Health and safety are crucial in any business, but they are even more vital in workplaces that handle machinery and equipment. In this guide, you can find our warehouse health and safety checklist to help guide you through exactly what tasks need to be completed to ensure your workplace puts the safety of your employees first and complies with various health and safety regulations. 

• What is Warehouse Safety?
• Why Health and Safety in a Warehouse Matters
• Key Health and Safety Regulations 
• The Most Common Warehouse Injuries and Safety Risks
• Steps to Ensure Warehouse Safety
• Our Warehouse Health and Safety Checklist 
• Ensure Your Staff are Trained in Health and Safety with HL Training 

What is Warehouse Safety?

Warehouse safety is crucial for protecting workers and maintaining efficient operations. Several key practices must be followed, including training for all employees on general health and safety, equipment usage and safety protocols, and conducting risk assessments to analyse a workplace’s safety. Health and safety also includes supplying personal protective equipment, such as hard hats and high-visibility vests. 

Why Health and Safety in a Warehouse Matters

Working in a warehouse comes with many risks, some of which can cause serious harm. From 2023 to 2024, the UK reported 25 fatalities in the workplace caused by being struck by a moving vehicle and a further eight fatalities involving contact with moving machinery. 

A business was fined over £320,000 in 2024 for the death of an employee back in 2020. The company did not comply with health and safety regulations, and as a result, an employee died due to a faulty attachment on a forklift. This case emphasises the need for regular health and safety checks to identify risks promptly and reduce injury and fatalities.  

Complying with health and safety regulations also ensures you: 

• Avoid hefty fines and prosecution
• Minimise the amount of lost time due to injury
• Promote a positive working environment 

Key Health and Safety Regulations 

There are several health and safety regulations you must follow in the UK. These are the key regulations you must be aware of and what health and safety measures they highlight: 

• Health and Safety at Work Act 1974: This regulation applies to all businesses, regardless of their sector. 
• Management of Health and Safety at Work Regulations 1999: Employers must carry out risk assessments and implement control measures to uphold health and safety measures. 
• Work at Height Regulations 2005: Employees should only work at heights when necessary, and measures must be in place to prevent falls. 
• Control of Substances Hazardous to Health Regulations 2002: This regulation requires employers to assess the risks of working with hazardous substances and implement measures to control exposure. 
• Provision and Use of Work Equipment Regulations 1998 (PUWER): Employers must ensure all work equipment is safe and properly maintained to protect workers. 

The Most Common Warehouse Injuries and Safety Risks

Warehouses can be full of risks, given the types of machinery that may be used and the tasks employees must carry out. Here are some of the main risks you should be aware of in a warehouse:

• Manual Handling Injuries
• Slips, Trips and Falls
• Vehicle-Related Hazards
• Collisions with Storage Racking, Goods or Equipment 
• Working at a Height
• Fire and Explosions
• Exposure to Chemical and Hazardous Substances
• Noise Exposure
• Electrical Hazards

Steps to Ensure Warehouse Safety

To create a safe working environment and comply with health and safety regulations, here is a step-by-step of the tasks you must complete to ensure all risks are identified and safety measures are implemented. 

1. Conduct Thorough Risk Assessments

While it is only a legal requirement to conduct a risk assessment if your business has five or more staff members, we recommend you still identify all risks to ensure the safety of your workforce, no matter how small it may be. To ensure all risks are identified, you should cover all areas, including machinery, substances and work processes, and evaluate the risks. You should then record and review these risks regularly. 

2. Inspect and Maintain the Facility

Preventative maintenance is key to identifying new risks and keeping the warehouse in good condition. By blocking regular warehouse inspections, you can identify new hazards, run-down equipment and other health and safety risks, such as blocked fire exits. All inspections should be recorded to keep a paper trail of your health and safety management efforts. 

3. Provide Training and Supervision Where Necessary 

All employees should be trained in general health and safety and job-specific tasks. This includes manual handling, fire safety and prevention, operating equipment, handling hazardous substances, working at height, and forklift operation. 

