Safety in Logistics and Warehouses: Underestimated Risks

At first glance, logistics and warehouse work seem straightforward: clear walking routes, fixed workstations, repetitive tasks, and well-defined processes. It is precisely for this reason that the risks are often underestimated. In practice, a warehouse is a dynamic environment with internal transport, fluctuating goods flows, seasonal peaks, temporary workers, and pressure to keep working. Even small deviations in behavior or layout can quickly lead to injuries, damage, or downtime.

In this knowledge base, we explain where the real risks lie in logistics environments, which measures you should take first according to the occupational health and safety strategy, and when personal protective equipment (PPE) is actually necessary and mandatory. We link this to the most important Dutch regulations: the Working Conditions Act, the Working Conditions Decree, and the requirement for an up-to-date Risk Inventory and Evaluation (RI&E) and Action Plan.

Why Safety in Logistics Is Often Underestimated

Many warehouses have a professional appearance: marked pathways, racking, scanners, forklifts, and clear targets. But a false sense of safety lurks around every corner. Accidents rarely result from a single major mistake, but usually from a chain of minor deviations. Think of a pallet that sticks out just a little, an employee who “quickly” cuts a corner, a temporary worker without full training, or a forklift operator who drives just a little too fast due to time pressure.

Common causes of underestimation:

• Routine and complacency: when something goes well for a long time, it automatically feels safe.

• Production pressure: Peak workloads and KPIs put safety under pressure, especially during loading and unloading.

• Inadequate risk assessment or failure to update it: processes change faster than the risk assessment is updated.

• Fatigue and shift work: reduced alertness increases the risk of errors.

• Use of temporary workers: rotating teams require repeated instruction and supervision; this aligns with the employer’s obligation to provide safe working conditions.

The foundation is therefore a proactive approach: identifying risks before an incident occurs and embedding measures into processes, behavior, and resources.

What risks are present in logistics and warehouses?

The risks in logistics are wide-ranging and vary by warehouse type, flow of goods, and degree of mechanization. The core issue is almost always the same: people and vehicles move through the same space, often with limited lines of sight and changing conditions.

• Fall and trip hazards: loose plastic film, strapping, thresholds, wet floors, cables, damaged floorboards, or poor housekeeping.

• Collision hazards: forklifts, reach trucks, pallet trucks, and order pickers cross walking routes or operate in the same zones.

• Falling loads: unstable pallets, improperly stacked boxes, damaged racks, or improper handling with forks.

• Crushing and entanglement: near roller conveyors, automatic conveyors, dock levelers, and packaging machines.

• Cutting and puncture hazards: from knives, cutters, strapping, and sharp edges on packaging or metal parts.

• Ergonomic strain: lifting, reaching, twisting, repetitive work, pushing, and pulling. This often leads to long-term health issues.

• Noise and dust: In larger warehouses, noise from transport equipment and machinery can be high; dust is released from bulk materials, cardboard, and return shipments.

• Chemical exposure: from batteries, cleaning agents, aerosols, leaks from packaged hazardous substances, or work in special storage areas.

• Fire and explosion risk: particularly with lithium batteries, aerosol cans, battery charging, and dust accumulation in specific processes.

It is important to consider not only “what could go wrong,” but also who is exposed, how often, and under what circumstances. For example, a risk point may be particularly dangerous during peak hours, in poor lighting, or when working with new employees.

Common Accidents in Warehouses

Practical experience reveals a number of recurring scenarios. These incidents can often be prevented through a combination of layout, training, supervision, and the proper PPE.

• Collisions and foot injuries caused by material handling equipment: a pedestrian in a blind spot, a pallet truck hitting a toe, or a forklift striking a rack, causing goods to fall.

• Falls from heights: from stairs, platforms, loading docks, or while order picking. Even “low” heights regularly cause serious injuries.

• Falling goods: due to overhang, poor wrapping, damaged pallets, or stacking too high.

• Hand and finger injuries: entrapment between a pallet and a rack, between roll containers, or in packaging machines.

• Eye injuries: caused by splinters, dust, straps coming loose, or during cleaning and maintenance.

