Warehouse WHS Checklist

Quick answer: Warehouse WHS hazards fall into predictable categories — traffic management, racking, manual handling, loading docks, and emergency preparedness. Use this checklist for your routine inspections and shift walkthroughs. Document your findings and track corrective actions to close every gap.

Last reviewed: June 2026 by the BlueSafe Technical Team. Reflects current Model WHS Regulations.

Warehouses combine a uniquely dense mix of hazards: moving plant, heavy loads, repetitive manual tasks, and significant traffic — all operating in the same space, often under time pressure. The consequences of getting it wrong are serious. Forklift incidents, racking collapses, and loading dock accidents account for a disproportionate share of serious workplace injuries in Australia.

This checklist is designed for warehouse managers, supervisors, and WHS coordinators to use as part of a regular inspection programme. Work through each section and document your findings. Any item marked as non-compliant should be assigned to a responsible person with a due date for corrective action.

For guidance on preparing SWMS for warehouse activities, see our Warehouse SWMS Guide and Loading Dock SWMS Guide.

1. Forklift and Pedestrian Segregation

Forklift and pedestrian interactions are among the most serious hazards in any warehouse. Physical separation — not just line markings — is the standard to aim for.

Clearly defined and marked pedestrian walkways are in place throughout the warehouse
Forklift travel lanes are clearly marked and separated from pedestrian routes
Physical barriers (bollards, safety rails, or barriers) protect pedestrian areas where practicable
Pedestrian exclusion zones around active forklift operating areas are enforced and clearly signposted
Convex mirrors are installed at blind corners and intersections
Speed limits for forklifts are posted and enforced
Line markings are clearly visible and not worn, faded, or obscured
Workers have been instructed not to walk under raised forklift loads
Visitors and non-warehouse personnel are escorted and kept within pedestrian zones

2. Traffic Management

Internal and external traffic flows must be managed to prevent vehicle and pedestrian collisions.

A documented traffic management plan is in place for the site
Entry and exit points for vehicles and pedestrians are separated where practicable
Designated parking areas for trucks, forklifts, and staff vehicles are clearly marked
Site speed limits are posted at entry points and throughout the facility
Reversing areas are controlled — spotters used or reversing alarms in operation
External truck movements (arrivals and departures) are managed to prevent conflicts with workers
Traffic management plan reviewed when layout or operations change

3. Racking Inspection and Load Limits

Racking failure is a major risk. Damaged racking must be taken out of service immediately — never left in use pending repair.

All racking has a load capacity placard displayed at each bay (in kilograms)
Loads stored on racking do not exceed posted load limits
Racking is inspected regularly by a competent person (at least every 12 months, or as recommended by the manufacturer)
A documented racking inspection record is on file
Damaged uprights, beams, or frames are immediately taken out of service and tagged
No makeshift repairs (wire, rope, wedges) are in use on racking components
Floor anchors are intact and racking is secured to the floor as required
Upright protectors are fitted to exposed racking legs in forklift operating areas
Workers know the procedure for reporting racking damage

4. Manual Handling Controls

Manual handling injuries are the most common cause of lost-time injuries in warehouses. Risk must be assessed and controls implemented — not simply accepted as part of the job.

A manual handling risk assessment has been conducted for significant manual tasks
Mechanical aids (pallet jacks, trolleys, conveyors, lift tables) are available and in good working order
Workers have received manual handling training appropriate to their tasks
Safe lifting and team-lift procedures are posted and communicated
Heavy or awkward loads are identified and flagged with a team-lift or mechanical aid requirement
Storage arrangements minimise the need to lift from floor level or above shoulder height
Manual handling incidents and near-misses are recorded and investigated

5. Safe Stacking

Unstable or excessive stacking creates crush and falling-object hazards for everyone in the area.

