Guarding and Fall Protection for Essential Warehouse Safety

The Importance of Warehouse Fall Protection

According to the U.S. Department of Labor, falls are the leading workplace safety violation. In fact, in 2023, the Occupational Safety and Health Administration (OSHA) received nearly 7,300 violations related to improper fall protection equipment practices on the job site.

In the warehouse, falls may occur for several reasons. They may result from slip and fall accidents from spills, loose material, clutter or uneven surfaces. They may also occur from heights if proper fall protection standards are not in place. Falls from heights can be particularly dangerous and may lead to serious injury or even death.

OSHA has developed fall protection standards designed to keep workers safe when working at heights. Per OSHA requirements, fall protection must be administered at elevations of at least four feet in general industry workplaces or risk a violation and/or fine for non-compliance. In construction environments, the standard is six feet.

There are two general types of fall protection: active and passive. Active systems largely consist of personal fall arrest systems like harnesses, horizontal lifelines, and lanyards. They are commonly used when passive systems aren’t feasible. Passive systems include safety netting and safety railings. In some situations, a combination of both active and passive systems may be utilized.

Types of Safety Guarding Systems

As mentioned, there are two general types of fall protection and safety guarding systems: active and passive. In this section, we’ll focus mostly on preventative solutions, which don’t require any user interaction after they’re installed. Passive systems are best used in high-traffic areas of the warehouse, including safety gates at stairways, loading docks, walkways, and even mezzanines.

Here’s a look at some of the common types of passive systems:

• Guardrails: Guardrail systems create physical barriers around dangerous equipment and help protect workers from falling from heights.
• Safety nets: Safety nets help protect workers, reducing the distance a worker falls from heights and absorbing any impact. Nets can significantly reduce injury from falls at heights and also protect other workers who may be working at lower levels.
• Pallet rack fall protection: Pallet rack fall protection is ideal for preventing any accidents that may occur when loading and unloading items. They work by preventing items from falling off racks and preventing injury from falling objects.

OSHA Regulations and Warehouse Compliance

Failure to comply with OSHA regulations in warehouse environments can result in violations and hefty fines. In fact, as of January 2024, the maximum penalty for regulatory, general willful, or repeat violations is nearly $16,000.

So, what are the OSHA regulations for warehouse fall protection? Here’s a look at some of the key details you need to know to stay in compliance and avoid penalties:

• Employers must develop a plan that identifies and accounts for potential hazards. This plan includes outlining how to prevent falls and what preventative systems to use. Workers must also be properly trained on fall hazards and fall protection systems.
• Guardrails that are at least 42 inches high and can withstand 200 pounds of force must be installed at heights of four feet or greater. Handrails and safety railings are critical components of this setup. 
• In situations where guardrails (or other passive systems) are not feasible, personal fall arrest systems must be used. These should include full body harnesses and anchor points.
• Safety nets that are installed must meet 29 CFR part 1926 requirements.
• Holes or openings in floors must be covered to prevent an accidental slip or fall.

Pallet Rack Fall Protection Measures

One of the key tasks carried out in the warehouse is loading and unloading pallets. However, items risk falling from pallet racks during loading and unloading, which can create a danger for nearby workers. Some of the pallet rack fall protection measures to implement in the warehouse include:

• Harnesses, railings, and safety netting systems protect people and materials from damage or injury. Rack guards and pallet straps can also help keep pallets stacked properly.
• Stacking pallets correctly is also important to worker safety. Heavier loads should be placed on the bottom of the pile to help avoid issues.
• Any safety systems should also be periodically inspected and maintained as necessary to ensure they’re able to continue to perform safely.

Order Picker Safety Protocols

It’s estimated that about one out of every ten forklifts in the United States will be involved in an accident each year. With the warehouse representing an environment of high forklift activity, it’s important to implement the right safety protocols to minimize the risk of accidents. Accidents can result in material damage and worker injury.

Some of the most common types of forklift accidents in the warehouse include incidents resulting from abrupt movements and issues resulting from poorly balanced loads.

Safety protocols to implement to increase warehouse safety include ensuring loads are properly secured, using the right forklift for the task at hand, installing machine guards to prevent workers from getting caught in forklifts, and making sure lights and warning devices are working properly.

Preventing Warehouse Accidents Through Safety Training and Planning

The best way to prevent warehouse accidents is through proactive training and planning. It’s also an ideal way to implement a safety culture within your organization.

It’s also important not just to empower your workers with the training and information they need to stay safe, but to hold them accountable for the safety of themselves and others. Remember, employee safety is everyone’s job.

One essential deliverable during safety planning is a warehouse safety plan. Some best practices for creating a comprehensive safety plan include:

• Identifying hazards and conducting regular audits to ensure information is up-to-date.
• Creating a “housekeeping” policy to ensure warehouse cleanliness. This helps keep pathways clear and the warehouse organized, thereby reducing the risk of injury.
• Positioning signs and labels accordingly throughout the warehouse to communicate hazards or expectations.
• Clearly identifying who workers can contact for help or assistance during a safety incident. This should include internal safety professionals and external emergency services or other resources.

Contact A-Lined Today

For more information on guarding and fall protection in the warehouse, contact A-Lined today.