Common Warehouse Injuries | Warehouse Accidents Statistics (2024)

There are various types of accidents which can occur in a warehouse, resulting in injuries which range from minor to fatal. Some of the most common are:

Common Warehouse Injuries | Warehouse Accidents Statistics (1)

Slips, trips and falls

Slips, trips and falls are common injuries in many workplaces. In fact, the HSE reported that in 2018/19, slips, trips or falls accounted for the greatest amount of non-fatal injuries.

Slips, trips and falls can often occur in a warehouse environment because of the fast moving nature of this type of work. Hazards such as discarded boxes, box ties, cables or spilt substances can all cause injury. Failure to remove, identify or make safe a hazard is not only dangerous but it also breaches health and safety.

Manual handling injuries

The HSE reports that handling, lifting or carrying accounts for 20% of non-fatal injuries in the workplace. In a warehouse, workers often have to lift heavy items, and if there is a lack of training, if the right equipment isn’t provided or if strenuous work is too repetitive, employees could sustain strain or sprain injures.

Crush injuries and machinery accidents

In a warehouse, the most common crush injuries result from operating forklift, pallet trucks and packaging machinery. Accidents caused by operating machinery in the warehouse can be severe, especially if workers become trapped in or underneath machinery.

The HSE reported that, in 2018, being trapped by something collapsing or overturning caused 10% of fatal accidents, and 10% of non-fatal accidents in the workplace.

Forklift injuries are among some of the most common in warehouses, and can prove the most dangerous. These accidents are usually caused by poor training, inadequate supervision, little or no maintenance of machinery or poor delineation of gangways.

According to the British Safety Council, around 1,300 UK employees are hospitalised each year with serious injuries following a forklift accident. These injuries can range from fractures, dislocations and broken bones, to life-changing amputations.

Falling objects

Being struck by a falling object is another common warehouse injury, with the HSE reporting that 10% of non-fatal injuries in the workplace in 2018/19 are the result of a moving object.

In a warehouse, failure to properly shelve items – because of a fellow employee’s carelessness or poorly constructed shelves – can cause serious head injuries. A heavy item falling on a worker could even cause a brain injury, particularly if a hard hat is not worn.

Preventing warehouse injuries

Employers have a legal responsibility to protect all of their employees as well as contractors and visitors to the warehouse from risk of accident or injury.

Accidents in a warehouse can be prevented with the following precautions:

  • Signs – signs and floor markings should be clearly placed around the warehouse to warn of hazardous areas and indicate where PPE is needed
  • Equipment checks – equipment and vehicles, like forklifts, should be maintained in a safe condition and should be inspected regularly to ensure they are safe to use
  • Training – all employees should have full health and safety training.

Common Warehouse Injuries | Warehouse Accidents Statistics (3)

What should I do if I have had a warehouse accident?

If you have been injured whilst working in a warehouse, this might be because your employer has failed to follow health and safety laws, or a fellow employee has acted carelessly. If you think you may be eligible to make a warehouse accident claim, follow the links below for more information.

Common Warehouse Injuries | Warehouse Accidents Statistics (2024)

FAQs

Common Warehouse Injuries | Warehouse Accidents Statistics? ›

As of 2021, warehouses made up less than 1 percent of the 8 million worksites that OSHA oversees nationwide. However, the 2021 injury and illness rate in warehouses— 5.5 incidences per 100 workers—is more than double the rate of 2.7 incidences per 100 for workers across all industries.

What are the statistics for warehousing injuries? ›

As of 2021, warehouses made up less than 1 percent of the 8 million worksites that OSHA oversees nationwide. However, the 2021 injury and illness rate in warehouses— 5.5 incidences per 100 workers—is more than double the rate of 2.7 incidences per 100 for workers across all industries.

What is the most common injury in a warehouse? ›

Crush injuries and machinery accidents

Forklift injuries are among some of the most common in warehouses, and can prove the most dangerous. These accidents are usually caused by poor training, inadequate supervision, little or no maintenance of machinery or poor delineation of gangways.

What is the number 1 cause of workplace accidents? ›

1. Overexertion. Overexertion can happen with lifting, pushing, pulling, holding, carrying, or throwing objects. To prevent injuries related to overexertion, be sure to provide your employees with ergonomic equipment and properly train them about safety involving physical tasks.