Stacking heights are within safe limits for the materials and storage method
Goods are stacked stably and will not topple if one item is removed
Heavy items are stored at lower levels; lighter items higher
Pallets are inspected before use and damaged pallets removed from service
No overhanging loads extend into aisles or pedestrian walkways
Stacking is not conducted near sprinkler heads or in a way that would obstruct fire suppression
Workers are not required to climb on racking or stacked goods to retrieve items

6. Loading Dock Safety

Loading docks are a high-risk interface between the warehouse environment and external vehicles. Truck restraint, fall prevention, and traffic control are the critical controls.

Dock levellers are in good working order and inspected regularly
Truck restraints (wheel chocks or mechanical restraints) are used before loading or unloading commences
Workers are not in the dock area while a truck is moving
Edge protection or dock barriers are in place when the dock is unoccupied or a truck is not present
Lighting at the dock is adequate for safe loading and unloading at all hours of operation
Communication procedure is in place between dock workers and truck drivers
Pedestrian access to the dock area is controlled during truck movements
Fall protection is in place for any work conducted at height on the dock (including accessing truck trays)
A documented safe operating procedure or SWMS is in place for loading dock operations — see our Loading Dock SWMS Guide

7. Housekeeping and Clear Aisles

Good housekeeping is not cosmetic — it directly affects the risk of slips, trips, falling objects, and fire.

All main aisles and emergency exit paths are clear of obstructions at all times
Spills are cleaned up immediately and the area barriered until clear
Waste and packaging materials are removed regularly and not allowed to accumulate
Pallets and empty containers are stored in designated areas, not left in aisles
Floors are free from damage (cracks, uneven surfaces, lips) that could cause trip or handling incidents
Cleaning schedule is in place and records maintained
Housekeeping standards are included in worker inductions

8. Lighting

Adequate lighting is a basic safety requirement and a common finding in WHS inspections of older warehouse facilities.

General lighting throughout the warehouse is adequate for the tasks being performed
All storage areas, including those away from main aisles, are adequately lit
Loading docks and external areas are lit for safe operation at night or in low-light conditions
Emergency lighting is installed and operational (tested in accordance with AS/NZS 2293)
Damaged or failed lights are reported and replaced promptly
Lighting levels have been assessed following any significant change to layout or operations

9. Emergency Exits and Evacuation

Emergency exit routes must be kept clear at all times — not just during an inspection.

All emergency exits are clearly marked with illuminated signage
Emergency exit doors are operable from inside without a key or special knowledge
Exit paths and muster areas are kept clear of stock, pallets, and equipment at all times
Emergency evacuation plan is documented, current, and posted in a prominent location
Muster point is clearly identified and communicated to all workers
Emergency drills are conducted at least annually and records retained
All workers (including contractors and regular visitors) know the emergency procedures

10. Fire Equipment

Fire equipment must be in the right locations, properly maintained, and accessible when needed.

Fire extinguishers are installed at required locations and are not obstructed
Fire extinguishers are within their service date (six-monthly inspection by a licensed technician)
Workers have been trained in the use of fire extinguishers
Fire hose reels (where installed) are accessible and unobstructed
Sprinkler heads are unobstructed — no stacking within the clearance zone specified by the system designer
Fire detection and alarm systems are tested and maintained in accordance with the relevant Australian Standards
Flammable and combustible materials are stored in designated areas away from ignition sources

11. Personal Protective Equipment (PPE)

PPE is the last line of defence. It should be appropriate, maintained, and actually worn.

PPE requirements for the warehouse have been documented (minimum standards by area or task)
Mandatory PPE (at minimum safety footwear) is worn by all workers and visitors in operational areas
Hi-visibility vests or clothing are worn where forklifts or vehicles are operating
Task-specific PPE (gloves, eye protection, hearing protection, hard hats) is available and used for relevant tasks
PPE is inspected regularly and replaced when damaged, worn, or expired
Workers have been trained in the correct use and care of PPE
PPE requirements are communicated during site induction

12. Plant Pre-Start Checks

Pre-start checks are a legal requirement for many types of plant and essential for identifying defects before they cause an incident.

