks that are likely to occur, and, if they do occur, would have minimal consequences or limited severity. Hot zone. Here are risks that are likely to occur, and, if they do occur, would be severe. Figure 7 also provides a reminder that in addition to the zones of risk, the likelihood of injury increases the more often workers experience a hazard. Not Very Likely & Not very Serious (Cool) Not very Likely but Very Serious (Warm) Very Likely but Not Very Serious (Warm) Very Likely & Very Serious (Hot) HOW OFTEN? More often = More likely Figure 7: Risk Assessment Tool LEARNING ACADEMY Warehouse Health & Safety 27
Assessing Risk Example Have a look at Figure 8. Many warehouse hazards are illustrated. For this example, consider the hazards indicated by the blue arrows. In the following table, the hazards are identified and then placed in a Risk Assessment Zone. 3 1 2 Figure 8: Assessing Hazards Example Source: TSCBC. https://www.safetydriven.ca/resource/warehouse-hazards/ 28
Table 2: Applying Risk Zones Example Hazard Risk Explanation Forklift backing up in a high traffic area (1). HOT ZONE Forklift use common and frequent in warehouse. Workers wearing headphones (3). Very likely for incident to occur, especially if pedestrians are not aware and environment is busy and noisy. In this picture, the worker is wearing headphones. Slip Hazard on the floor (2). WARM ZONE Severe Consequences of being hit. Worker could slip and fall. Possibility of falling around moving vehicles. Very likely chance of slipping but moderate consequences. 2.6. Guided Activity Assessment of Risk 2.6.1. Introduction In this activity, you will practice assessing the risk associated with a variety of hazards. You will use the same hazards you identified in the WorkSafeBC photos. The goal of this activity is to give you the skills to assess the level of risk in your worksite before you begin to work. 2.6.2 Instructions Turn to Appendix 2 in this book and complete the Assessment of Risk Activity table. 2.7. Mitigating Risk using Controls So far this module has provided some tools for identifying hazards in the workplace and assessing what kind of risk they represent. The final and necessary step in this process is to mitigate this risk as much as possible. Mitigating risk means using some kind of control to remove or reduce the hazard. Obviously, the first goal is to eliminate the hazard but this is not always possible. This section will cover several different types of controls that can be used to mitigate risk and prevent injury. Remember, if at any time you spot a hazard and are not sure how to control it, or are not personally able to control it, you must ask for help! The following table describes five different controls commonly used to mitigate risk. These controls are listed in order, with the most desirable ones at the top. The controls closer to the top are more desirable because they are better at mitigating risk by being more consistent and leaving less to chance and user error. LEARNING ACADEMY Warehouse Health & Safety 29
The more desirable controls, however, are often the most difficult to put in place and sometimes are not practical or possible. Some activities are inherently risky and would not be possible if all of the controls were put in place. When considering what controls to put in place, start at the top and select the best control that is possible and practical given the situation. Figure 9: Mitigating Risk with Controls Mitigating Risk Choose the best control possible. If you cannot place the control yourself, ask for help. Elimination Can I eliminate the hazard? Substitution Can I substitute different action or equipment? Engineering Can I request engineered controls such as guard rails? Administrative Can I request adminstrative controls such as a safework procedure? PPE Can I use PPE to make the situation more safe? 30
2.7.1. Elimination Elimination of the hazard is the best control as it removes the exposure to the worker. Elimination may be using equipment in place of manual handling or even eliminating a task. An example in a warehouse may be having a forklift move a pallet of freight instead of trying to move it by hand or using a pallet jack. 2.7.2. Substitution If the hazard cannot be eliminated, can a different process, piece of equipment or material be substituted that will reduce or eliminate the hazard? An example may be the use of a powered pallet jack instead of a hand model for delivery drivers. 