Warehouse & Logistics Safety Compliance Tips Ontario [Guide]

 Summary 

Warehouses and logistics operations face hazards involving forklifts, heavy loads, racking systems, and fast moving traffic. This guide explains OHSA compliance steps for safe equipment operation, material handling, rack stability, and traffic flow.

Learn key OHSA safety compliance tips for warehouses and logistics operations. Covers forklift safety, rack stability, traffic control, and load security. Improve your warehouse safety with Achieve Safety trainings in Ontario and audits.

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Intro

Warehouses and logistics facilities move products at a fast pace, which creates real safety challenges. Forklifts, pallet jacks, order pickers, racking systems, and pedestrian traffic all operate in tight spaces. When hazards are not controlled, injuries happen quickly.

The Occupational Health and Safety Act requires employers to train workers, maintain equipment, manage traffic, and secure loads. Many warehouses struggle because conditions change throughout the day. New shipments arrive, aisles fill, and equipment moves constantly.

This guide explains the essential OHSA compliance steps warehouses must follow to keep workers safe and maintain efficient operations. It covers forklift competency, rack safety, traffic management, proper lifting techniques, and safe ladder use during order picking.

If you want to confirm your warehouse meets Ontario standards, Achieve Safety provides forklift training, ladder safety training, and full warehouse safety audits.

Key OHSA Requirements for Warehouses and Logistics Facilities

Warehouses fall under the Occupational Health and Safety Act, which sets clear expectations for employers, supervisors, and workers. Because warehouses involve constant movement of people, products, and equipment, OHSA focuses on training, supervision, hazard control, and equipment maintenance.

• Employer → ensures → safe equipment, proper training, and organized work areas
• Supervisor → monitors → worker practices and corrects unsafe behaviour
• Worker → follows → safe procedures and uses equipment properly

Core OHSA requirements for warehouses include:

• Training operators on forklifts, pallet jacks, order pickers, and lifting equipment

• Maintaining aisles, exits, docks, and storage areas in safe condition

• Securing loads to prevent shifting, falling, or collapsing

• Inspecting equipment daily before use

• Read moreConfined Space Safety Ontario: OHSA Compliance & Trainings

  Installing traffic management plans for pedestrian and vehicle flow

• Ensuring workers follow safe manual material handling practices

• Completing regular workplace inspections

• Providing safe ladder use practices for order picking and elevated access

• Keeping racking systems stable and undamaged

• Investigating incidents and making corrective actions clear

Warehouses are dynamic environments. Hazards change quickly, which is why OHSA places responsibility on supervision and daily monitoring. If your team needs support meeting these requirements, Achieve Safety offers warehouse safety audits that align with Ministry of Labour expectations.

Forklift and Equipment Safety Requirements

Forklifts and powered material handling equipment create the highest risk in warehouses. Most warehouse injuries involve struck by, crushed between, or tip over incidents. OHSA requires employers to train operators, maintain equipment, and control traffic to prevent these hazards.

• Forklift Operator → must be → trained and competent
• Employer → verifies → daily inspections and safe operation

Operator Competency

Workers must be trained and able to operate forklifts, pallet jacks, reach trucks, walkies, and order pickers safely. Training must cover load capacity, stability, speed control, and workplace navigation.

Achieve Safety offers Forklift Training that helps warehouses meet OHSA competency expectations.

Equipment Inspections

Forklifts must be inspected before each shift. Operators must check brakes, hydraulics, forks, steering, horn, warning devices, tires, and mast operation. Any defect requires immediate removal from service.

Safe Operating Practices

Operators must:

• Travel at safe speeds

• Maintain visibility

• Keep forks low when traveling

• Sound horns at blind corners

• Maintain safe distances from pedestrians

• Avoid sharp turns that can cause tip overs

• Use spotters when visibility is limited

Load Handling

OHSA requires loads to be stable, secured, and within the forklift’s rated capacity. Falling products cause many warehouse injuries. Operators must tilt and position loads properly before lifting or placing material on racks.

Charging and Maintenance Areas

Battery charging and propane exchange areas must have ventilation, clear signage, and proper PPE for workers performing exchanges.

