Warehouses use many kinds of storage system, depending on the size, shape and fragility of the goods. Whichever system you use, workers must be trained to store goods correctly and safely.

In this module you will learn about:

• Storage systems, pallets and racking.
• Inspecting racking, and classifying damage.
• Automated storage systems.
• General storage hazards.
• Storing hazardous substances and dangerous goods safely.
• Dealing with emergencies and spillages.

The right storage depends on the goods. Long, thin items may need horizontal racking, while boxed goods may be block stacked. Some goods are crushed if stacked, and some must be kept at a set temperature. Common systems include:

• Racking: a metal framework that holds palletised loads.
• Block stacking: loaded pallets stacked directly on the floor, up to a safe, stable height.
• Temperature-controlled storage: about 4 or 5°C for chilled goods, and minus 20 to minus 30°C for frozen goods. The harsh conditions bring extra hazards.
• Automated storage and retrieval systems.

The type of storage system a warehouse uses depends on the nature of the goods. Long, narrow items are often kept on horizontal racking, while boxed or loose goods are stacked. Some products need cold storage, and others cannot be stacked at all without being damaged. Whatever the mix, every storage system should be clearly labelled and specifically intended for the goods placed in it, so that nobody improvises by putting heavy or awkward items where they do not belong.

The design and arrangement of the storage layout are just as important for safety as securing individual items and keeping stacks stable. Aisle widths, sight lines at the ends of racks and the routes trucks take all shape the risk. Automated storage and retrieval systems are one option for larger sites. The main types are man-aboard, single-mast and double-mast machines. They improve accuracy, keep goods cleaner, help track stock levels and use space efficiently, but they bring their own hazards.

Pallets are portable platforms, usually made of timber, plastic or steel, used to store and move a unit load of goods. Pallets used in racking must be strong enough for the bending stresses on them, and should meet the European standard EN 13698. Common types include:

• Flat pallets, the most common type, along with post and box pallets.
• Reversible pallets, with matching top and bottom decks. Do not use them with hand pallet trucks, which can damage the bottom deck.
• Wing pallets, whose decks overhang the bearers. They are ideal for lifting slings, but must not be used in drive-in racking.
• Cage pallets, with mesh or slatted sides.

Most pallets are designed for one class of goods, one handling method and one storage method. A pallet designed for boxed biscuits may not be suitable for paint cans, and a pallet made for single storage in racking may not be suitable for stacking three high.

Most pallet accidents are caused by:

• Using an unsuitable pallet for the goods or the racking.
• Using a damaged pallet.
• Poor design or construction.
• Bad handling.

• Have a system for inspecting pallets, and always follow it.
• Inspect every pallet for damage before use. Remove unsafe pallets for repair or disposal.
• Never drag, throw, slide or drop pallets.
• Make sure the forks of any handling equipment are at least three quarters of the pallet depth, and do not stick out beyond it.
• Never reuse one-trip pallets for storage or racking. They should be clearly marked.
• Load in a set pattern, apply loads gradually, and spread the weight evenly.
• Keep the load no higher than the longest side of the pallet base, and use shrink wrap or strapping to secure it.

Racking is the metal framework used to support loads without the need for shelves. It saves space and gives easy access to goods.

Racking must be strong enough for the loads stored on it. The maximum safe working load must be clearly displayed, and never exceeded. Because racking is made from relatively light materials, any damage reduces its strength.

A technically competent person must inspect racking regularly, at least every twelve months. Workers must report any damage straight away to the person responsible for racking safety, and everyone should be trained in its safe use.

Hazards with racking include:

• Loose floor fixings. Racking must be anchored to the floor, with base plates secured by anchor bolts.
• Impact damage from trucks. Keep aisles clear, allow enough clearance, and report every impact.
• Misaligned racking, which can lead to the whole system collapsing. Check that it is straight and level.
• Overloading. Know the maximum load capacity of each bay and beam level, and never exceed it.

Racking failures can bring down tonnes of goods in seconds, so small signs of damage matter.

After an inspection, damaged racking is given one of three risk levels:

• Green means surveillance only. The racking is safe to use, but should be kept under regular inspection.
• Amber means hazardous damage that needs action as soon as possible. The racking can stay in use, but once offloaded it must not be reloaded until repaired. If it is not repaired within four weeks, it becomes red.
• Red means very serious damage needing immediate action. The racking must be offloaded immediately, and not reloaded until it has been repaired. The area must be isolated, for example by roping it off.

