10 Top Safety Mistakes Warehouses Make and How to Avoid Them

Warehouses are high-pressure environments where operations often move faster than safety systems can keep up. Over time, processes drift, equipment wear is ignored, and new risks emerge. When these are not addressed, even small oversights can lead to life-altering injuries or legal consequences.

Ignoring warehouse safety comes at a cost. In NSW, a 56-year-old worker was crushed between two slabs after a site failed to provide basic controls. This wasn’t an isolated event—it reflects a widespread issue where safety systems either don’t exist or are no longer fit for purpose. 

Legal action, worker injuries, and shutdowns follow preventable mistakes. Warehouse incidents can be prevented by targeting high-risk gaps—where people walk, how equipment moves, and how staff interact with their environment.

No Separation Between People and Moving Vehicles

Forklifts and pedestrians crossing paths is one of the most dangerous yet common issues inside warehouses. Paint on the floor does not stop a moving forklift. In areas where vehicles operate close to foot traffic, collisions can occur with little to no warning.

Permanent barriers are needed to separate walking zones from active vehicle areas. Bollards, handrails, and rail systems are effective only when they are positioned to block movement—not just suggest it. 

Clear access points, pedestrian crossings, and loading dock exclusion areas are critical in managing risk during peak activity.

No Site-Specific Traffic Management Plan

Warehouses that operate without a documented traffic plan leave too much to memory and habit. When routes, crossing points, and waiting zones are not formalised, movements become inconsistent—especially when shift rotations or new hires are involved.

A traffic management plan should define vehicle flow, pedestrian access, delivery holding zones, and high-risk intersections. It must reflect your current layout—not a template. Plans should be visible, updated when workflows change, and communicated during toolbox talks. 

Without one, responsibility becomes unclear when incidents happen.

Poor Visibility Around Intersections and Entry Points

Obstructed views are a major factor in warehouse incidents. Narrow aisles, stacked goods near corners, or blocked lines of sight make it impossible for workers or drivers to react in time.

Rather than relying on staff to proceed cautiously, visibility must be engineered into the space. This includes convex mirrors at blind corners, motion-triggered alarms at shared doorways, and layout changes that prevent high stacking near turn points. 

Good lighting alone is not enough—sightlines must be built into racking orientation and material flow.

Poor Forklift Safety Enforcement

When forklift use becomes casual or goes unmonitored, the risk increases. Incidents involving speeding, reversing without spotters, or use without induction often happen in environments where rules are loosely applied.

All operators must hold current licences and undergo site-specific induction. But beyond that, site rules must be enforced—speed limits, pedestrian priority areas, and reversing procedures must be monitored and reinforced daily. Observations and peer reporting help identify unsafe practices early.

Damaged or Exposed Racking Structures

Forklifts often strike racking during loading and unloading. Over time, unreported dents, twisted frames, or loose connections build up. If racks aren’t inspected or protected, a single impact can trigger a full structural collapse.

Each exposed racking corner must be fitted with impact protection. Verge rack guards are designed to absorb collisions and prevent direct frame contact. Racking should be assessed weekly, with damaged frames isolated until reviewed by a competent person. 

Damage must be treated as a structural risk—not just a maintenance issue.

Unsafe Racking Loads

Not all racking issues are caused by impacts. Many failures happen due to overloading or unbalanced stacking. When load limits are exceeded, stress points shift, causing hidden failures in beams or connections.

Load capacities must be clearly displayed and reinforced through training. Before changes in product type or weight, the racking system should be reassessed for compatibility. Safe stacking includes even weight distribution, correct pallet alignment, and stable anchoring for heavier goods.

Poor Manual Handling Practice

Manual tasks often go overlooked during risk assessments. Yet musculoskeletal injuries make up the bulk of warehouse injury claims. They often occur from repetitive movement, lifting in tight spaces, or carrying unbalanced loads.

Staff must be trained not just in lifting technique, but in recognising tasks that require aids. Tools like trolleys, mobile lifters, or slide sheets must be available and usable on all shifts. 

Task rotation can reduce repetitive stress and support long-term health across teams.

Unsafe and Cluttered Warehouse Conditions

Poor housekeeping leads to more than just untidiness—it creates physical hazards. Loose shrink wrap, spilled fluids, and stray materials in walkways cause trips and falls daily.

Warehouses must assign housekeeping duties as part of shift tasks, not just end-of-day cleaning. Entry paths, aisles, and exit zones must be kept clear at all times. Spill kits, bin stations, and hazard cones should be placed near high-activity zones so they can be used quickly when needed.

Outdated Safety Documents and SWMS

Out-of-date documents are a sign that safety processes are disconnected from real operations. If procedures don’t match the site’s layout, or if no one knows where the documents are, they provide no protection.

All SWMS, induction content, and risk assessments should be reviewed quarterly or after any change in layout, equipment, or workflow. Use a digital system for access so staff can refer to documents at point of use—not just in an office. 

QR codes posted in active zones are one of the simplest ways to give real-time access to current versions.

Weak Safety Culture and No Ongoing Training

Training without follow-through creates blind spots. When workers treat safety as paperwork or compliance, they disengage. Over time, unsafe practices become the norm—especially if nobody speaks up.

Safety must be part of daily conversation. This means toolbox talks focused on real events, mentoring from experienced staff, and leadership walking the floor. We work with clients to reinforce that every role—from operator to supervisor—has ownership of safety outcomes.

Final Advice from Verge Safety Barriers

Every risk listed here is preventable. At Verge Safety Barriers, we help warehouse operators apply the right physical controls to match real movement and behaviour. Our barrier systems reduce impact risk, guide safe flow, and protect your team—whether it’s from forklifts, falling stock, or structural damage.

If your site lacks proper segregation, our Verge Safety Barrier HD Series with Handrail is a strong place to start. It creates enforced walkways that withstand daily forklift use and ensures people move where it’s safe.

We support warehouses across Australia to move from reaction to prevention—so you don’t have to learn safety the hard way.