Safe forklift operation protects workers and prevents costly damage to racking, products, and equipment. A warehouse safety audit from Achieve Safety can identify gaps in equipment operation, traffic flow, and competency records.

Traffic Management and Pedestrian Safety

Warehouses mix fast moving equipment with pedestrian traffic. Without clear controls, visibility issues and tight aisles can lead to serious injuries. OHSA requires employers to manage vehicle and pedestrian interactions through planning, training, and physical controls.

Defined Travel Routes

Warehouses must mark designated lanes for forklifts, pallet jacks, and pedestrian movement. Clear floor markings, barriers, and one way routes help prevent conflicts between workers and equipment.

Safe Dock and Shipping Areas

Loading docks present high risk conditions. Employers must ensure:

• Dock edges are guarded

• Workers stay clear of reversing trucks

• Forklifts and trailers remain secured during loading

• Communication between drivers and warehouse staff is clear

Pedestrian Controls

Pedestrians must stay in marked walkways and avoid equipment blind spots. Workers must never walk behind forklifts or enter aisles without checking for traffic.

Visibility and Line of Sight

Warehouses should install convex mirrors, warning lights, and alarms in areas with limited visibility. Operators must slow down, use horns, and make eye contact with pedestrians when possible.

Spotter Training

Workers acting as spotters must understand equipment blind zones, hand signals, and safe communication methods. Spotters must stay in visible, protected positions at all times.

Order Picking From Heights

Workers climbing ladders or elevated order pickers must follow safe access and fall prevention practices.

Achieve Safety offers Ladder Safety Training to support safe picking and elevated access tasks.

Strong traffic management reduces the risk of severe injuries and improves workflow efficiency.

Rack Safety and Load Stability Requirements

Racking systems hold thousands of pounds of product. When they are overloaded, struck by forklifts, or improperly installed, the entire structure can fail. OHSA requires employers to keep racks stable, secured, and in good condition. Poor rack safety is one of the most overlooked hazards in warehouses.

Rack Inspection and Maintenance

Warehouses must inspect racking regularly for:

• Damaged uprights

• Bent beams

• Missing safety pins

• Loose anchors

• Rust or corrosion

• Dented or twisted components

Damaged racks must be repaired or replaced immediately. Never load damaged racks.

Load Ratings and Capacity Limits

Racks must display clear load capacity signs. Workers must never exceed the rated limit, even during peak demand periods. Overloaded racks are a leading cause of partial collapses and falling products.

Safe Loading and Unloading

Forklift operators must place loads squarely on beams, avoid pushing racks, and prevent horizontal impact. Loads must be wrapped, secured, and stable before placement. Operators must also avoid tilting or leaning loads while traveling.

Securing Racks to the Floor

Racks must be anchored to the floor to prevent tipping or movement. Missing or loose anchors compromise the entire structure.

Clearances and Aisle Widths

Warehouses must maintain safe aisle widths and adequate overhead clearance for forklifts and reach trucks. Tight aisles increase the chance of rack strikes, which weaken the structure over time.

Pallet Condition

Broken pallets cause falling loads. Warehouses must remove cracked, missing board, or unstable pallets from use.

Rack safety protects workers, prevents costly product damage, and reduces the risk of catastrophic failure. Achieve Safety’s warehouse audits include rack inspections, load capacity checks, and corrective action guidance.

Load Security and Safe Storage Practices

Warehouses handle heavy pallets, stacked materials, and fast moving shipments. When loads are unstable or stored incorrectly, the risk of falling products, crush injuries, and equipment damage increases. OHSA requires employers to secure loads, maintain safe storage systems, and prevent materials from shifting or collapsing.

Securing Loads Before Moving

Operators must ensure loads are wrapped, banded, or stabilized before lifting or transporting. Palletized goods must sit squarely and not lean or overhang. Forklift operators must tilt loads back slightly to improve stability.

Stacking Heights and Stability

Warehouses must follow safe stacking heights based on the type of product, pallet condition, and racking limitations. Stacks must be even, compact, and secured to prevent shifting.

Safe Storage of Hazardous Materials

Hazardous products must be stored according to WHMIS and manufacturer guidelines. This includes proper segregation, labeling, ventilation, and spill control. Workers who handle or store chemicals need WHMIS 2015 Training.

