Top 10 common workplace hazards and how to prevent them

Employers in supply chain, logistics, manufacturing, warehousing and transport operations have a legal duty to protect workers, site visitors and others from harm. Failing to address health and safety risks can lead to injuries, regulatory penalties and accident at work claim payouts that raise insurance premiums. Understanding and proactively managing common workplace hazards is therefore vital not only for compliance but also for ensuring business continuity, staff wellbeing and reputation.

1. Slips, trips and falls

Slips and trips are a common cause of non-fatal workplace injuries in haulage and distribution, often due to wet or uneven surfaces, poor lighting, trailing cables or cluttered walkways.

Prevention tips:

• Keep walkways clear and regularly inspect trailer docks, warehouse floors and yard areas.
• Use slip-resistant mats or flooring in loading areas and those at risk of getting wet.
• Maintain good lighting, mark changes of levels clearly, and fix trailing cables.
• Encourage a “see it, clear it” culture so hazards are removed or reported immediately

2. Manual handling and lifting

Manual handling of heavy goods is a daily task across many workplaces, such as warehousing, ports, logistics and unloading operations. Repeatedly lifting, twisting or carrying loads without proper technique can lead to back strain and musculoskeletal disorders. These issues often develop gradually, making them harder to identify until the damage is done. A business may be held liable for these injuries if it fails to provide necessary training and equipment to workers.

Prevention tips:

• Use palletising, trolleys or mechanical lifting aids wherever possible.
• Encourage team lifts for bulky or awkward items.
• Provide regular manual handling training tailored to the tasks carried out on site.
• Carry out ergonomic assessments to identify high-risk activities and redesign processes where needed.
• Rotate jobs to reduce the strain of repetitive lifting or carrying tasks.

3. Vehicle and transport hazards

Collisions involving forklift trucks, delivery vehicles or trailers are a major risk in logistics and warehouse environments. Collisions involving forklift trucks, HGVs, delivery vans or trailers can cause serious or even fatal injuries.

Prevention tips:

• Separate pedestrian walkways from vehicle routes wherever possible.
• Mark designated crossing points and install protective barriers.
• Enforce on-site speed limits and one-way systems to reduce collision risks.
• Require high-visibility clothing in all areas with moving vehicles.
• Provide thorough driver training and refresher assessments.
• Carry out daily vehicle safety checks and remove faulty vehicles from service.

4. Load security

Poorly stacked or unsecured loads can shift or topple, causing crush injuries and damage. In addition, working at height while loading or unloading vehicles creates a risk of falls.

Prevention tips:

• Secure cargo correctly using appropriate restraints and checks.
• Train staff in safe stacking, loading and unloading practices.
• Include fall prevention techniques in safety briefings and refresher training.

5. Hazardous substances and chemical exposure

From cleaning agents and pallet treatment chemicals to dust, fumes or packaging materials, many substances handled in supply chain settings can carry risks and must be handled according to the Control of Substances Hazardous to Health (COSHH) regulations. Exposure to airborne particles such as wood dust, flour dust or packaging dust, can harm workers’ respiratory health if not managed.

Prevention tips:

• Carry out COSHH risk assessments and make sure substances are labelled and stored correctly.
• Provide suitable PPE, such as gloves, respirators or goggles, and train staff in safe handling.
• Establish proper procedures for disposal and cleaning to minimise exposure risks.

6. Mechanical hazards and moving equipment

Where machinery such as forklifts, pallet trucks, conveyor systems and automated handling equipment is in use, there is risk of entrapment, crush injuries, cuts or equipment malfunction. These hazards are particularly acute in fast-moving supply chain environments, where high throughput and time pressure can make workers more vulnerable to unsafe practices.

Prevention tips:

• Maintain machinery regularly, install guards and emergency stop controls, and remove faulty equipment from service.
• Allow only trained and authorised staff to operate or maintain machinery, following lockout/tagout procedures during servicing.
• Provide clear signage and regular training so employees understand how to use equipment safely and recognise potential faults.

7. Ergonomic and workstation hazards

Poorly designed workstations, repetitive tasks (such as order picking, packing or scanning), awkward postures and repetitive motion increase the risk of musculoskeletal disorders, especially for staff working long shifts or in packing/fulfilment tasks.

Prevention tips:

• Tailor workstations to individual workers’ needs and provide suitable ergonomic tools, such as adjustable packing tables, display screen equipment training and lifting aids.
• Allow regular breaks and rotate tasks to reduce the strain of repetitive movements.
• Update ergonomic risk assessments whenever new tasks are introduced or work patterns change.

8. Temperature, ventilation and environmental stress

Employees working in cold storage, refrigerated areas, or poorly ventilated warehouses face risks from temperature extremes, poor air quality and fatigue. Heat or cold stress, build-up of dust or humidity, and respiratory irritants can all affect health, performance and safety.

Prevention tips:

• Manage ventilation systems and keep workplace temperatures within safe limits.
• Provide suitable PPE or clothing for staff working in extreme or fluctuating conditions.
• Introduce monitoring and regular breaks to reduce fatigue and prevent heat or cold stress.

9. Noise and communication breakdowns

Working around heavy machinery, loading dock doors, transport vehicles and mechanical handling systems exposes workers to sustained noise levels and communication barriers. Without proper controls, persistent noise can lead to long-term hearing damage, while missed signals or unclear communication increase the likelihood of accidents in busy environments.

Prevention tips:

• Carry out noise risk assessments and provide appropriate hearing protection.
• Use clear signalling systems, visual aids or alarms to support communication in noisy areas.
• Train staff on how to report near misses and incidents when verbal communication is difficult.

10. Workplace stress and fatigue

In supply chain operations, many leaders recognise the pressures created by shift work, delivery deadlines and staffing demands. These factors have an effect on morale, increase fatigue, reduce concentration and make accidents or errors more likely.

Prevention tips:

• Build mental health considerations into your safety assessments.
• Manage workloads realistically, with proper scheduling and rest breaks.
• Provide access to occupational health or wellbeing services and implement a clear policy on stress and fatigue.

Preventing accidents and limiting liability

Safety in the supply chain, logistics and warehousing depends on consistent attention to risks. With the right training, risk assessments and protective measures in place, employers can reduce accidents, protect their workforce and maintain reliable operations.

Ensure your supply chain is a safe, productive working environment with skilled employees, an effective company culture and a great workplace morale. IoSCM qualifications, resources and support help you drive positive change in your business. Call 0800 1422 522 today to find out how we can help.