4. Document Procedures 

Any hazardous tasks should have complementary step-by-step guides on how to perform them following health and safety procedures. Some examples of hazardous tasks include working with dangerous substances and working at heights.

5. Provide Suitable Personal Protective Equipment

Health and safety isn’t just about ensuring procedures are followed but also making sure the correct equipment is supplied to employees to carry out their roles safely. This means employers must provide suitable personal protective equipment, including eye protection, hearing protection, steel-capped footwear and hi-vis jackets. 

6. Report All Incidents

If any accidents are to occur, you must record them following your business’s incident reporting procedure. All injuries, safety observations and new perceived risks must be recorded. You should also implement new safety measures accordingly and conduct post-incident analysis to reduce the risk of the same incident occurring again. 

7. Practice Emergency Protocols

All workplaces must have emergency procedures in place to ensure a quick response to a fire, chemical spill, injury or any other emergency. You are also advised to conduct drills to ensure all staff understand the procedures and are aware of their responsibilities in the event of an emergency. 

Our Warehouse Health and Safety Checklist 

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Ensure Your Staff are Trained in Health and Safety with HL Training 

Training is one of the best ways to ensure health and safety regulations compliance. At HL Training, we pride ourselves on providing high-quality training in forklift operation, first aid, and other health and safety courses to ensure your staff can handle any situation calmly and safely. Book a training course with us today to protect your staff from avoidable harm! 

FAQs

Is it illegal to leave keys in a forklift?

Never leave keys in an unattended forklift. It’s illegal and unsafe, and it violates health and safety regulations. Anyone could operate the forklift without proper training, increasing the risk of accidents and injuries. 

Remember: Always remove keys when leaving a forklift unattended. This simple step helps prevent unauthorised use and keeps everyone safer.

What are the general safety rules for a warehouse?

To comply with health and safety regulations, you should ensure you abide by the following rules:

• Conduct Risk Assessments
• Inspect and Maintain the Facility
• Provide Training and Supervision 
• Document Procedures 
• Provide Suitable Personal Protective Equipment
• Report All Incidents
• Practice Emergency Protocols

What is the biggest safety issue in a warehouse?

Warehouses can have many safety hazards, so it is crucial you understand them and how to avoid them. The main risks in a warehouse include manual handling injuries, slips, falls, and trips, vehicle-related hazards, and working at a height. 

Related Articles 

Are Forklifts Dangerous? Most Common Accidents Explained

The Ultimate Guide to Forklift Safety

Who Can and Can’t Drive a Forklift

Forklifts are the workhorses of warehouses and many other industrial and commercial settings. And batteries are the life force behind forklifts. Therefore, forklift batteries are a fundamental aspect of your operations. Ensuring your batteries work effectively is crucial to optimal performance. Here’s how to maximise your battery’s performance and longevity. 

Types of Forklift Batteries

Forklift batteries come in various types, each with its characteristics and benefits. Understanding these distinctions is crucial to choosing the right power source for your needs.

Lead-Acid Batteries

Lead-acid batteries have been the traditional workhorses of the forklift industry. These robust batteries are known for their reliability and are well-suited for various applications. However, they require diligent maintenance and have limitations regarding charging speed and overall lifespan.

Lithium-Ion Batteries

Lithium-ion batteries represent a modern and increasingly popular alternative. They offer faster charging, longer cycle life, and reduced maintenance needs. Lithium-ion batteries are ideal for operations that require high productivity and minimal downtime.

Fuel Cell Batteries

Fuel cell technology is gaining traction as a green and sustainable forklift power source. These batteries use hydrogen to generate electricity, emitting only water vapour as a byproduct.

Charging an Electric Forklift: A Step-by-Step Guide

Charging an electric forklift battery is relatively straightforward, but following the correct procedures is essential to safety, battery health, and performance.

Step 1: Prioritise Safety

Equip yourself with personal protective gear, including safety glasses and gloves.

