When it comes to managing a warehouse in Australia or New Zealand, safety is never optional. Warehouses are fast-paced environments with heavy machinery, high storage systems, moving vehicles, and teams working under time pressure. A single lapse can cause injuries, product loss, or costly downtime. That’s why regular safety audits are required and a comprehensive warehouse safety audit checklist helps ensure nothing is overlooked.
In this article, we’ll walk you through what to expect during a warehouse safety audit, the key areas auditors assess, and how tools like SiteConnect can streamline the process.
Why Warehouse Safety Audits Matter
WorkSafe NZ and Safe Work Australia both set clear expectations for employers to identify hazards, manage risks, and provide a safe workplace. For warehouses, this means:
- Preventing injuries from forklifts, slips, trips, and falls.
- Ensuring racking and storage systems are safe and compliant.
- Protecting workers from exposure to hazardous substances.
- Meeting obligations under the Health and Safety at Work Act 2015 (NZ) and the Work Health and Safety Act 2011 (AUS).
Audits not only demonstrate compliance but also reduce risk, improve efficiency, and show staff that safety is a priority. You can learn more about common audit blind spots in our blog on 10 Overlooked Things to Include in Your Next Warehouse Safety Audit.
Key Areas of a Warehouse Safety Audit Checklist
Here are the main elements a typical warehouse safety audit checklist will cover:
1. Housekeeping and General Conditions
A clean, well-organised warehouse reduces risks significantly. Auditors will check for:
- Clear walkways and aisles free of obstructions.
- Adequate lighting throughout the warehouse.
- Proper signage for exits, fire extinguishers, and restricted zones.
- Spill control and waste management processes.
2. Racking and Storage Systems
Pallet racking failures can be catastrophic. Inspections will include:
- Correct installation and secure anchoring of racking.
- No visible damage, rust, or overloading.
- Safe stacking practices (pallets not protruding into aisles).
- Load ratings clearly displayed.
3. Material Handling Equipment
Forklifts, pallet jacks, and other lifting equipment must be in safe working order. The audit will cover:
- Forklift operator licences and training records.
- Daily pre-start checks and maintenance logs.
- Safe charging/refuelling areas.
- Pedestrian exclusion zones clearly marked.
4. Hazardous Substances Management
Warehouses often store chemicals, cleaning products, or dangerous goods. Auditors look for:
- Compliance with HSNO (Hazardous Substances and New Organisms) in NZ or WHS Regulations in Australia.
- Correct labelling and storage in approved containers.
- Updated Safety Data Sheets (SDS).
- Staff trained in spill response and PPE requirements.
5. Fire Safety and Emergency Preparedness
No warehouse audit is complete without ensuring workers can respond quickly in an emergency:
- Fire extinguishers serviced and accessible.
- Sprinkler systems tested.
- Clearly marked and unobstructed emergency exits.
- Evacuation drills completed regularly.
6. Manual Handling and Ergonomics
Auditors assess whether workers are protected from strain and injury:
- Training on correct lifting techniques.
- Use of trolleys, conveyors, or lifting aids.
- Workstations designed for safe movement.
7. Electrical and Machinery Safety
With warehouses relying heavily on machinery, electrical and plant safety checks are vital:
- All equipment tagged, tested, and maintained.
- Guarding on machinery is in place.
- Lockout/tagout (LOTO) procedures for servicing.
8. Worker Health, Safety, and Training Records
People are at the heart of warehouse safety. Expect auditors to review:
- Induction records for new staff and contractors.
- Ongoing training for forklift use, first aid, and hazard awareness.
- Records of incidents, near misses, and corrective actions. For guidance, see our blog on How to Conduct Effective Safety Inductions: A Step-by-Step Guide.
9. Contractor and Visitor Safety
Warehouses often have contractors and visitors onsite. Auditors will check:
- Induction processes for contractors.
- Site access controls.
- Supervision and safety protocols.
10. Technology and Reporting Systems
Increasingly, auditors want to see how data is captured and acted upon. Using digital safety management tools like SiteConnect allows businesses to:
- Complete warehouse safety audit checklists digitally.
- Record hazards, incidents, and corrective actions in real-time.
- Generate reports for compliance audits.
- Notify managers instantly of safety issues.
For example, our blog on The Hidden Value of Incident Reporting for Online Warehousing Safety Systems explores how capturing incidents digitally can transform safety culture.
How SiteConnect Helps With Warehouse Safety Audits
Traditional audits often involve paperwork, follow-up phone calls, and lost records. SiteConnect makes the process faster, more transparent, and more compliant by:
- Providing customisable digital checklists for warehouses.
- Allowing managers to assign corrective actions instantly.
- Storing training records, licences, and incident reports in one central system.
- Offering mobile accessibility so audits can be done onsite with photos, notes, and signatures.
By digitising your warehouse safety audit checklist, you not only improve accuracy but also build a culture of accountability and continuous improvement.
Final Thoughts
A warehouse safety audit isn’t just a box-ticking exercise. It’s an opportunity to protect workers, improve operations, and demonstrate compliance with Australian and New Zealand safety laws. By knowing what to expect and preparing with a comprehensive warehouse safety audit checklist, businesses can stay ahead of risks.
With SiteConnect, you can make audits simpler, smarter, and more effective. To learn more, explore our features page or check out our past blogs.