A mature safety approach uses incidents and near-misses as input: what was the immediate cause, but more importantly, what underlying factors were at play, such as unclear routing, unrealistic turnaround times, or a lack of clear accountability.

Law and Responsibility: From RI&E to PPE

According to the Working Conditions Act, the employer has a duty of care to ensure safe and healthy working conditions. The basis for this is an up-to-date RI&E with an Action Plan. In this plan, you identify the risks and how to manage them. PPE is not the starting point, but the final step.

The logic follows the occupational hygiene strategy (often explained in the Netherlands as source measures → collective → organizational → PPE):

• Source control: eliminate the hazard, for example by separating workflows or automating processes.

• Collective measures: physical barriers, fencing, rack safety guards, dock shelters, lane markings, mirrors, traffic lights.

• Organizational measures: work instructions, driving rules, qualifications/training for internal transport operators, speed policies, scheduling, and breaks.

• PPE: Only when residual risks remain should you select protective equipment that is demonstrably appropriate for the work.

PPE must also be available, fit properly, be used, be maintained, and be part of training and supervision. In practice, this is where things often go wrong: PPE is available but is not consistently worn or is not tailored to the risks.

Which PPE items are essential in logistics environments?

Which PPE is required depends on the Risk Inventory and Evaluation (RI&E), the zone classification, and the specific tasks. Nevertheless, in logistics, there is a clear basic set that is relevant in many warehouses.

• Safety shoes: often the most important PPE in warehouses. Consider toe protection, slip resistance, and—depending on the environment—also puncture protection and ESD. A commonly used standard for safety footwear is EN ISO 20345. Choose the appropriate class based on the risks: wet floors require strong slip resistance, handling pallets requires toe protection, and the risk of nails or splinters requires midsole protection.

• High-visibility workwear: Visibility is crucial in areas with internal material handling. In practice, the EN ISO 20471 standard (high-visibility clothing) is often used for high-visibility workwear. Choose clothing with sufficient visibility and reflectivity that suits the environment and lighting conditions.

• Gloves: to protect against cuts, abrasion, cold, or chemicals. Keep in mind that “more protection” isn’t always better: gloves that are too thick can reduce grip and precision. Match the material and cut resistance to the task. 

• Safety glasses: for dust, straps, damaged pallets, grinding or maintenance work, and when handling chemicals. In some situations, a face shield is also required.

• Head protection: in areas with a risk of falling objects or when working on scaffolding. Depending on the situation, an industrial safety helmet or a bump cap may be appropriate, but this requires a deliberate choice based on the risk.

• Hearing protection: for ongoing exposure to noise from vehicles, conveyors, or packaging lines. Noise levels and duration determine whether earplugs or earmuffs are needed. 

• Respiratory protection: for dust, vapors, or aerosols, such as during cleaning, leaks, or work in specific storage areas. This always requires careful selection, a face fit test, user instruction, and proper management.

Important: PPE only works if it is worn correctly. This means the right size, compatibility between items (for example, safety glasses with a face shield or a helmet with hearing protection), and clear guidelines for each zone.

Selecting PPE Based on Tasks and Zones

An effective approach is to use a zone-based system. Not everyone in the warehouse faces the same risks. By defining zones, you make your PPE policy concrete and verifiable.

• Shipping and docks: increased risk of collisions, falling loads, and wet floors. Common requirements: safety shoes, high-visibility clothing, and sometimes a helmet, depending on the situation.

• Order-picking zones: a lot of walking, turning, and lifting. Focus on slip resistance, comfort, ergonomics, and gloves with a good grip.

• Automation zones: entrapment and unexpected movements. PPE is supplementary; guarding and lockout/tagout-style procedures and safe work practices take precedence.

• Chemical or battery charging areas: eye and face protection, chemical-resistant gloves, and possibly an apron or respiratory protection, depending on the substances and tasks involved.

• Outdoors and in cold/freezer areas: protection against the cold, grip on slippery surfaces, and attention to maintaining finger sensitivity.

Involve employees in the selection process. If PPE is uncomfortable or ill-suited to the task, compliance will naturally decline. Therefore, test with a pilot group, document the choices, and ensure there are alternatives for different body types.