A pre-start checklist exists for each item of powered mobile plant (forklifts, order pickers, reach trucks, ride-on cleaners, etc.)
Pre-start checks are completed by the operator before each shift or use
Completed pre-start check records are retained (paper or digital log)
Defects identified during pre-start checks are reported immediately and the plant taken out of service
Out-of-service tags are used and plant is not returned to service without authorisation from a competent person
Operators hold the required High Risk Work Licence (for forklifts and other licensed plant)
Maintenance records for all plant are current and accessible

13. Spill Management

Chemical spills can create slip hazards, fire risks, and health exposures. Controls must be in place before a spill occurs.

A chemical register is maintained listing all hazardous chemicals stored or used in the warehouse
Safety Data Sheets (SDS) are current (issued within five years) and accessible to workers in the areas where chemicals are used or stored
Spill kits are located in areas where chemical spills are likely and are fully stocked
Workers know the procedure for responding to a spill (contain, report, clean up, dispose of waste correctly)
Spill response training has been provided to relevant workers
Spill incidents are recorded and investigated
Bunding or secondary containment is in place for bulk liquid storage

Completing this checklist

Go through each section during your inspection. For every item marked as non-compliant:

Note the specific issue and its location.
Assign a responsible person and a due date for corrective action.
Follow up to confirm the corrective action has been completed.
Retain your completed checklists as evidence of your ongoing WHS monitoring.

A single completed checklist filed away is not a safety system. The value is in the pattern — consistent inspections, documented corrective actions, and a visible commitment to improvement.

For a full suite of warehouse safe work procedures and SWMS templates, visit the Blue Safe Online platform.

Frequently asked questions

How often should a warehouse WHS inspection be carried out?

There is no single prescribed frequency in the Model WHS Regulations, but best practice is a full documented inspection at least monthly, with supervisors conducting informal walkthroughs at the start of each shift. High-risk areas such as loading docks and racking should be checked more frequently — daily in active warehouses. Plant pre-start checks must be completed before each use.

Who is responsible for warehouse WHS in a leased facility?

Responsibility is shared. The business occupying the warehouse (as a Person Conducting a Business or Undertaking, or PCBU) has the primary duty to ensure the workplace is safe. The building owner or landlord has obligations for the structural elements and shared areas they manage. Where these obligations overlap — for example, floor loading limits or dock leveller maintenance — both parties should communicate clearly and document agreed responsibilities.

Does a warehouse need a SWMS for forklift operations?

A formal Safe Work Method Statement (SWMS) is not automatically required for forklift operations in a non-construction setting. However, a documented safe operating procedure (SOP) or work instruction for forklift use — including pedestrian segregation, load limits, and pre-start checks — is considered essential for demonstrating due diligence under the WHS Act. For loading dock operations that involve truck restraints, elevated work, or proximity to traffic, a SWMS is strongly recommended.

What are the most common WHS breaches found in warehouses?

Common findings from WHS regulator inspections of warehouses include: inadequate forklift and pedestrian separation; racking damage not reported or tagged out; blocked emergency exits and aisle obstructions; incomplete or missing plant pre-start checks; lack of documented manual handling risk assessments; and insufficient lighting in storage and loading areas. These are also the areas where serious injuries most frequently occur.

Make compliance easier with Blue Safe Online

Running through this checklist is the first step. Closing the gaps — with documented procedures, SWMS, training records, and a maintained plant register — is where the real work happens.

Sign in to Blue Safe Online to access warehouse-specific WHS documents, SWMS templates, and registers ready to use on your site.

This article provides general information only and does not constitute legal advice. WHS requirements vary by jurisdiction and by the nature of your work. Always refer to the legislation and guidance published by your state or territory WHS regulator, and seek independent legal or safety advice where required.