2.7.3. Engineering Engineering controls typically involve the control of the hazard at the source and include isolation, equipment guarding and other engineered solutions. Examples include minimizing noise from an air compressor by isolating it in a sound proof room or installing ventilation fans on areas that may be used to store chemicals or in oil change pits in a shop or by installing a guard around an automated stretch wrapping machine. 2.7.4. Administrative When a hard hazard control solution cannot be used administrative controls must be used. Administrative controls are written processes and procedures that are used to limit exposure to a hazard. Administrative controls are less effective because they rely on people using them. Examples of administrative controls include: the requirement to use 2 people to lift heavy items the requirement to use designated walkways for pedestrians in areas where mobile equipment are working written procedures for operation of forklifts or other mobile equipment 2.7.5. Personal Protective Equipment The least preferred control method is the use of personal protective equipment such as hard hats, eye protection, respirators and masks. PPE is not inherently safe and provides a measure of direct protection of a worker. If not worn, or if it fails, PPE obviously offers no protection whatsoever. LEARNING ACADEMY Warehouse Health & Safety 31
Mitigating Risk Example Consider again Figure 8. In the previous section, the hazards were noted and placed in a Risk Zone. Now, possible controls are assigned to mitigate the risks. These controls are listed in Table 3 below. Table 3: Applying Controls Example Hazard Risk Zone Explanation Control Forklift backing up in a high traffic area (1). Workers wearing headphones (3). HOT ZONE Forklift use common and frequent in warehouse. Very likely for incident to occur, especially if pedestrians are not aware and environment is busy and noisy. In this picture, the worker is wearing headphones. Severe Consequences of being hit. Elimination. The forklift can be redirected off the pedestrian area. The worker can remove headphones. Administrative. Clear policy on forklift practices and headphone use must in instigated. Slip Hazard on the floor (2). WARM ZONE Worker could slip and fall. Possibility of falling around moving vehicles. Very likely chance of slipping but moderate consequences. Elimination. It is possible and practical for the spill to be cleaned up immediately. 2.8. Guided Activity Mitigating Risk through controls 2.8.1. Introduction Identifying risks and assessing them will not be useful unless you then act to control those risks. Sometimes acting to control hazards can be done by yourself, immediately. Sometimes it requires you to ask for help. This exercise will help you to understand the range of options you have for controlling safety at work. 2.8.2. Instructions Turn again to Appendix 2. In this activity, you will complete Table 4: I AM Safety Driven Practice Exercise. In the previous section, you assessed the risk for the selected hazards. Now, you will 32
mitigate that risk by assigning controls using Figure 9: Mitigating Risk with Controls. Detailed instructions are included in the Appendix. 2.9. Truck Stop Use your course book and any notes you have taken to answer the following questions. When everyone is finished, the instructor will review the answers..# Question Answer Space 1. Identify the four common types of hazards and give an example of each one. 2. List the three Risk Assessment Zones and explain how you decide which zone to use. 3. Explain the problem with administrative controls. 4. What do you do when you are not personally able to control a hazard that you have spotted at the worksite? LEARNING ACADEMY Warehouse Health & Safety 33
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Module 3 Common Hazards in a Warehouse
3.1. Introduction Each worksite has its own unique hazards and it is important for workers to be aware of those hazards before they start work. Workers can use the Site Specific Information Checklist, discussed in Module 1, to ensure they have the information they need when starting at a new worksite. Also workers can use the I AM Safety Driven Hazard awareness process to assess a new worksite before starting work. This process is explained in Module 2. These two tools are provided in a useful carry card for workers as part of this course. In this final module, you will be introduced to a set of hazards that are common in a warehouse environment. When you are on orientation for a new work site, you can be looking out for these common hazards and the controls that are in place. 3.2. Learning Outcomes By the end of this module, participants should be able to: 1. Explain generic hazards associated with warehouses 2. Explain generic controls associated with those hazards 36
