Is Your Warehouse Truly Safe? When Was Your Last Safety Inspection?

When was the last time you walked through your warehouse with a critical eye, one that wasn’t focused on operations, production targets or logistics, but safety? 

Not just a tick-box exercise, but a real inspection?  Because if you are not asking that question regularly, you may already be exposed. 

Warehouses are high-risk environments.  Between moving plant, racking systems, forklifts, heavy loads, mezzanine floors, loading docks and human traffic there’s no room for assumption.  Safety in this environment doesn’t happen by chance.  It happens by deliberate design, consistent implementation and regular reviews. And that’s where safety inspections come in.

Why Safety Inspections Matter in Warehouses and Storage Facilities

Creating a safe warehouse is not a one-off task.  It is a system a living, breathing part of your business that requires ongoing attention.  Under the Work Health and Safety Act 2011, Persons Conducting a Business or Undertaking (PCBUs) and Officers (directors, senior managers) have a legal obligation to ensure the workplace is safe, so far as is reasonably practicable.

A comprehensive safety inspection identifies hazards you may have become blind to over time.  Familiarity breeds complacency and that’s when serious incidents happen. 

Some of the most common risks found in warehouse inspections include:

• Damaged or overloaded racking
• Inadequate traffic management
• Poorly maintained forklifts or equipment
• Obstructed fire exits or emergency egress routes
• Poor lighting in storage areas
• Inadequate fall protection on mezzanine levels and loading docks
• Incomplete or missing signage
• Poor housekeeping practices

Every one of these risks can result in serious injuries, legal consequences and significant business disruption. 

What the Data Tells Us …

Warehousing and storage consistently report above-average injury rates.  A 2019 Safe Work Australia report revealed that warehousing and storage experienced 4. 8 recordable injuries per 100 full-time workers, well above the national private industry average. 

Safe Work Australia Industry Statistics report that between 2003 and 2015, the transport, postal, and warehousing industry recorded the highest number of workplace fatalities in New South Wales.  

This is not scare tactics, it’s reality.  And it reinforces the importance of proactive safety management, not reactive clean-ups. 

Inspections: More Than Just Compliance

WHS inspections tick the compliance, however, compliance alone does not protect your team, your assets or your reputation. 

A thorough safety inspection can:

• Identify risks before they become incidents
• Save your business from costly downtime and insurance premiums
• Improve productivity by removing hazards and inefficiencies
• Reinforce your commitment to safety with your workforce
• Support your legal defence should an incident occur

Essentially, when safety improves, so does morale.  Workers want to know their wellbeing is taken seriously.

What a Warehouse Safety Inspection Should Include

A proper safety inspection is not just a walk-through.  It should be structured, documented and action-oriented.  

At a minimum, it should assess:

• Racking & Shelving Systems: Are they damaged? Overloaded? Compliant with AS 4084:2023?
• Traffic Management: Are there clear routes for forklifts and pedestrians? Is signage in place?
• Machinery & Equipment: Are forklifts maintained? Do operators hold valid licences?
• Lighting & Visibility: Are aisles, work areas, and emergency exits well-lit?
• Manual Handling Risks: Are loads ergonomically positioned? Is training provided?
• Fall Prevention Measures: Are mezzanine floors protected? Is edge protection adequate?
• Housekeeping & Storage: Are items stored safely? Is the warehouse kept clean and clutter-free?
• Emergency Preparedness: Are extinguishers, alarms, and exits clear and functional?

Do not Assume – Assess

The biggest mistake is when businesses assume their warehouse is “fine” because there has not been an incident yet.  But near-misses often go unreported.  And hazards do not announce themselves they build up quietly, until one day, they reveal themselves. 

Importantly, do not wait for an incident to remind you what should have been done.  Proactive inspections save lives, protect businesses and reinforce a strong safety culture. 

Your Responsibilities Under the Law

Under the WHS Act 2011, PCBUs and Officers must exercise due diligence.  This means being proactive in understanding the hazards in your operations and ensuring systems are in place to control them.  

That includes:

• Keeping up to date with WHS matters
• Understanding the nature of your operations and the hazards involved
• Ensuring appropriate resources and processes are used to eliminate or minimise risks
• Ensuring incidents are reported, and hazards are acted upon

If you do not have a structured inspection process or safety management system, you are at risk not just operationally, but legally and personally. 

How Often Should Safety Inspections Be Carried Out?

This depends on the size, risk profile and complexity of your operations.  

However, as a general guide:

• Monthly: Internal walk-throughs and housekeeping checks
• Quarterly: Formal inspections of racking, storage and plant
• Annually: Comprehensive WHS audit by a qualified safety professional
• After any incident or near-miss: Immediate hazard inspection and review

Consistency is key.  The more regular the review, the earlier the issues are identified and resolved before harm occurs. 

Not Sure Where to Start?

At Verge Safety Barriers, we support warehousing, manufacturing and logistics environments.  Our Inspection Audits give you clear visibility over your current risks and obligations.  From there, we help you plan your safety improvements in manageable stages prioritised by risk, urgency and resources. 

We also provide:

• Customised Traffic Management Plans
• Racking Compliance Assessments
• Mezzanine & Fall Protection Reviews

If you’re overdue for an inspection or not confident in what you’ve currently got in place reach out. 

Final Word

A safe warehouse does not happen by luck.  It happens through systems and follow-through.  And that starts with asking the right question:

When was your last safety inspection and what did you do with the results?

If you’re unsure, that’s your red flag.  Let’s change that.  Let’s get proactive.

Take Action:

• Book a Safety Inspection 
• Download our Warehouse Safety Inspection Checklist
  

Visit: www.vergesafetybarriers com.au – Or call us directly for tailored advice and support.