When is PPE mandatory in logistics and warehouses?

PPE is mandatory when risks cannot be sufficiently eliminated through source, collective, or organizational measures. In practical terms, this means: if there is a real risk of injury or harm to health and the Risk Inventory and Evaluation (RI&E) indicates that protection is necessary, then the employer must provide PPE and enforce its use. 

In day-to-day warehouse operations, this requirement is most commonly reflected in:

• Safety shoes in areas with pallet handling, racking, rolling stock, or a risk of falling objects.

• High-visibility clothing in areas where pedestrians and material handling vehicles may cross paths.

• Eye protection during work involving dust, tie-down straps, compressed air, maintenance, or chemicals.

• Gloves for cutting and sanding tasks or contact with substances that can cause skin irritation.

Note: Mandating PPE without addressing the underlying risks is ineffective. At the same time, the reverse is also true: perfect signage won’t help if employees still walk through transport zones without visibility or if there is no enforcement.

Common Mistakes in PPE Use in Warehouses

In audits, we often see the same issues recurring. They may seem minor, but they have a major impact on safety and compliance.

• Unclear rules by zone: employees don’t know which PPE is required where, or rules vary by supervisor.

• Comfort and fit are underestimated: shoes that are too heavy or the wrong size lead to employees not wearing them or using their own unapproved alternatives.

• No replacement policy: worn-out soles, broken toe caps, damaged eyewear, or dried-out gloves remain in use for too long.

• No instruction on proper use: safety glasses worn on the head, gloves worn near moving parts, or hearing protection used “only when it’s busy.”

• Insufficient supervision and lack of leadership by example: if managers themselves do not follow the rules, compliance quickly declines.

PPE policies only truly work when they’re integrated into daily work: during pre-shift briefings, toolbox meetings, workplace inspections, and the onboarding of new employees.

Practical tips for improving safety in logistics

Improving safety doesn’t always have to be complex. The greatest gains often come from consistent basic measures and closing the gaps between policy and practice.

• Update the Risk Inventory and Evaluation (RI&E) when processes change: new racking systems, different goods, increased automation, or a new WMS directly alter risks.

• Separate people and machines wherever possible: physical barriers, walkways, turnstiles, and clearly marked crossings are more effective than floor markings alone.

• Make traffic rules specific and enforceable: speed limits, right-of-way rules, horn policies at intersections, and mandatory stops at aisle exits.

• Improve housekeeping: set times for cleanup, remove plastic wrap and strapping immediately, and remove damaged pallets from the workflow. This greatly reduces the risk of tripping, cuts, and falls.

• Provide task-specific training: not just general safety, but also specific instruction for order picking, loading and unloading, working at heights, and battery charging.

• Hold brief toolbox meetings based on incidents and near-misses: discuss what almost happened, which safety barrier was missing, and what you’ll do differently tomorrow.

• Make PPE available by job function and size: quick distribution, clear inventory, and easy replacement prevent people from working “without it for a moment.”

• Measure and improve: conduct periodic safety inspections using a standard checklist: floors, racking, lighting, zone separation, PPE compliance, and emergency exits.

Technology can provide support, such as collision prevention, zone detection, blue lights on forklifts, or access control to high-risk areas. But it remains essential to have the basics in order: layout, rules, behavior, and the proper PPE.

Conclusion

Safety in logistics and warehouses is not an afterthought, but a prerequisite for business continuity. The greatest risks often lie in daily routines: internal transport, falling loads, tripping hazards, and physical strain. With an up-to-date Risk Inventory and Evaluation (RI&E), clear zone-specific guidelines, proper training, and consistent use of appropriate PPE, you can prevent not only injuries but also property damage, absenteeism, and disruptions to your operations.

Practical next step: Want a quick overview of where your biggest warehouse risks lie? Then use a brief internal scan based on your RI&E and walk through

1. route separation

2. rack safety

3. housekeeping

4. PPE compliance.

Would you like to better align PPE with your warehouse processes, or make your PPE policy practical and workable for each zone and job function? Check out our product range and consulting services at allsafety.com or contact us for a tailored assessment.