Automated storage and retrieval systems use computer control, conveyors, automated guided vehicles and storage machines to place and retrieve loads. They save space and improve stock control.

They also bring hazards:

• Automated guided vehicles may move off unexpectedly, or collide with people and structures.
• People can be trapped between machinery, loads and fixed structures, at transfer points and in the storage area.
• Loads can collapse, and people can fall from height.

Keep people out of automated areas unless the system is safely isolated.

• Falls from height: never climb racking, use proper access equipment for jobs such as changing lights, and fit edge protection to mezzanine floors.
• Manual handling: use conveyors and lift trucks, and train staff in safe handling.
• Falling objects: use pallets and racking suitable for the load, report damage straight away, and wear safety footwear.
• Machinery: fit fixed guards, maintain machines, and train staff before they use them, as moving parts and loads can trap and crush.

Large quantities of hazardous substances can put workers, the public and the environment at serious risk. Your risk assessment should cover which substances are present, the hazards they create, such as fire, corrosion or toxicity, and how you will prevent and control them. Review it whenever you store a new product.

Accidents with dangerous goods are usually caused by poor training, not understanding the chemicals, unsuitable storage conditions, poor control of heat and ignition sources, poor building design or maintenance, and arson.

Depending on what you store, and how much, other law may apply:

• The Chemicals Act (Control of Major Accident Hazards Involving Dangerous Substances) Regulations 2015, known as COMAH, apply to sites storing large quantities of named dangerous substances. The HSA is the central competent authority. COMAH sites need specialist guidance.
• Pesticide stores must follow the specific rules on plant protection products, and large stores need a trained, competent storekeeper.
• All workers must understand the hazard labels used under CLP, and the transport markings used for dangerous goods.

Before you order and accept a shipment of dangerous goods, discuss the hazards with the supplier, who has a legal duty to give you health and safety information. The safety data sheet is a good source of information on storage needs. Find out whether the goods:

• Must be kept apart from other substances they could react with.
• Must be kept away from sprinkler systems.
• Must be stored at a certain temperature.

Make sure you can store the goods safely before they arrive.

When a delivery of dangerous goods arrives:

• Check each package against the shipment documents and the driver’s delivery note.
• Make sure every package can be identified from its transport labels. Never put an unidentified package into storage. Quarantine it until the information is obtained, or ask the supplier to remove it.
• Before storing the goods, check what is stored next to the chosen location, and make sure the goods are compatible.

Repeat these checks every time all or part of the shipment is moved within the warehouse.

• Packaging: check containers routinely for damage and leaks, handle them carefully, and dispose of waste through licensed hazardous waste routes.
• Segregation: keep dangerous substances in dedicated, fire-separated areas, away from incompatible materials.
• Ignition sources: control smoking, heat and electrical sources.
• Stock control: set a maximum quantity for each location, never overstock, keep gangways clear, and leave at least one metre between the top of the stock and the roof, beams and lights.
• Stability: never exceed the maximum storage weight, and store goods at the correct temperature.

You must have an emergency plan, suited to the substances and quantities you store. It should cover training, evacuation, the possible effects on people, property and the environment, and the equipment available to limit harm.

If there is a spill, move untrained people away, and follow your spill procedure:

• Contain liquid spills with compatible barriers, such as absorbent pads or sandbags.
• Never dry-brush powder spills. Use damp sweeping or a suitable vacuum cleaner.
• Wear the PPE shown on the safety data sheet.

An emergency plan for hazardous goods must be clear, practical and adaptable, and it must comply with the law. Its size and complexity depend on the substances and quantities you store, and support from qualified outside experts may be needed when preparing it. It should set out the training staff need, the evacuation steps, the possible risks to people, facilities and the environment, and the resources and protective equipment available to limit harm.

The plan rests on your risk assessment, which should ask which hazardous substances are present or may be introduced, what threats they pose, what controls are in place, and how the risks can be reduced further. Review it whenever new products arrive. When a spill happens, the right response depends on the material. Absorbent barriers, pads and sandbags must be compatible with the substance spilled, and procedures should be in place to neutralise or dilute spills safely. Always check the safety data sheet for the specific PPE required.