3.3. Physical Hazards Manual Lifting and Handling Back injury and other kinds of repetitive strain can result from excessive and repetitive manual lifting. The risks of this hazard are increased with: Overhead lifting Awkward body positions Over-reaching or using excessive force or exertion Poor posture Frequent repetitive motions Poor lighting, including glare Controls Use powered equipment when possible to minimize the need for manual lifting Ask for help if the load is too heavy Get training on correct lifting techniques to reduce chance of back injury Avoid twisting and lifting from shoulder height or floor. Avoid standing for long periods on hard floors, use rubber mats and good sturdy footwear Reduce need for repetitive motion, and, when required, change the pace frequently and take breaks regularly. Ensure overhead lighting is adequate Proper lifting procedures: 1. Plan the move. Assess the size, shape and weight of the material to be lifted. Make sure the pathway is clear. Get help for heavy and awkward objects. Use a dolly or trolley or other mechanical means if possible. 2. Use proper stance: wide balanced with one foot slightly in front of the other. Keep your back straight. 3. Get close to the load. As close as possible. 4. Tighten your stomach muscles as you start to lift. 5. Use your legs not your back to lift. 6. Don t twist your back to turn. Pivot on your feet. 7. Lower the load slowly, maintaining a stiff posture and using your legs not your back. LEARNING ACADEMY Warehouse Health & Safety 37
Load Shifting/Falling Objects A lot of freight is moved through the warehouse environment, putting workers at risk of being hit or crushed by shifting loads. Improperly stored materials may fall, crushing or pinching workers. Equipment and tools being used in elevated areas can fall if not secured. Controls Stack loads evenly and straight Place heavier loads on lower shelving Lift and move one item at a time Ensure walkways and aisles are clear Wear all PPE such as hard hat and safety boots. Moving Machinery and Equipment Congestion. When the warehouse is busy, workers and machinery work quickly side by side, increasing the chances of injury: Workers can be struck by mobile equipment Workers can be caught or crushed behind / between stacks Forklifts/Pallet Movers Workers at risk of being hit be moving vehicles in a warehouse Forklifts can turn over Freight can be dislodged by forklift, creating risk of crushing or pinching Conveyers Workers can be caught in pinch points or hit by falling items from the conveyer Source of ergonomic hazards as well, such as sprain and repetitive stress Docks/Ramps Forklift can run off the dock Items fall on workers Workers struck by machinery in the area Workers falling from heights Controls Preventing injury from congestion and machinery Place convex mirrors strategically to improve visibility Avoid working with or around machinery if safeguards are not in place and being used 38
Know the safety procedure for working with or around any machinery Avoiding using bare hands to touch or lift materials that are sharp or broken Forklifts Ensure only trained workers operate forklifts Ensure forklift operators follow all safe work procedures for moving and stacking loads and for moving around the warehouse Avoid standing between a forklift and a fixed object, such as a wall Maintain safe clearances for forklifts in aisles and dock areas Stay behind all guards and on pedestrian pathways to give space for forklifts Ensure adequate ventilation in areas where forklifts and other machinery in use Conveyers Ensure pinch points are guarded Train workers on lockout procedure Ensure adequate lighting Docks/Ramp Provide visual warnings of dock edges Avoid jumping from dock area Ensure forklifts stay back from dock edges Housekeeping - Slips/Trips/Falls The warehouse environment can become cluttered with materials, creating a hazard. As workers move through the warehouse, on walkways, on ladders, and other ramps or other elevations, the chance of injury is higher if the area is not clean and secure. Controls Keep walkways, exits and doors clear Paint designated walkways Define and use designated storage areas Ensure floor is in good condition Clean up all debris from floor and other work surfaces regularly Ensure appropriate guardrails are in place and respected Preventing Slips, Trips and Falls Clean floors regularly and immediately if a spill is spotted Keep floors and workspaces free of debriswear appropriate non-skid footwear Report uneven floor surfaces or damage to mats Place warning signs for wet floors Replace burnt out lighting LEARNING ACADEMY Warehouse Health & Safety 39
