How to prevent struck-by incidents

Incidents involving being struck by objects are a major hazard in warehouses and distribution centres, often resulting in severe, life-altering injuries and fatalities. These incidents typically happen in two ways: when vehicles or mobile equipment hit pedestrians, and when materials fall from racks or high storage, striking nearby workers.

Given the significant impact these incidents have on workers and workplaces (including both direct and indirect costs), warehouses and distribution centres need to take proactive steps to prevent them.

This requires a thorough hazard-management process to identify and effectively control struck-by risks. Engage internal stakeholders in the process, including the warehouse manager, shippers/receivers, safety committee members, mobile equipment operators, truck drivers and pedestrians, among others.

A proven approach includes reviewing all related documentation, such as incident reports, policies, procedures and training records; conducting observations and interviewing key staff; and consulting applicable industry best practices, such as CSA Standard B335, Safety Standard for Lift Trucks and A344, User Guide for Steel Storage Racks.

How can incident reports help?

Reviewing past incidents and asking relevant questions can help isolate root causes, address them, and determine appropriate control measures. Here are two examples:

Incident 1: Struck by a falling load

A lift truck operator places a pallet on the upper level of a storage rack. Unaware, the operator inadvertently pushes a dislodged box into an adjacent pallet, causing it to fall to the floor and strike a worker.

Questions arising from this incident include:

1. Are loads secured with wrapping or strapping before being placed on racks?

2. Are workers, such as order pickers, working on one side of back-to-back racking while a load is being placed from the opposite side?

3. Do lift truck operators have good visibility, possibly aided by camera technology?

4. Are lift truck operators competent, with sufficient practical training, including experience placing pallet loads at higher elevations in a safe environment?

5. Are racking accessories like mesh decks, safety bars, backstop beams or netting in place to prevent loads from falling?

6. Are pallets inspected to ensure they can support the load and are free of damage that could cause instability?

7. Are pallets the correct size for the racks? A pallet that’s too large (with excessive overhang on the beam) or too small (barely touching the beam) increases the likelihood of loads falling.

8. Is there sufficient flue space between back-to-back racks to prevent one pallet from pushing against another?

Incident 2: Struck by a forklift truck

A lift truck operator reverses into a worker pulling a pallet jack to the shrink wrapper, causing a critical injury.

Questions to consider:

1. Do lift truck operators need to reverse? Can risks be minimized by implementing a one-way traffic flow?

2. Can foot traffic be reduced or eliminated in areas where lift trucks operate?

3. Can workplace equipment, including the pallet wrapper, garbage compactor and pallet dispenser, be reorganized to reduce traffic congestion for both people and mobile equipment?

4. Is the correct mobile equipment being used? Would a standup counterbalance forklift, which allows operators to face their direction of travel, be safer than a sit-down model?

5. Could pallet loads be lower to improve visibility and reduce the need for reversing?

6. Do lift trucks have safety features such as backup alarms, cameras or swivel seats to improve operator comfort and allow for safer operation?

7. Are operators trained to use the horn to warn pedestrians at blind corners or when reversing, especially since battery-powered equipment may be harder to see or hear?

8. Are mobile equipment operators maintaining a safe speed, particularly when people are nearby, in confined spaces or at blind corners? Should the workplace adopt lift truck speed control technology to limit speeds? The Material Handling Equipment Distributors Association generally recommends a maximum speed of 13 km/h (8 mph).

Hazard management, including identifying struck-by risks, cannot be left to chance. Follow a structured process, involve appropriate personnel and seek input from those with firsthand experience. Lift truck operators, who perform their tasks daily, often have valuable insights into preventing struck-by injuries.