Workplace safety is a crucial issue, and warehouses, with their dynamic nature and potential hazards, are no exception.
Ensuring a safe working environment not only protects the health and well-being of employees but also optimises efficiency and productivity.
According to the latest Inail report, 251,132 accidents occurred in Italian warehouses in the first half of 2024.
This alarming number highlights the need for a concrete commitment to improve safety in warehouses.
Current European warehouse safety regulations
In relation to warehouse safety, specifically regarding metal shelving, the following regulations are in place:
- EN 15512: Structural design principles: this regulation specifies the structural design requirements applicable to all types of adjustable pallet racking systems made of steel components, intended for storing palletized loads and subject to predominantly static loads.
- EN 15620: Tolerances, deformations, and clearances: this regulation specifies the tolerances, deformations, and clearances relating to the manufacturing, assembly, installation, and performance under load of pallet racking and cantilever racking.
- EN 15629: Storage equipment specifications: the standard provides technical specifications that enable the design of racking and shelving systems in various forms, including adjustable pallet racking, automated stacker systems, drive-in racking (DIR), cantilever racking, and shelf systems, all served by manually guided or automated mechanical handling systems.
- EN 15635: Use and maintenance of storage equipment: this defines the procedures for proper inspection and maintenance of racking systems, as well as detecting damaged and non-compliant components. According to UNI EN 15635, racking inspections must be carried out periodically, no later than 12 months after installation, and subsequently at regular intervals. The user is primarily responsible for the safety of those working in the facility and must ensure the storage systems are in good condition.
Key points for ensuring safety in a warehouse
To ensure maximum safety and minimise risks in a warehouse, it is essential to make significant investments in training and prevention, properly design the warehouse layout, perform predictive analysis, and conduct regular inspections.
Training and prevention
Safety training is a critical investment for any company, especially in warehouses. It is crucial to ensure that all employees receive adequate and up-to-date training on safety procedures, including load handling, proper equipment use, and emergency protocols. Each operator must have a thorough understanding of the specific risks related to their role and the necessary prevention measures.
It is fundamental to provide workers with appropriate personal protective equipment (PPE) tailored to the specific risks of each position. Common PPE includes safety shoes, gloves, helmets, hearing protection, and safety glasses.
Proper warehouse layout design
Careful warehouse layout design is essential for ensuring operator safety and optimising logistics processes. A well-thought-out layout minimises the risks of accidents, such as collisions or falling materials, while maximising operational efficiency.
The three key steps for effective design are:
- Detailed Mapping: a precise map of the warehouse provides an overview of the available space and the activities taking place. This phase is crucial for identifying critical areas and making informed decisions regarding equipment choice and goods organisation.
- Space optimisation: the optimal arrangement of goods in the warehouse is vital for facilitating picking and material movement while minimising handling times and errors. It is important to allocate appropriate spaces for different activities and ensure maximum access to goods.
- Equipment selection: the choice of equipment, such as industrial shelving, should be based on the characteristics of the goods stored and the specific needs of the warehouse. Customised and versatile solutions help optimise space while ensuring operator safety.
Technical tests and maintenance: the key to a fully safe warehouse
A fully safe warehouse is based on a predictive and descriptive analysis of the storage structure dedicated to merchandise.
The predictive phase, grounded in rigorous technical tests, is crucial for certifying the quality of the racking systems and forecasting their behaviour under different load conditions.
ROSSS, with its cutting-edge internal laboratory, subjects each component to specific tests, such as:
- Biaxial and uniaxial bending tests on posts
- Stiffness tests on beam connections
- Tests for the identification of distortional, torsional, and flexural-torsional phenomena under axial compression and multiaxial bending conditions
- Stub column tests for the identification of local instability phenomena
- Tensile tests on steel specimens
- Live load tests on light racking systems
Once you allocate goods within the shelving, the next step is to perform periodic inspections of the rack components.
Risk mitigation is only possible if the warehouse is used according to the supplier’s guidelines, ensuring proper maintenance of the racking and its accessories.
Warehouse safety: practical solutions
How can a warehouse be transformed into a safe environment?
The elements to satisfy the “warehouse = safe environment” equation can be divided into two categories: those concerning the building and those concerning the racking system.
To ensure better safety inside the building, the following aspects must be considered:
- Signage: install clear and understandable signs to indicate pedestrian areas, work zones, evacuation routes, and danger zones.
- Flooring: ensure the flooring is in good condition to prevent slips and falls and that it is suitable for supporting the racking loads.
- Lighting: provide adequate lighting in every area to ensure visibility and prevent accidents.
- Emergency exits: well-marked and always clear escape routes.
Conversely, to ensure safer racking systems, the following considerations should be made:
- Safety devices: install on the shelves safety devices that protect goods from accidental falls and make the warehouse safer for operators.
- Load capacity signs: ensure the actual load capacity of the racks is displayed with visible signs listing all the product’s technical parameters.
- Stability and proper placement of load units: ensure that goods are stably and properly positioned on the racking systems.
- Clearances: maintain adequate clearances between racks to facilitate circulation and prevent accidents.
Conclusions
In summary, warehouse safety presents itself as a crucial challenge that requires a holistic and well-structured approach.
In recent years, awareness of the importance of warehouse safety has grown significantly, highlighting how important it is to safeguard the working environment for operators.
To achieve a protected work environment, it is essential to:
- Act in compliance with safety regulations in the workplace and warehouses;
- Train employees.
- Design a warehouse layout suited to the type of load units to be stored.
- Perform technical tests on individual racking components to verify quality and certify load capacity.
- Conduct regular maintenance activities.
- Enhance rack safety by installing protective devices, load capacity signs, proper load unit placement, and maintaining adequate clearances.
- Maintain a safe work environment by improving signage, flooring, lighting, and emergency exits.
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