Preventing Ladder Falls Use ladders with slip resistant feet and place on flat firm surface Inspect the ladder before use Use the correct ladder for the task Face the ladder when climbing and do not twist Do not work from top two steps Containers Shipping containers have their own set of unique hazards. In all cases, it is important to know what is in the container before opening the doors. Loads may have shifted, creating risks of falling, pinching or trapping or crushing Container have controlled atmospheres where oxygen is removed and replaced with another gas. Container may contain hazardous materials Container may have temperature extreme Controls Environment control Ensure container is ventilated prior to entry Follow controls for working in areas of extreme heat or cold Load Shifting Stand aside while opening doors Block or support loads while unloading Work from the top down Ensure a clear escape route is maintained 40
3.4. Chemical and Biological Hazards Dangerous Warehouse Materials Different chemicals may be stored or used within the warehouse. These chemicals pose a risk of burning and/or of inhalation of dangerous fumes. During an incident in the warehouse, it is possible that workers could come into contact with biological material, such as blood or vomit. Controls Train workers on risks of all chemicals and hazardous materials being stored Store chemicals safely and securely Train workers on clean up, including how to protect themselves and dispose of used materials Follow MSDS instructions Wear appropriate PPE e.g. respirators, rubber gloves, etc. Provide spill cleanup kids Ensure equate ventilation for engine exhaust and other noxious gases Train workers on hazards associated with carbon monoxide LEARNING ACADEMY Warehouse Health & Safety 41
Temperature Exposure In the warehouse, workers are often exposed to extremes of cold and hot temperatures. Cold exposure: Hazards that may lead to hypothermia Coolers and walk-in freezers Working outdoors in winter Heat exposure: Hazards that may lead to heat stress, heat exhaustion and heat stroke include Working in direct sunlight, near a heat source or in a hot space such as a container Lack of cooling air circulation High humidity and warm / hot temperatures Controls Wear appropriate clothing in layers Wear protective equipment Take frequent breaks to warm up or cool down Be aware of the hazards of heat exposure Ensure training in symptom recognition Ensure good cool air ventilation Drink plenty of water, use electrolytic drinks if necessary. Take frequent breaks / rotate crew Re-schedule to a cooler time of day 42
3.4. Psychological Hazards Fatigue Tired or distracted workers are much more likely to be a hazard to themselves and others in the work environment. Fatigue or distraction may be caused by working long or double shifts or by personal problems outside of work. Controls Ensure proper rest breaks, hydration and nutrition at work Use fatigue mats and other ergonomic features to limit physical fatigue Arrive at work rested and prepared for the shift Adhere to the company drug, alcohol and impairment policy 3.5. Truck Stop Use your course book and any notes you have taken to answer the following questions. When everyone is finished, the instructor will review the answers. # Question Answer Space 1. List 3 physical hazards common in a warehouse and indicate how these hazards could be controlled. 2. List 2 chemical or biological hazards common in a warehouse and indicate how these hazards could be controlled. 3. Explain how fatigue and distraction could be controlled. Congratulations! You have completed the course Working Safely in Warehouses offered by the Trucking Safety Council. Your instructor will now give instructions about the quiz for this course. LEARNING ACADEMY Warehouse Health & Safety 43
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Appendix 1 Identification Practice
4.1. Identify Hazards Guided Activity The photos below (Figure 10, Figure 11, Figure 12, & Figure 13) cover several different scenarios associated with working in Warehouses and the Trucking Industry. For each photo, identify all the hazards you can find. Fill in the table after each photo. You can also circle or mark the hazards on the photo itself for clarity. Work in groups and compare with others when you are finished. 46
Figure 10: Photo 1 Trucking Safety [2013] WorkSafeBC Source:http://www2.worksafebc.com/Publications/Multimedia/PastPhotos.asp?ReportID=37282 Hazard Type of Hazard Your Experience with this hazard? LEARNING ACADEMY Warehouse Health & Safety 47
