Common Safety Hazards in Material Handling Operations

A streamlined work process needs to be evaluated continuously to ensure its effectiveness. Unfortunately, in the rush to satisfy clients or hit production targets, many workers expose themselves to safety risks. With so many different materials, machinery and equipment in the workplace, employers must ensure safety remains a priority.

Whether you’re working in a warehouse, a loading dock or on a new jobsite, most accidents are preventable through clear procedures and communication. The layout, environment and equipment used in your workplace can all contribute to a potential accident. However, identifying common safety hazards in material handling operations before they happen can reduce workplace risks and create a more secure environment.

How to Identify Common Safety Hazards

Any workplace that involves machinery or material handling has potential safety risks. Industrial safety hazards can stem from flammable or toxic materials and improper use of mechanical equipment. Poor training and incorrect personal protective equipment (PPE) use are also contributing factors.

Under the Occupational Health and Safety Act, companies must create a safe working environment. Below are some key areas to consider when looking for material handling injury causes in the workplace.

Ergonomic Material Handling Safety Hazards

Material handling safety hazards are common in warehouse environments. However, manually lifting with force can lead to back pain, hernias and muscle sprains. These injuries can be due to repetitive movements or poor training and information on handling materials safely.

Preventing accidents in material handling situations is achievable through training employees on the correct way to lift. A safe lifting technique includes bending the knees to lift and keeping the material close to the body as you lift. Encouraging regular breaks for repetitive lifting work and wearing the correct PPE is also important. Finally, encourage team members to stop and check the size and weight of any object before lifting.

The right equipment can help avoid common material handling dangers. If available, workers should use ergonomic lifting aides to reduce the chances of a physical injury and maintain a safe load.

Forklift Accidents

Forklifts can cause serious injuries and even death if not operated responsibly or maintained regularly. The most common safety hazards involving forklifts in the workplace include:

• Uneven loads or loads that exceed the specific lift limit
• Insufficient training and certifications for operators
• Mechanical defects due to poor maintenance
• Speeding or driving recklessly
• Poor visibility due to lighting
• Collisions

All forklift operators should be trained and certified according to the standards associated with their industry. Employers should inspect forklifts regularly to check for faults and provide clear instructions on who to report any service issues to. For improved driver safety, operators should wear seat belts and PPE when driving.

Enforcing rules on driving near edges or not cleaning up slippery spills immediately can also reduce issues and prevent workplace forklift accidents. Warehouse column protectors can also help reduce collision impact and increase visibility.

Falling Objects

Looking for ways to identify warehouse safety hazards doesn’t end with known potential risk areas. It requires a detailed look at areas of the workplace that are high up or out of the way, where objects could fall and have fatal consequences. Risks include any hazard from loose tools, poorly stacked loads and potential structural issues.

Regularly inspecting equipment, structural weaknesses and tool storage practices can keep your workplace secure from falling hazards. Clear signage of falling risks while tools are in use or structures are being loaded with heavy objects can also prevent incidents of falling objects.

Additional solutions to prevent falling objects in your warehouse include:

• Rack Safety Nets
• Topple Wall Systems
• Mezzanine Safety Gates
• Wire Mesh Enclosures 
• Zoneworks Curtain Walls

Loading Dock Hazards

Loading docks play a vital role in the successful functioning of a workplace. But with so many different vehicles, loads and people weaving in and out of the area, it can also be dangerous. Clear order and prevention measures create a safer loading dock, including:

• Implementing trailer restraint measures and safe sequence of operations during all loading and unloading.
• Fitting quality physical guardrails and other barriers to prevent falls and collisions.
• Putting up clear signage and appropriate lighting to avoid dark spots and prevent accidents.
• Keeping all surfaces dry and free of slip hazards with quality dock shelters.
• Providing all PPE equipment like high-visibility vests, steel-toe boots, glasses, gloves and hard hats.
• Regular awareness training that encourages care and clear risk report measures.

Combining best practice safety measures with the right dock safety equipment can reduce safety risks while increasing productivity.

Preventing Accidents and Streamlining Productivity

A safe workplace is all about creating a culture that prioritizes safety above all else. Key considerations in preventing accidents in material handling environments include education, communication and expectations.

• Education: Implement and enforce a strict, clear maintenance program for forklifts, dock equipment and other machinery. Train all operators on the equipment they use, and don’t allow non-certified individuals to use it. Have a professional demonstrate the best techniques for safely using the equipment.
• Communication: Make safety procedures an immediate part of onboarding new hires and temp workers. Introduce hand safety signals so employees can use them in loud areas for risk prevention. Forklift operations, truck drivers and dock personnel should understand these signals and implement them universally. Consider radio coordination for unexpected emergencies.
• Expectation: If industrial safety hazards aren’t shown to be serious, no one will treat them as such. Strict safety adherence can save a life. Make it clear that PPE, maintenance and other safety policies are nonnegotiable and must be respected. To send a message, enforce strict penalties for negligence and poor safety practices.

Finally, create an open forum where everyone can express what works and what doesn’t in your current safety guidelines. Be open about suggestions for improving how to identify warehouse safety hazards to get everyone on the same page. The more involved your team is, the more streamlined and productive you’ll be.

How Arbon Canada Can Help

The right safety solutions can help you avoid the most common material handling dangers, even those you may not have considered. Arbon Canada is dedicated to improving the safety and efficiency of our clients’ workplaces in all areas of their facilities.

Contact us today for a free facility evaluation of your needs from one of our skilled team members. We’ll explain how we can assist with your loading dock survey, racking assessments and other safety hazard prevention needs.