Avoid These 5 Common Crush & Fall Injuries

Posted on by Monarch Shelving

With the holiday shopping season in full swing, there is a significantly higher demand for more processing at warehouses and other distribution centres. One of the best ways to offset this influx of work is to increase the amount of staff on-site. But the increase in staff numbers also increases the potential of accidents occurring.

According to the HSE, slips, trips and falls are the most common warehouse accidents, but did you know that musculoskeletal injuries alone, account for up to 30% of lost-time injuries? Other injuries with even more life-changing impact include electrocution, inhalation of dangerous chemicals and crush injuries. Falls and crushes in the workplace are infamous for having very low survival rates.

To keep your warehouse running and staff alive this peak, here are five crush injuries to watch out for:

1. Falls from Height

When you hear the term ‘fall from height,’ one pictures an accident at a construction site. But warehouse workers are constantly injured falling from heights. They have been known to climb machinery to sort blockages, hitched ‘rides’ on forklift truck tines, even climbing racking to reach parcels. Falls from height are almost always fatal, and those that survive sustain life-altering injuries.

To prevent these accidents:

  • Ensure workers receive training before operating any powered equipment.
  • Train workers in how to shut down machinery like conveyors in an emergency.
  • Set a no-climbing policy in place.

2. Falls & Crushing at the Docks

It’s estimated that 25% of all warehouse injuries occur around the loading dock. Shipping and receiving docks are very busy parts of any distribution centre and during peak (now) can get very busy. The more workers you have at a dock, the higher the likelihood of an accident happening.

Wet floors and discarded wrapping are blamed for workers falling of docks, but opening a truck door can lead to crush injuries. When the truck is in transit, pallets can break open, causing the load to spill against the door and crush an unsuspecting worker.

To prevent these accidents:

  • Staff should clean up their environment as they work.
  • Workers must be cautious when the opening truck trailer doors.
  • Workers must wear the recommended PPE; sturdy work boots, work gloves, ear plugs etc.

3. Forklifts Falling Off Docks

Did you know forklifts also fall of docks? According to the HSE, forklift related accidents are attributed to poor operating procedures, lack of safety rule enforcement, and inadequate training. 9% of fatal forklift accidents are the result of falls. Forklift drivers are injured when the forklift is driven off a loading dock or falls between a dock and an unsecured trailer. This can be extremely dangerous if the driver panics and extends any limbs outside the cab.

To prevent these accidents:

  • Don’t allow drivers to back out of any dock without clearing them.
  • Train staff to close doors as soon as the job is finished.
  • Have spotters on the ground to guide the forklift.

4. Collapsed racking by a Forklift Collision

SEMA reports that “the two biggest threats to racking safety are damage and misuse”. Years of misuse may not appear to be obvious, but it’s an accident waiting to happen. Overloading racking is a common precursor to eventual collapse, and is one of the most common examples of racking misuse.

The culprit in 95% of racking collapse is damage from a distracted forklift driver. Racking protectors can be used to protect corners, but SEMA advises that physical racking protection should only be seen as a last resort.

To prevent these accidents:

  • The best form of protection is prevention, using established safety protocols and driver training.
  • An annual rack inspection can also help identify any structural damage.

5. Workers Struck by Forklift

With the average forklift weighing several thousand kilos, a forklift and pedestrian collision is often a fatal one. Up to 16% of forklift fatalities occur when victims are crushed by the vehicle. Forklift drivers are also known to break the speed limit of 5mph which can prove fatal if the brakes on the truck are faulty.

To prevent these accidents:

Management should:

  • Separate forklift traffic and other workers as much possible. You can even demarcate worker-only and forklift only aisles.
  • Restrict the use of forklifts in areas with high pedestrian traffic e.g. around break rooms and the main exits.
  • Install physical barriers where possible.
  • Enforce safe driving practices such as obeying speed limits, stopping at stop signs, and slowing down and blowing the horn at intersections.

Drivers should:

  • Avoid driving close to employees working nearby or their workstations.
  • Check the truck before each use.

Because we know warehouse safety is the cornerstone of any supply chain, at Monarch Limited, we remind our customers about the importance of training all the staff in the warehouse. Warehouse workers are constantly exposed to dangerous conditions, and the only way to keep them safe is to educate them of these conditions.

Apart from safety training, we also recommend having your racking inspected regularly to prevent any ‘sudden’ collapse. For more information on how to avoid crush injuries, contact us here.