Step 2: Battery Inspection

Inspect the battery for any visible damage, leaks, or other issues. If any problems are detected, address them before proceeding with charging.

Step 3: Disconnect the battery

Before charging, ensure that the forklift is powered off, and safely disconnect the battery from the forklift. 

Step 4: Charger Connection

Ensure mains power is switched off, then plug the charger into an appropriate power source and attach it to the charger. 

Step 5: Commence Charging

Start the charging process. Most modern chargers come with indicator lights or displays to track the progress.

Step 6: Close Monitoring

Regularly check charging batteries. Immediately stop charging if you notice any unusual heat, smoke, or leaks. These could indicate more significant issues that require professional attention.

Step 7: Disconnect Charger

The charger should automatically transition to maintenance charge mode when the battery is fully charged. If not, stop the charger and then disconnect it to prevent overcharging. ALWAYS stop the charger and isolate the power source before disconnecting the battery. 

Best Practices for Forklift Battery Maintenance

The different kinds of forklift batteries have different maintenance requirements. Whether you have lead-acid or lithium-ion, knowing how to look after them is essential to keep your forklifts running smoothly. Here are some helpful best practices to keep in mind to get the most from your forklift batteries and maximise their longevity. 

Watering and Electrolyte Levels

Maintaining the proper water levels and ensuring the correct electrolyte levels in lead-acid batteries are critical. Here’s how to do it effectively:

1. Scheduled Watering: Follow a regular watering schedule per the manufacturer’s recommendations.
2. Use Distilled, Deionised or Demineralised Water: Always use distilled water when topping off battery cells to prevent impurities.
3. Correct Levels: Maintain water levels to cover the battery plates without overfilling.

Cleaning and Inspection

1. Exterior Cleanliness: Keep the battery and its surroundings clean to prevent dirt and debris from affecting connections and ventilation.
2. Internal Examination: Routinely inspect the battery for corrosion, leaks, or damage. Address any issues promptly.

 Preventing Overcharging and Undercharging

1. Equalisation Charges: Implement equalisation charges as the manufacturer recommends to maintain consistent cell voltage.
2. Avoid Overcharging: Prevent overcharging, which can harm the battery and shorten its lifespan.
3. Prevent Undercharging: Avoid undercharging to prevent sulfation, which reduces battery capacity.

These practices will help ensure your forklift batteries’ longevity and optimal performance.

Forklift Training

Forklifts are powerful tools that help support a variety of operations across a broad range of industries. However, they must be used with care. Proper forklift training is essential to not only effective operation but also safety. Understanding forklift batteries and how to safely and effectively use and charge them is key to workplace safety, maximising effectiveness and avoiding unnecessary expenses (such as needing to replace batteries more frequently).

To learn more about forklift operator training, speak to our team of experienced forklift training instructors. 

Forklift Battery FAQs

How long does it take to charge a forklift battery?

Charging time varies based on battery type, capacity, and the state of charge. Typically, charging a forklift battery takes 8-10 hours.

When should your forklift battery be recharged?

Recharge your forklift battery when it reaches 20-30% capacity to prevent deep discharges, which can harm the battery.

Can you charge a forklift overnight?

Yes, many forklift batteries can be charged overnight. Modern chargers often have features to prevent overcharging, but proper monitoring is essential.

How many hours does a forklift battery charge last?

A battery charge will typically offer a full shift (8 hours) of use before reaching the recommended charging point of 20-30% charge. It is recommended to follow the 8-8-8 rule: 8 hours of operation, 8 hours of cooling, and 8 hours of charging. 

How long do forklift batteries last?

Forklift battery lifespan depends on usage and maintenance. Typically, they last 1,500 to 2,000 charge cycles or around 5-7 years with proper care and maintenance.

Learn more about forklift safety

For more great advice on how to get the most from your forklifts, check out our blog. Here are some helpful guides you may be interested in:

• A Guide To Forklift Types
• The Biggest Do’s and Don’ts of Forklift Safety
• Do You Need a Forklift Licence? Spoiler: It Doesn’t Exist!

