120 Warehouse Safety

Glossary

Use the keyboard function: "Ctrl F" to search for terms in this glossary

A

• Administrative Controls. Policies, procedures, and work practices designed to reduce risk by modifying employee behavior (e.g., training, scheduling, and signage).
• Aisle Marking. Painted lines or physical barriers used to designate safe pedestrian pathways and equipment routes in a warehouse to minimize collision risks.
• Angle Grinder. A handheld power tool used for grinding, cutting, and polishing materials such as metal, stone, and concrete.
• Angle of Visibility. The clear line of sight operators must maintain when using forklifts and other equipment to avoid collisions and accidents.

B

• Back Injuries. Common warehouse injuries resulting from improper lifting, repetitive motion, or poor ergonomics when handling materials manually.
• Battery Charging. The process of replenishing the energy of industrial batteries used in forklifts and other warehouse equipment; must follow safety protocols to prevent electrical hazards and chemical exposure.
• Battery Spill Kit. A collection of tools and materials designed to safely neutralize and clean up battery acid spills in charging stations or on warehouse floors.
• Blind Spots. Areas where operators of forklifts or other vehicles have limited or no visibility, increasing the potential for accidents if not properly addressed with mirrors or signals.

C

• Carbon Monoxide Exposure. A hazard in poorly ventilated warehouses where propane-powered forklifts or equipment may release dangerous levels of carbon monoxide gas.
• Charging Stations. Designated areas within a warehouse for the safe charging of forklift and equipment batteries, equipped with ventilation and emergency response equipment.
• Common Forklift Accident Types. Frequent types of incidents involving forklifts, including tip-overs, collisions, pedestrian strikes, and load drops.
• Confined Space Entry. Procedures and precautions for working in limited-access areas within a warehouse where hazardous atmospheres or engulfment risks may exist.
• Conveyor Equipment and Hazards. Systems used to transport materials throughout a warehouse that pose risks such as pinch points, entanglement, and falling materials if not properly guarded.
• Conveyor Lockout/Tagout. The process of disabling conveyor systems to prevent accidental startup during maintenance or repair activities, in compliance with OSHA lockout/tagout standards.
• Corrective Maintenance. Repairs performed on warehouse equipment and systems after a failure or issue has been identified to restore normal operation.
• Crush Hazards. Risks of injury caused by moving equipment, collapsing materials, or narrow spaces that can trap or crush workers in a warehouse.

D

• Dock Leveler. A device installed at loading docks to bridge the gap between a truck and the dock, allowing safe and level loading and unloading of materials.

E

• Emergency Action Plan (EAP). A written plan that describes procedures for evacuation, reporting emergencies, and coordinating emergency response in a warehouse facility.
• Emergency Exits. Clearly marked and unobstructed routes that provide a means of escape during emergencies, as required by OSHA regulations.
• Emergency Preparedness. Plans, training, and resources in place to ensure a safe response to fires, chemical releases, medical emergencies, and natural disasters in a warehouse setting.
• Energy Isolation. The practice of physically disconnecting energy sources (electrical, hydraulic, pneumatic) before performing maintenance on warehouse equipment, often part of lockout/tagout procedures.
• Ergonomic Assessments. The systematic evaluation of job tasks and work environments to identify ergonomic hazards and recommend improvements to reduce injury risk.
• Ergonomic Hazards. Workplace risk factors that can lead to musculoskeletal disorders, including repetitive tasks, awkward postures, and manual lifting of heavy loads.
• Ergonomics. The science of designing work environments and tasks to fit the capabilities of workers, reducing the risk of musculoskeletal disorders and increasing productivity.
• Extinguishers. Portable devices used to suppress small fires in their early stages, categorized by the type of fire they are designed to combat (e.g., Class A, B, C).

F

• Fall Protection. Equipment, systems, and procedures used to prevent falls from heights or elevated work surfaces, such as guardrails, harnesses, and fall arrest systems.
• Fire Hazards and Safety. Potential sources of ignition or fuel within the warehouse and the measures implemented to prevent fires and ensure worker safety.
• Floor Load Limits. The maximum weight capacity of warehouse floors, which must not be exceeded to maintain structural safety, especially in multi-level storage facilities.
• Forklift Capacity Plate. A manufacturer-installed plate on a forklift that provides essential safety information such as load capacity, lift height, and attachment use limits.
• Forklift Equipment. Powered industrial trucks used to lift, move, and transport materials within a warehouse environment.
• Forklift Operations. The procedures and practices involved in the safe and effective use of forklifts in a warehouse setting, including maneuvering, load handling, and parking.
• Forklift Pre-Use Inspection. A required daily check to ensure a forklift is in safe operating condition before use, covering brakes, lights, horn, tires, and hydraulic systems.
• Forklift Safety. OSHA-mandated standards and best practices aimed at preventing accidents and injuries when operating forklifts.

