Warehouses are essential for Canada’s supply chain, keeping goods moving across industries. But behind the scenes, warehouse work comes with risks.
Heavy machinery, high shelves, fast-paced operations, and human error can all lead to serious accidents.
That’s why understanding warehouse safety statistics is so important—it helps businesses identify risks, improve safety measures, and protect workers from injuries.
Every year, thousands of Canadian workers suffer injuries in warehouse environments. According to the Association of Workers’ Compensation Boards of Canada (AWCBC), the transportation and warehousing sector reported over 26,000 lost-time injuries in 2022 alone.
Falls, forklift accidents, and musculoskeletal injuries are among the most common hazards. Shockingly, one in five workplace fatalities in Canada occurs in this sector especially due to fall, highlighting the urgent need for stronger safety protocols.
Knowing the numbers behind warehouse accidents isn’t just about statistics—it’s about saving lives.
Employers who track incident rates, equipment failures, and compliance violations can take preventive action before accidents happen. This includes better training, stricter safety policies, and improved workplace design.
In this blog, we’ll explore key warehouse safety statistics, breaking down trends in workplace injuries, common causes of accidents, and how businesses can create safer environments.
By understanding these numbers, companies can take the right steps to protect workers and improve overall safety standards.
The Growing Importance of Warehouse Safety
In recent years, the focus on warehouse safety in Canada has intensified. As the logistics and warehousing sector expands, so do the associated risks to workers.
This increased attention includes a combination of increased workplace incidents and evolving industry trends.
Rising Incident Rates
The warehousing industry has seen a notable rise in workplace accidents. Recent reports highlight several serious incidents:
- December 2023: A 20-year-old worker tragically died after a fall in Zorra Township, Ontario.
- November 2023: A second worker succumbed to injuries following an April incident at a Nanticoke steel mill.
- November 2024: In British Columbia, a forklift operator sustained injuries when their machine fell approximately five feet during loading operations.
These incidents highlight the urgent need for enhanced safety protocols in warehouse environments.
Emerging Trends Impacting Safety
Several trends have brought warehouse safety to the front:
- Mental Health Awareness: The COVID-19 pandemic has exacerbated issues like worker burnout and workplace harassment. Organizations are increasingly recognizing the importance of addressing mental health to ensure overall workplace safety.
- Regulatory Changes: Efforts are underway to implement electronic registries for handling dangerous goods, aiming to streamline safety compliance and incident tracking.
- Technological Advancements: The adoption of automation and robotics in warehouses necessitates updated safety protocols to address new types of hazards associated with advanced machinery.
The combination of rising incident rates and these emerging trends highlights the critical importance of proactive measures to enhance warehouse safety across Canada.
Top Warehouse Safety Statistics
Understanding warehouse safety statistics is crucial for identifying risks and improving workplace conditions.
Forklift accidents, pedestrian injuries, and loading dock incidents are among the leading causes of injuries and fatalities in warehouse environments. Below, we break down key statistics to highlight the most common safety concerns in warehouses.
1. Forklifts are involved in approximately 10% of workplace fatalities and 5% of serious workplace injuries each year in Canada.
Forklifts are essential for warehouse operations, but they also pose serious risks. Collisions, overturning, and pedestrian accidents are leading causes of injury and death.
Employers must enforce strict forklift safety training and operational protocols to minimize these risks.
2. Forklift-related accidents cost Canadian workplaces over $125 million annually in direct compensation costs alone.
The financial impact of forklift accidents extends beyond compensation costs. Businesses also suffer from lost productivity, legal liabilities, and increased insurance premiums. Investing in forklift safety measures can help mitigate these costs.
3. In 2021, Ontario reported 633 forklift or industrial-powered vehicle lost-time injuries.
Of these injuries, 23% resulted from pedestrians being struck by industrial-powered vehicles (Inside Logistics). This highlights the importance of pedestrian safety measures, such as designated walkways, warning signals, and operator awareness training.
4. Around 75 to 100 workers are killed annually in forklift accidents, with a rough average of 87 deaths per year.
This number has increased by nearly 30% over the past decade, emphasizing the growing need for improved safety regulations. The Occupational Safety and Health Administration (OSHA) estimates that between 35,000 and 62,000 forklift-related injuries occur every year.
5. On average, 95 people are seriously injured in a forklift accident every day, and 1 person is killed every 4 days in the United States.
Additionally, 36% of forklift-related fatalities involve pedestrians. These alarming statistics stress the need for strict traffic management in warehouses, including speed limits, warning systems, and pedestrian exclusion zones.
6. The warehousing and transportation sector ranked second in workplace fatal injuries.
In 2017, this sector accounted for a significant portion of the $161.5 billion total cost of occupational injuries across all industries (National Safety Council). Preventable deaths in warehouses remain a major concern, second only to construction.
7. Overturning accounts for approximately 24% of all forklift accidents at the worksite.
Forklift overturning is the leading cause of forklift-related injuries and deaths. Overloading, uneven surfaces, and sharp turns contribute to these accidents, making proper operator training and load management essential.
8. Pedestrian accidents account for 20% of forklift incidents but 36% of resulting fatalities.
Although pedestrian-related forklift accidents are less common than other incidents, they are disproportionately more fatal (OSHA). Warehouses must implement physical barriers, strict pedestrian pathways, and clear visibility measures to reduce risks.
9. OSHA estimates that forklifts contribute to tens of thousands of injuries annually, including 35,000 serious injuries and 85 deaths.
These figures highlight the severe consequences of improper forklift operation. OSHA recommends continuous operator training and improved warehouse safety procedures to reduce these numbers.
DART (Days Away from Work, Restriction, or Transfer) cases refer to injuries severe enough to require time off or job restrictions. These incidents significantly impact worker productivity and employer costs).
11. More than 25% of all industrial accidents occur at loading docks.
For every one serious loading dock accident, there are approximately 600 near misses (ISHN). The loading dock is one of the most hazardous areas in a warehouse, requiring strict safety controls, such as dock levelers, edge barriers, and fall protection measures.
Warehouse safety remains a critical concern for businesses across Canada. The statistics show an urgent need for enhanced safety measures, including forklift training, pedestrian protections, and proper loading dock protocols.
Employers who prioritize warehouse safety not only reduce injuries and fatalities but also improve efficiency, lower costs, and ensure compliance with workplace safety regulations.
Conclusion
The statistics on warehouse safety paint a concerning picture of the risks workers face daily. With forklifts involved in 10% of workplace fatalities in Canada and over $125 million lost annually due to forklift-related accidents, it’s clear that warehouses must prioritize safety.
Additionally, one in four industrial accidents occur at loading docks, and pedestrian accidents account for 36% of forklift-related fatalities, further emphasizing the need for stricter safety protocols.
In addition to human cost, workplace accidents disrupt productivity and result in financial losses due to medical expenses, lost workdays, and potential legal claims.
Warehouse incidents also drive up insurance premiums and regulatory fines, making them an expensive liability for businesses.
By implementing comprehensive safety programs, businesses can prevent injuries, improve efficiency, and reduce costs.
Investing in structured workplace safety training, proper equipment, and compliance with safety regulations such as OSHA standards is critical to reducing risks.
Training should cover hazard identification, forklift operation, pedestrian safety, and emergency response planning. Safety technologies, such as real-time monitoring systems and automated alerts, can further enhance workplace security.
Warehouse managers and business owners must act now to strengthen safety protocols. A proactive approach to warehouse safety statistics ensures a safer work environment, boosts worker morale, and protects businesses from unnecessary financial losses. Prioritizing safety today can save lives and resources in the future.