Broken or Unstable Pallets

Damaged pallets compromise entire stacks. Warehouses must remove broken pallets from circulation and replace them immediately.

High Level Order Picking

Workers retrieving items from upper rack levels must use safe ladder practices or approved equipment. Achieve Safety offers Ladder Safety Training that supports safe order picking and elevated access.

Safe storage and load security reduce injuries, protect products, and help employers meet OHSA expectations.

Required Workplace Inspections and Supervisor Responsibilities

Warehouses change constantly. New shipments arrive, equipment moves, and aisles fill quickly. OHSA requires employers and supervisors to inspect the workplace regularly and correct hazards before they cause injuries.

Daily Supervisor Walkthroughs

Supervisors must walk the floor at the start of each shift to check:

• Aisle obstructions

• Damaged racks

• Forklift conditions

• Spill or slip hazards

• Poor visibility zones

• Unsafe pedestrian traffic

• Missing signage or floor markings

Any issue must be corrected immediately.

Monthly Workplace Inspections

Warehouses must complete documented monthly inspections covering:

• Storage systems

• Fire safety equipment

• Exits and egress paths

• Lifting equipment

• Electrical hazards

• Dock areas

• First aid supplies

• Housekeeping

These records must be available during Ministry of Labour inspections.

Corrective Actions

Supervisors must assign corrective actions, follow up, and verify that hazards are resolved. This documentation shows due diligence.

Worker Participation

Workers should report hazards to supervisors as soon as they appear. The internal responsibility system requires everyone to be involved in keeping the workplace safe.

Achieve Safety provides warehouse audits that assess supervision quality, inspection routines, and corrective action systems.

When to Request a Warehouse Safety Audit

Warehouses can develop hidden hazards that are easy to miss during daily operations. A safety audit helps identify risks, confirm compliance, and prevent injuries. Many employers request an audit when they are unsure if their current practices meet OHSA expectations.

When an Audit Is Needed

A warehouse audit is recommended when:

• Forklift or equipment incidents occur

• Racking damage happens repeatedly

• Pedestrian and equipment conflicts are common

• Loads shift, fall, or appear unstable

• A Ministry of Labour visit is expected

• New supervisors or operators join the team

• Warehouse layout changes

• Significant growth or expansion creates new hazards

What an Audit Reviews

A warehouse audit examines:

• Forklift operation and operator competency

• Traffic management and pedestrian controls

• Rack safety and structural stability

• Load security and storage practices

• Housekeeping and aisle conditions

• Ladder use for order picking

• Training and documentation gaps

• Emergency procedures and fire safety compliance

Benefits of a Third Party Audit

A third party sees hazards internal teams may overlook.
Audits provide:

• Fresh perspective

• Clear corrective action steps

• Strong preparation before inspections

• Improved workflow and safety culture

Achieve Safety provides warehouse safety audits, forklift training, ladder safety training, and WHMIS training to help employers maintain safe and compliant operations.

Warehouse and Logistics Safety Compliance

What are the main OHSA requirements for warehouse safety?

Warehouses must train equipment operators, control traffic, secure loads, maintain racking systems, inspect the workplace regularly, and keep aisles clear. Employers must provide competent supervision and ensure workers follow safe material handling practices.

Do forklift operators need certification in Ontario?

Yes. OHSA requires forklift operators to be trained and competent before using lift trucks, reach trucks, pallet jacks, or order pickers.

How often should warehouse racks be inspected?

Racks should be inspected daily by workers and monthly by supervisors. Damaged racking must be repaired or removed from service immediately.

What is required for safe pedestrian and forklift interaction?

Warehouses must use marked walkways, mirrors, floor lines, barriers, and traffic rules to separate pedestrians from forklifts. Operators must slow down and use horns at blind corners.

How can employers reduce load shifting and falling product incidents?

Secure loads, use stable pallets, avoid overloading racks, and ensure operators place products squarely. Workers must check load stability before lifting and stacking.

When should a warehouse safety audit be requested?

Request an audit when incidents occur, racking damage increases, new equipment is added, or when a Ministry of Labour visit is expected. Audits help identify compliance gaps and improve safety practices.