Forklifts are an indispensable tool in various industries, serving a critical role in material handling and logistics. These powerful machines make the movement of heavy loads easier and more efficient. However, to understand the safe operation and transport of forklifts, it’s crucial to grasp just how heavy these machines can be.

Understanding the weight of forklifts is not just an academic exercise; it has real-world implications for safety, maintenance, and logistics planning. Understanding and appreciating the scale of the machinery you are working with is key to using them safely and effectively.

Types of Forklifts and Their Weights

Forklifts are not a one-size-fits-all solution; they come in various types, each tailored to specific tasks and industries. Different categories of forklifts will provide trucks in varying weight ranges. The weight of a forklift may be a byproduct of its design or an intentional part of its design intended to help it better serve its function. 

How Much Do Counterbalance Forklifts Weigh?

Counterbalance forklifts are the workhorses of many industries, designed with a straight-mast configuration for balancing loads in front of the front wheels. These versatile machines come in various weight ranges, typically starting from around 1,300kg. Typical counterbalance trucks may be as heavy as 4,000kg, with some specialist options being even heavier. 

How Much Does A Forklift Counterweight Weight

Counterbalance forklifts use counterweights to offset the weight of the load they are carrying. A counterweight can weigh in the region of 1300kg – 2300kg.

How Much Do Telescopic Handlers Weigh?

Telehandlers combine forklift functionality with extended reach, making them versatile in agricultural and construction settings. They can weigh from approximately 6,800Kg up to more than 13,500Kg.

How Much Do Order Pickers Weigh?

Order pickers are ideal for precise inventory handling, with operators standing on a platform that raises them to access items on shelves. Their weight ranges from 1,200Kg to 8,000Kg.

How Much Do Pump Trucks Weigh?

Pump trucks are compact, manual, or electric tools for short-distance pallet transport. They are commonly lighter, weighing as little as 100Kg.

How Much Do Side Loaders Weigh?

These forklifts are specifically designed for handling long and heavy loads from the side. The side loader attachment provides strength and stability but also adds to the weight of the forklift. Their weight varies based on capacity but often falls between 4,500Kg to 11,000Kg – although it can be more.

How Much Do Electric Forklifts Weigh?

Electric forklifts offer an eco-friendly and indoor-friendly option. Despite having large, heavy batteries, electric forklifts are often lighter than diesel and gas equivalents. Depending on their capacity and design, they can range from 1,100Kg to 8,000Kg in weight.

How Much Do Rough Terrain Forklifts Weigh?

These rugged forklifts tackle outdoor tasks, featuring large, robust tires to navigate uneven terrain. Their weight often starts at 4,500Kg.

Forklifts come in many types and sizes, and their weight is influenced by their lifting capacity and design, materials, and power source. While larger and more powerful forklifts tend to be heavier to accommodate their enhanced capabilities, electric models, favoured for their eco-friendliness, are generally lower capacity. Understanding the relationship between forklift weight and capacity is vital for safety, efficiency, and informed decision-making in the material handling industry. Whether you’re a forklift operator or a logistics professional, knowing the intricacies of forklift weight ensures that these indispensable machines can be utilised effectively and securely in various work environments.

Learn More About Forklift Safety

For more guidance on forklifts and forklift safety, check out our other blog posts, such as these recommended reads:

• A Guide To Forklift Types
• The Biggest Do’s and Don’ts of Forklift Safety
• Do You Need a Forklift Licence? Spoiler: It Doesn’t Exist!

Forklift Training

Forklifts are pivotal in diverse industries, but their safe and efficient operation requires proper training. Understanding crucial aspects such as a forklift’s weight is imperative to ensure your team’s safety and maximise forklift performance. Discover more about forklift operator training from our team of experienced instructors. Contact us today to equip your workforce with the knowledge and skills needed for secure, effective forklift use.