G

• Guardrails. Physical barriers installed to protect pedestrians and equipment from falls, collisions, or entry into hazardous areas in a warehouse environment.

H

• Hand and Power Tool Safety. Guidelines and procedures for the proper selection, use, maintenance, and storage of tools to prevent injuries and equipment damage.
• Hazard Communication Program Requirements. OSHA requirements for informing workers about chemical hazards through labeling, safety data sheets (SDS), and training programs (HazCom).
• Hazard Recognition. The process of identifying potential workplace hazards through inspections, job hazard analyses, and employee reporting.
• Hazardous Materials. Substances that pose physical or health risks to workers, requiring special handling, storage, and communication under OSHA regulations.
• Hierarchy of Controls. A framework for minimizing workplace hazards by prioritizing control methods: elimination, substitution, engineering controls, administrative controls, and personal protective equipment (PPE).
• High-Risk Tasks. Warehouse operations or activities that pose significant risk to worker safety, such as working at heights, confined space entry, or handling hazardous materials.
• Hot Work Permit. A written authorization required for welding, cutting, grinding, or other operations that produce heat, sparks, or flames in warehouse environments.
• Housekeeping. Regular cleaning and organizing of warehouse spaces to prevent hazards such as slips, trips, falls, and fire risks.
• Housekeeping Program. A systematic approach to keeping work areas clean, orderly, and free of hazards such as debris, spills, or unsecured tools and equipment.

I

• Incident Investigation. The process of identifying the root causes of workplace accidents or near misses to prevent recurrence and improve warehouse safety procedures.

J

• Job Hazard Analysis (JHA). A systematic process used to identify potential hazards associated with specific job tasks and to develop safe procedures to mitigate risks.
• Joint Health and Safety Committee (JHSC). A workplace committee made up of management and employee representatives that meets regularly to address health and safety concerns in the warehouse.

K

• Key Control Procedures. Security and safety policies governing the issuance, use, and storage of keys to warehouse equipment such as forklifts or restricted access areas.
• Kick Plates. Low-mounted protective barriers installed on walls or shelving in warehouses to prevent pallet jacks, forklifts, or other equipment from causing damage or creating hazards.

L

• Loading and Unloading Trucks. The safe process of moving materials onto and off of transport vehicles, requiring equipment and procedures to prevent injuries and product damage.
• Loading Dock Equipment. Tools and machinery used at loading docks, such as dock levelers, bumpers, and restraints, to facilitate safe loading and unloading activities.
• Loading Dock Fall Protection. Guardrails, barriers, and other measures designed to prevent employees from falling off dock edges during loading or unloading operations.
• Loading Dock Lights. Adjustable lighting installed on loading docks to improve visibility inside trailers during loading or unloading activities, reducing accident risk.
• Load Securement. The process of properly positioning and restraining cargo to prevent shifting, tipping, or falling during transport or material handling operations.

M

• Machine Guarding. Physical barriers and protective devices used to prevent workers from coming into contact with moving machine parts and other hazards.
• Machine Safeguarding. The installation of protective devices or barriers on machinery to prevent accidental contact with moving parts and reduce injury risk to workers.
• Manual Material Storage and Handling Safe Procedures. Practices for safely lifting, carrying, stacking, and storing materials by hand to prevent injuries such as strains and sprains.
• Material Handling Equipment (MHE). Tools and machines such as forklifts, pallet jacks, conveyors, and hoists used to move, store, and control materials in a warehouse.
• Material Safety Data Sheet (MSDS). A document that provides detailed information about the hazards, safe handling, and emergency measures for a particular chemical product (now called Safety Data Sheet, SDS).

N

• Near Miss Reporting. A process that encourages employees to report incidents that could have resulted in injury or property damage, in order to correct hazards before accidents occur.

O

• Operator Certification. OSHA-mandated process requiring forklift operators and users of other powered industrial trucks to complete formal training and performance evaluations before operating equipment.
• OSHA Requirements for Warehouse Safety. The OSHA regulations and standards designed to ensure safe working conditions in warehouse environments.

P

• Pallet Handling Safety. Procedures for the safe movement, stacking, and storage of pallets to prevent injury and product damage.
• Pallet Racking Systems. Structures used to store palletized materials in warehouses; must be designed, installed, and maintained to prevent collapse or product falls.
• Pedestrian Safety Zones. Clearly marked walkways and crossings designed to separate pedestrian traffic from powered industrial truck routes in the warehouse.
• Personal Fall Arrest System (PFAS). A system of equipment including a harness, lanyard, and anchor point used to safely stop a fall from heights in warehouse environments.
• Physical and Environmental Hazards. Workplace dangers stemming from noise, temperature extremes, lighting, air quality, and other environmental factors that can affect worker health and safety.
• Pinch Points. Areas where parts of equipment move together, posing a risk of crushing or pinching a worker's body or clothing.
• Powered Conveyor Systems. Mechanized systems for moving materials automatically within a warehouse; require proper guarding, controls, and maintenance to prevent injuries.
• Powered Industrial Trucks (PIT). OSHA term for forklifts and other mechanized industrial trucks used for material handling, requiring operator training and certification.
• Preventive Maintenance. Routine inspections and maintenance tasks performed on warehouse equipment to prevent failures and ensure continuous safe operation.