Figure 11: Photo 2 Chemical Safety [2010] WorkSafeBC Source: http://www2.worksafebc.com/publications/multimedia/pastphotos.asp?reportid=37101 Hazard Type of Hazard Your Experience with this hazard? 48
Figure 12: Photo 3 Retail [2012] WorkSafeBC Source: http://www2.worksafebc.com/publications/multimedia/pastphotos.asp?reportid=36803 Hazard Type of Hazard Your Experience with this hazard? LEARNING ACADEMY Warehouse Health & Safety 49
Figure 13: Photo 4 Forklift [2010] WorkSafeBC http://www2.worksafebc.com/publications/multimedia/pastphotos.asp?repor- Source: tid=35979 Hazard Type of Hazard Your Experience with this hazard? 50
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Appendix 2 Assessment and Mitigation Practice
5.1. Part 1 - Assessment of Risk Guided Activity The WorkSafeBC photos from Appendix 1 are reproduced here with the hazards marked in red circles. 1. Explanations for some of the hazards from each photo are given and noted in the Table 4. 2. For each hazard assign a Risk Zone, using the Risk Assessment Tool (Figure 7). 3. Explain why you chose the zone, noting how likely it is that there will be an incident and how serious the incident might be. Note: The Control Column will be completed in a later exercise. 54
Table 4: I AM Safety Driven Practice Exercise I AM Safety Driven I - Identify A - Assess M - Mitigate Trucking Safety Photo: Hazard Risk Zone Explanation Control A loose strap on the ground is a tripping hazard. The trailer deck is cluttered. A worker is standing on debris while adjusting the tarp. Chemical Safety Photo: The worker is using a grinder in an area where flammable chemicals are in use. The electrical cable is lying across the equipment. Retail Safety Photo: Milk cartons are not intended to be used for standing on nor to be used as a stepping stool. Awkward posture, overhead lifting and the possibility of heavy load and repetitive strain. Forklift Safety Photo Forklift is on the pedestrian pathway. Pedestrians are not paying attention. One is not wearing PPE. Debris hanging from the pallet. Other? Other? LEARNING ACADEMY Warehouse Health & Safety 55
Hazard Photos Source: All photos adapted from http://www2.worksafebc.com/publications/multimedia/photos.asp A worker is standing on debris while adjusting the tarp. A loose strap on the ground is a tripping hazard. The trailer deck is cluttered. Figure 14: Trucking Safety with Hazards [2013] WorkSafeBC The worker is using a grinder in an area where flammable chemicals are in use. The electrical cable is lying across the equipment. Figure 15: Chemical Safety with Hazards [2010] WorkSafeB 56
Awkward posture, overhead lifting and the possibility of heavy load and repetitive strain. Milk cartons are not intended to be used for standing on nor to be used as a stepping stool. Figure 16: Retail Photo with Hazards [2012] WorkSafeBC. Forklift is on the pedestrian pathway. Pedestrians are not paying attention. One is not wearing PPE. Debris hanging from the pallet. Figure 17: Forklift Photo with Hazards [2010] WorkSafeBC LEARNING ACADEMY Warehouse Health & Safety 57
5.2. Part 2 - Mitigating Control Guided Activity In this activity you will complete the final column of Table 4 by adding in controls for each hazard you have assessed. For each hazard, choose the best possible control to mitigate risk. Use Figure 9 to help you to select controls, decide which controls are practical and required for each hazard. Review you answers with the group and discuss any differences of opinion. 58
Site Specific Information Checklist Basic site rules and policies such as entry / exit procedures, smoking areas, what you can t do and what you must do Emergency response procedures How to obtain first aid and first aid location Introduction to the supervisor Incident reporting requirements Clear explanation and demonstration of your task and duties Personal protective equipment required Known and foreseeable hazards Any specific written procedures, such as lock-out Anything else that is not clear I AM Safety Driven I Identify Hazard Not very Likely but Very Serious (Warm) Not Very Likely & Not very Serious (Cool) Very Likely but Not Very Serious (Warm) HOW OFTEN? More often = More likely Risk Zones A Assess Risk Zone Very Likely & Very Serious (Hot) M Mitigate Control CONTROLS: Elimination Substitution Engineering PPE LEARNING ACADEMY Warehouse Health & Safety 59
Congratulations! Well done. You have finished all six modules of Canadian Occupational Health and Safety Legislation. You will now need to complete the final quiz. Your Instructor will give you instructions on this process. 60
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