20 Warehouse Accident Statistics You NEED To Be Aware Of

Over the last few years, warehouse injuries and deaths have increased, making safety for workers a huge concern, especially within the logistics industry. Before we reveal some warehouse accident statistics, emphasising how essential it is that businesses have appropriate safety measures in place, let’s look at why warehouse accidents have increased.

With such rapid growth, the pressure on safety systems and procedures can lead to gaps, creating more opportunities for workplace accidents. Many factors lead to accidents and warehouse work is dangerous – it’s a busy environment, full of activity throughout the day with multiple people and vehicles often working closely together. Heavy equipment, machinery and forklifts are all commonly used, creating opportunities for dangerous scenarios.

Below we have compiled twenty warehouse safety statistics that might surprise you and help to raise awareness of the potential dangers in warehouses and transportation.

Fatal Injuries Increased by 23%

• RIDDOR (Reporting of Injuries, Diseases, and Dangerous Occurrences Regulations) released figures in 2021 revealing the number of employees who suffered fatal injuries in the warehouse industry. These figures showed that fatal injuries had increased by 23% when compared to figures released at the same time the previous year.

Loading Docks Singled Out As A High-Risk Area

• The loading dock is a common high risk area with the Occupational Safety and Health Administration (OSHA) reporting that a quarter of all accidents take place in this location. Many of the reported accidents in loading docks involve individuals being crushed between forklifts and trailers while loading or unloading goods.

Non-Fatal Injury Rate Higher Than All Industries

• Between 2012/13 and 2019/2020, the percentage rate of non-fatal injuries in transportation and storage (per 100,000 workers) was higher than most of the all-industries average of 1.9%, according to the HSE^[1].

Workplace Accident Fines Can Cripple Businesses

• Fines for workplace accidents can be detrimental to a business. Following the death of an HGV driver at a drinks company,  the HSE investigation found the company had failed in several areas, including a lack of segregation of vehicles and pedestrians in the loading area and unclear directions to visiting drivers. The company was fined more than £800K^[2].

Warehouse Occupation Is The Third Most Dangerous Job

• A recent survey carried out by Forbes indicated warehouse work was found to be the third most dangerous job behind firefighters and police officers^[3].
• In the United States, struck-by injuries are the second highest cause of warehouse fatalities accounting for 16% in the year 2020.

Warehouse Fined £500,000 Following Workplace Accident

• A warehouse was fined £500K following the death of a man when a forklift truck he was operating overturned. The Health and Safety Executive (HSE) found that the warehouse failed to enforce the use of seatbelts by forklift truck operators^[4]
• The fatal injury rate in transportation and storage is 0.91 per 100,000 workers . This is around 2.2 times the all industry rate.
• The HSE recommends the complete separation of vehicles and pedestrians. If this is not possible, business owners must implement alternate measures. ZoneSafe can create segregation in areas so vehicles and pedestrians can work safely.

6.6 Serious Injuries For Every 100 Workers

A report found that there were 6.6 serious injuries for every 100 workers at Amazon warehouses,  more than double the injury rate for other warehouses. Amazon has made efforts to address this and stated that rates have improved significantly since the report.

Fatal Accidents in 2022/23

• According to HSE 2022/23 figures, the most common kinds of fatal accidents to workers across all industries were falls from a height, being struck by a moving/flying/falling object, and being hit by a moving vehicle. On the whole, these account for around two-thirds of fatal injuries to workers in 2022/23.

Forklifts Defined As The Most Hazardous Workplace Transport

• Forklifts are essential in a warehouse operations but are the most dangerous form of workplace transport, responsible for more accidents and serious injuries every year than any other vehicles including HGVs.

1,300 Workers Hospitalised Annually

• According to the British Safety Council around 1300 workers are hospitalised with severe injuries following a forklift accident every year in the UK.

Fatalities in 2022/23

• There were 15 fatal injuries to workers in the UK transportation and storage industry in 2022/23. This is compared to 14 fatalities over the five-year period, 2018/19-2022/23.

Moving Vehicle Accidents Account for 37% of Fatalities

• 37% of fatal accidents in transportation and storage were due to being hit by a moving vehicle making it the most common cause of fatal accident in UK transportation and storage.

29,000 Non-Fatal Accidents

• 29,000 workers sustained non-fatal injuries in the sector averaged over the three-year period 2020/21-2022/23.

£1 Billion Workplace Injury Cost

• The total economic cost of workplace ill health and workplace injury in the sector was estimated at £1.0 billion in 2021/22.
• 135 people were killed at work in 2022/23 in the UK, 20 of which were due to being hit by a moving vehicle.

1.8 Million Workers Suffering

• During the fiscal year 2022/23, approximately 1.8 million workers found themselves grappling with illnesses that they attributed to their work, believing that their occupational environment either caused or exacerbated their health conditions. This underscores the significant impact of workplace-related health issues, emphasising the need for comprehensive strategies to safeguard employee well-being and occupational health.

Agriculture, Forestry and Farming Have Highest Rate of Self-Reported Non-Fatal Injuries

• With a staggering rate of 3,730 injuries per 100,000 workers, the Agriculture, Forestry, and Farming sectors top the list for non-fatal self-reported workplace injuries. This data underscores the pressing need for targeted safety measures and interventions to mitigate risks and enhance worker well-being in these demanding environments.

Useful Information

• The HSE provides a helpful checklist on its website to help businesses address workplace safety concerns around workplace transport Site inspection – Workplace transport checklist (PDF)

ZoneSafe helps address workplace safety risks and protect workers against collisions with moving vehicles. A ZoneSafe customer stated  “Since the implementation of ZoneSafe, the occurrences of near misses or accidents have been reduced to zero.” after the system was applied to enhance warehouse safety. Virginia Howard case study

The ZoneSafe safety system applies to a wide range of industries, providing high-risk businesses with a highly adaptable and effective way to prevent accidents in the workplace. Talk to us to learn more.

^[1] https://www.thompsons-scotland.co.uk/accidents-at-work-new/workplaces/logistics

^[2] https://www.fleetnews.co.uk/news/latest-news/2023/01/31/wine-company-fined-800k-after-hgv-driver-killed#:~:text=At%20a%20sentencing%20hearing%20at,pay%20costs%20of%20%C2%A35%2C614.30.

^[3] .https://www.forbes.com/uk/advisor/life-insurance/what-are-the-uks-most-dangerous-jobs/

^[4] https://www.shponline.co.uk/prosecutions/barcode-warehouse-ltd-fined-half-a-million-pounds-after-forklift-truck-death/.