Warehouse Safety Inspection Checklist: Keep Your Workplace Compliant and Safe
Ensure HSE & PUWER Compliance + Protect Your Team
Warehouse operations live on efficiency – but safety failures can shut you down overnight. In the UK, where HSE prosecutions for racking collapses or forklift incidents carry six-figure fines, a rigorous inspection routine isn’t optional. It’s survival.
Why Generic Checklists Fail You
Most free templates miss critical UK-specific risks like:
- PUWER 1998 equipment inspection mandates
- SEMA tolerances for racking damage
- Workplace (Health, Safety and Welfare) Regulations 1992 requirements
This checklist fixes that.
Your Actionable Warehouse Safety Inspection Checklist
Frequency: Weekly (Internal) + Quarterly (Professional)
1. Pallet Racking & Storage (HSE HSG76 Compliance)
- Beams/Uprights: Zero bends/dents >10mm depth (use damage assessment gauge)
- Safety Pins/Locks: 100% present & intact (Missing = immediate offload)
- Load Notices: Visible, updated, and never exceeded
- Flue Spaces: ≥75mm clearance between back-to-back racks
- Anchors: All uprights securely fixed to floor (no movement)
- Column Guards: Installed on end-of-aisle uprights (no impact damage)
2. Walkways & Flooring
- Aisles: Clear of debris, spills, cables (1m minimum width)
- Signage: Speed limits, pedestrian zones visible at intersections
- Drain Covers: Securely fitted (no trip hazards)
- Emergency Exits: Unobstructed, illuminated, signed
3. PPE & Staff Safety
- High-Vis Gear: Worn by all personnel in operational zones
- Hard Hats: Mandatory in racking aisles/loading bays
- Training Records: Valid FLT licenses, manual handling certs
4. Fire & Electrical Safety
- Fire Extinguishers: Serviced, accessible, type-appropriate (CO2 for electricals)
- Sprinklers: No stock stacked within 18" of heads
- Electrical Panels: Clear 1m access perimeter
5. Forklift & MHE Operations
- FLT Checks: Lights, horn, brakes, seatbelt functional (pre-shift log)
- Charging Stations: Ventilated, no exposed cables, acid spill kit present
- Overhead Guards: No cracks/deformation
Why This Checklist Becomes Your Legal Shield
Under UK law (PUWER 1998, Management of Health and Safety at Work Regulations 1999), this checklist provides documented proof you:
- Systematically identified hazards
- Took corrective actions
- Met "due diligence" requirements
Without it, HSE inspectors can issue prohibition notices on the spot.
When You Need Professional Backup
While internal checks catch surface issues, UK regulations require quarterly inspections by a "technically competent person" (SEMA-approved or equivalent). They detect:
- Micrometre-level beam deflection
- Hidden corrosion
- Load capacity miscalculations
- Foundation stress fractures
Pro Tip: Book professional inspections before peak seasons – never during.
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