Q

• Quality Control. Procedures used to ensure that warehouse operations and outputs meet established standards of quality, safety, and efficiency.

R

• Rack Collapse Prevention. Engineering and administrative controls implemented to prevent the collapse of pallet racking systems due to improper loading or damage.
• Respiratory Hazards. Airborne contaminants such as dust, fumes, vapors, or gases that can harm warehouse workers if inhaled without proper respiratory protection.
• Rollover Protection System (ROPS). A structural feature on some industrial vehicles designed to protect the operator in the event of a rollover accident.
• Routine Inspections. Regular checks of warehouse equipment, facilities, and processes to identify hazards, ensure compliance, and maintain a safe work environment.

S

• Safety Committee. A group of employees and management representatives that meets regularly to review workplace hazards, develop safety initiatives, and promote a culture of safety.
• Safety Data Sheet (SDS). A standardized document that provides detailed safety and health information about hazardous chemicals used in the workplace, replacing the former MSDS format.
• Safe Lifting Techniques. Methods for manually lifting and moving materials that reduce strain on the body and minimize the risk of injury, such as using legs instead of the back.
• Scissor Lift Safety. OSHA standards and manufacturer guidelines for the safe operation of scissor lifts in a warehouse, including fall protection and stability requirements.
• Slips, Trips, and Falls. Common workplace accidents caused by wet floors, uneven surfaces, poor lighting, and other hazards, often preventable through good housekeeping and hazard awareness.
• Spill Containment. Procedures and equipment used to contain and clean up accidental spills of hazardous materials in a warehouse to prevent injury and environmental damage.
• Stacking Materials Safely. Procedures and guidelines to ensure that pallets and materials are stacked to a safe height and are stable to prevent collapse or falling objects.
• Stability Triangle. A safety concept used in forklift operation to illustrate how load position, speed, and turning affect the stability of the equipment.
• Struck-By Hazards. Warehouse hazards where workers may be struck by moving equipment, falling materials, or collapsing structures, leading to serious injury or death.

T

• Tool Tethering. The practice of securing tools to prevent them from falling and causing injury to workers below in elevated warehouse work areas.
• Traffic Management Plan. A written plan that outlines safe movement of pedestrians and vehicles within a warehouse to reduce the risk of collisions and injuries.
• Training. Educational programs designed to ensure that warehouse employees understand safety procedures, equipment use, emergency response, and regulatory compliance requirements.

U

• Utility Knife Safety. Safe handling practices for using utility knives in the warehouse to avoid lacerations, including using proper grips, retractable blades, and cut-resistant gloves.
• Ultraviolet (UV) Hazard. The risk of skin or eye damage caused by exposure to ultraviolet light from some warehouse equipment or processes such as welding or sterilization lamps.
• Unauthorized Access Control. Systems and procedures to prevent entry by untrained personnel into dangerous or restricted warehouse areas, such as battery charging stations or chemical storage zones.

V

• Vehicle Restraint Systems. Mechanical devices used on loading docks to secure trucks or trailers in place during loading/unloading operations to prevent accidental separation from the dock.
• Visibility Mirrors. Convex mirrors strategically installed in warehouse areas to help operators and pedestrians see around corners and blind spots, improving safety.

W

• Walk-Behind Pallet Jack. A manual or powered piece of equipment used to lift and move pallets, typically operated from behind by a pedestrian worker.
• Warehouse Hazards. Various risks present in warehouse environments, including mechanical, chemical, ergonomic, and environmental dangers that can harm workers or equipment.
• Warehouse Layout. The design and organization of space, equipment, and workflows within a warehouse to optimize safety, efficiency, and productivity.
• Warehouse PPE. Personal Protective Equipment used by warehouse workers, such as hard hats, gloves, safety shoes, high-visibility vests, and eye protection, to reduce injury risk.
• Warehouse Safety Culture. The collective attitudes, beliefs, and behaviors of employees and management toward workplace safety in a warehouse environment.

X

• X-Ray Equipment Safety. Safe use and handling of any x-ray scanning systems used for warehouse security or product inspection, ensuring proper shielding and operator training.

Y

• Yield to Pedestrians Policy. Warehouse safety rule that requires forklift operators and other powered equipment operators to yield the right of way to pedestrians at all times.

Z

• Zero-Energy State. A condition achieved through lockout/tagout procedures where all potential energy sources on warehouse equipment are isolated, ensuring the machine cannot move or start unexpectedly.
• Zone Control Systems. Technologies or procedures that create designated zones within a warehouse where equipment or pedestrian movement is controlled to enhance safety and efficiency.