What is the biggest safety issue in a warehouse? ›

Forklifts

Unsafe use of forklifts is the most often cited hazard in warehousing operations by OSHA. Below are a few basic warehouse safety tips to follow in forklift use: Ensure all forklift operators are competent and have completed certified training.

What is the most frequent source of injuries among warehousing personnel? ›

Overexertion Injuries

Overexertion is a massive problem for warehouse workers, resulting in injuries from employees putting their bodies through too much stress. These injuries can limit their movement and cause chronic pain for their entire lives.

What are the most common risks in a warehouse? ›

10 Common Warehouse Hazards + How to Prevent Them
  • Hazard #1 – Poor layout. ...
  • Hazard #2 – Slips trips and falls. ...
  • Hazard #3 – Falling objects. ...
  • Hazard #4 – Loading dock accidents. ...
  • Hazard #5 – Poor ergonomics and manual lifting technique. ...
  • Hazard #6 – Lack of safety measures for warehouse workers. ...
  • Hazard #7 – Poor storage facilities.

What causes 90% of all workplace injuries? ›

But the reality is, close to 90 percent of all workplace injuries are caused by the worker's own unsafe actions. Although injuries are physical and visceral, they're more often rooted in something that's much less visible—a worker's attitude or state of mind.

What part of the body is injured most often at work? ›

The most common areas of injury for the workers in agriculture, industry, construction and services to the business economy were the upper extremities (41.8%) and lower extremities (29.2%).

What are the statistics on workplace injuries? ›

The preventable injury death rate of 3.2 per 100,000 workers is up from 3.1 in 2021. Work-related medically consulted injuries totaled 4.53 million in 2022. Source: Deaths reflect National Safety Council (NSC) analysis of data from the Bureau of Labor Statistics (BLS) Census of Fatal Occupational Injuries (CFOI).

What are the 5S safety in warehousing? ›

The methods of 5S – sort, set in order, shine, standardize and sustain – are used to improve and maintain an organized environment. In warehousing, kaizen also involves thinking with your team and finding creative ideas to solve problems.

What PPE is required in a warehouse? ›

Common types of PPE used in a warehouse include: Hard hats. High-visibility jackets. Safety glasses or goggles.

What industry has the highest injury rate? ›

Industry Incidence and Rates

In 2022, depending on the measure used, each of these four industries could be ranked as most dangerous: Construction– experienced the most workplace deaths. Education and health services– experienced the most nonfatal injuries and illnesses involving days away from work.

What are the statistics of warehouse workers? ›

17.3% of all warehouse employees are women, while 82.7% are men. The average warehouse employee age is 37 years old. The most common ethnicity of warehouse employees is White (57.8%), followed by Hispanic or Latino (20.9%), Black or African American (8.2%) and Asian (6.8%).

Which industry has the highest rate of workplace injuries? ›

In 2021-22, the occupation groups with the highest rates of work-related injuries were:
  • Community and personal service workers - 7.0%.
  • Machinery operators and drivers - 6.5%.
  • Labourers - 5.7%.
  • Technicians and trades workers - 5.3%.
Feb 15, 2023

What percentage of warehouse injuries occur at the loading dock? ›

Loading docks are notoriously dangerous. Approximately 25% of all reported warehouse injuries occur on the loading dock, and for each accident, there are hundreds of near misses.

Top Articles
Latest Posts
Article information

Author: Tuan Roob DDS

Last Updated:

Views: 6169

Rating: 4.1 / 5 (62 voted)

Reviews: 85% of readers found this page helpful

Author information

Name: Tuan Roob DDS

Birthday: 1999-11-20

Address: Suite 592 642 Pfannerstill Island, South Keila, LA 74970-3076

Phone: +9617721773649

Job: Marketing Producer

Hobby: Skydiving, Flag Football, Knitting, Running, Lego building, Hunting, Juggling

Introduction: My name is Tuan Roob DDS, I am a friendly, good, energetic, faithful, fantastic, gentle, enchanting person who loves writing and wants to share my knowledge and understanding with you.