7 Ways Your Warehouse Probably Isn’t OSHA-Compliant

Despite your best efforts, the odds are that your warehouse will not be completely OSHA-compliant.

Let’s look at seven of the most commonly missed OSHA warehouse standards. While these standards are easy to violate, they are also easy to meet. Frequently, a few simple changes are all that it takes.

Here are the top seven OSHA warehouse rules that are most often broken.

1. Fall Protection - General Requirements (1926.501)

Fall protection has a long history and is the number one most cited OSHA violation.

This standard deals with what fall protection systems are required. It states, “Each employee on a walking/working surface (horizontal and vertical surface) with an unprotected side or edge which is 6 feet (1.8 m) or more above a lower level shall be protected from falling by the use of guardrail systems, safety net systems, or personal fall arrest systems.” Failure to provide such protections is a violation and can lead to a costly fine.

Thankfully, this is easily remedied.

Personal fall arrest systems, like the Miller H700 full body harness, are simple ways to ensure employee safety while working a height. These devices meet OSHA requirements, making it a convenient way to avoid a citation.

Without such protections, your employees and your facility are at risk.

2. Hazard Communications (1910.1200)

Chemicals are common in almost every workplace, especially warehouses.

Yet, hazardous communication is often lacking. OSHA standard 1910.1200 requires employers to provide thorough information regarding the hazards of any chemicals at the job site. It states, “The transmittal of information is to be accomplished by means of comprehensive hazard communication programs, which are to include container labeling and other forms of warning, safety data sheets and employee training.” Unfortunately, these communication programs are often less than comprehensive.

Thorough training is one part of ensuring the proper dissemination of information.

Investing in a published training program, such as the WHMIS 2015 self-paced training program, is a convenient way to ensure your team knows how to handle, use, store, and dispose of the hazardous chemicals in your facility.

Sometimes, a little knowledge stands between you and a steep OSHA fine.

3. Ladders (1926.1053)

Ladders are easily one of the most dangerous pieces of equipment in any warehouse.

The trouble isn’t that ladders are an especially faulty piece of equipment. It’s that they don’t often receive the same thought and care as other industrial tools.

This OSHA standard says a ladder must support “at least four times the maximum intended load, except that each extra-heavy-duty type 1A metal or plastic ladder shall sustain at least 3.3 times the maximum intended load.” Most manufactured ladders meet that specification. The issue arises when a ladder is either damaged or built to purpose. In either case, the ladder in question generally falls short of the load specifications.

The best solution is to avoid ladders altogether.

Aerial, scissor, and boom lifts are safer working platforms than your traditional ladder. These machines provide a more stable working surface and receive better care than your typical ladder. They are especially useful at warehouses since they can live and work at the job site.

Scissor lifts are not a small investment, but their cost pales in comparison to expensive OSHA fines.

4. Respiratory Protection (1910.134)

This standard is less about respirators and more about prevention.

It states, “In the control of those occupational diseases caused by breathing air contaminated with harmful dusts, fogs, fumes, mists, gases, smokes, sprays, or vapors, the primary objective shall be to prevent atmospheric contamination. This shall be accomplished as far as feasible by accepted engineering control measures (for example, enclosure or confinement of the operation, general and local ventilation, and substitution of less toxic materials).”

In a warehouse, this often comes down to a question of ventilation.

One of the most common atmospheric contaminants in a warehouse environment is emissions from IC forklifts. These fumes contaminate the air and put a greater load on the ventilation system. One convenient way to solve this is to switch your fleet to an electric one, reducing your emissions to zero.

Electric forklifts are a huge step toward improving the air quality of your warehouse.

5. Lockout/Tagout (1910.147)

"This standard covers the servicing and maintenance of machines and equipment in which the unexpected energization or start-up of the machines or equipment, or release of stored energy could cause injury to employees."

In other words, if damaged equipment could accidentally turn on and injure someone, a lockout/tagout procedure is needed.

While lockout/tagout procedures are not terribly complicated, they demand more than just removing the key. The problem with only removing the key is the energy source isn’t isolated and could discharge, injuring someone. To fully meet the standard, you must disconnect the energy source and keep it disconnected until repairs are complete.

That’s where lockout boxes and tags become so important.

These simple tools ensure the equipment in question stays out of commission. The lockout box helps to isolate the power source, while the tag explains why the equipment is out of service. Together, they keep well-meaning employees from injuring themselves.

Lockout/tagout systems are simple but necessary tools for avoiding hefty OSHA fines.

6. Powered Industrial Trucks (1910.178)

This standard codifies the "safety requirements relating to fire protection, design, maintenance, and use of fork trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines." As a warehouse manager, this is probably one of the OSHA standards you are the most familiar with.

Still, it remains one of the most violated standards.

A lot goes into the safe operation of forklifts and platform lift trucks. The citations don’t stem from one specific commonly missed practice. Instead, they run the gambit of forklift use.

That’s why training is so vital.

Forklift safety training helps operators understand the full spectrum of safety requirements that OSHA will hold them to. It covers everything from the importance of safety belts to load balancing. It is absolutely critical if you want to avoid OSHA citations.

Of all the things you can do to protect your facility from OSHA violations, nothing beats better training.

7. Fall Protection - Training Requirements (1926.503)

Fall protection is so commonly violated that it made the list twice.

In this case, the citations focused on a lack of fall protection training. This standard states, “The employer shall provide a training program for each employee who might be exposed to fall hazards. The program shall enable each employee to recognize the hazards of falling and shall train each employee in the procedures to be followed in order to minimize these hazards.”

Once again, nothing beats effective training.

To avoid OSHA fines, fall protection training is a must. Thankfully, there are ready-made training programs, like the Personal Fall Arrest Systems video kit, so you can get back to meeting OSHA standards right away.

Training packages like this are simple, cost-effective ways to keep you from falling afoul of an OSHA inspection.

Your OSHA Compliance Partner

With all the OSHA warehouse rules out there, it can be difficult to stay in compliance.

That’s where we can help. Our expert team has the industry knowledge you need to stay ahead of OSHA inspections and keep your facility in compliance. Let us keep your warehouse safe and fine-free.

To learn more about what safety products we offer to help you stay OSHA-compliant, contact us online or visit one of our locations throughout Georgia and Florida.

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Further Reading
Forklift Lockout/Tagout – Removing the Key Is Not Enough
6 Different Types of OSHA Fines – What Warehouses in Florida & Georgia Need To Know
Top 10 OSHA Violations of 2024