How to Eliminate Floor Hazards in Your Production Facility
Why Floor Hazards Are a Serious Workplace Risk? Obstacles on the floor slow down work, cause injuries, and increase liability. When people fall or trip at work, it's often due to objects left in walkways or tools placed without thought. These incidents can result in worker downtime, damaged stock, and legal trouble.
In production areas, risks multiply in high-traffic zones. Fast-paced movement, heavy machinery, and limited visibility all contribute to the danger. If an emergency exit is blocked or a cable is left exposed, the risk isn't hypothetical—it’s immediate.
A single mishap can result in:
- Injury claims
- Equipment damage
- Missed deadlines
- Staff shortages
- Higher insurance premiums
Managing floor hazards isn’t just about ticking boxes. It directly affects safety, productivity, and your bottom line.
How to Conduct a Floor Hazard Risk Assessment
Break the task down into clear steps. A basic table structure can help you record what you see and what might happen next.
| Area | Existing Hazards | Potential Hazards |
| Loading Bay | Loose packaging, oil stains | Stacked pallets near vehicle paths |
| Machine Zone A | Coiled hoses | Overfilled bins near walking area |
| Exit Corridor | None visible | Overflow from storage room |
| Assembly Section | Extension cords | Tools left beside workstations |
Walk the site section by section. Assign someone to each zone if it's a large facility. Look for any object, tool, or spill that might interfere with movement.
Potential hazards include anything that isn’t an issue yet—but might become one if left unchecked. A broom leaning against a wall. An unmarked wet spot. These are problems waiting to happen.
Finish with a compiled report. Use it to track which hazards need action now, and which ones require longer-term planning.
High-Risk Areas to Inspect Closely
Certain parts of a facility tend to gather the most hazards. These zones should be prioritised in your inspection.
• Access Paths and Corridors: Obstructions in movement paths are common. Loose mats, delivery trolleys, and buckets should never be left here.
• Emergency Exits: Anything blocking an exit—no matter how small—can lead to injury or prosecution. Exits must remain clear at all times.
• Wet Zones and Spill Areas: Water, oil, or chemicals on the floor create major slipping hazards. These need dedicated drainage or matting.
• Active Work Areas: The busier the zone, the more clutter tends to build up. Even temporary obstacles create problems.
• Shared Equipment Areas: Cables, hoses, and movable machinery often span across walkways. If they’re not managed, people trip.
Each zone has different needs. What works for a dry packaging area won’t work for a wet processing section. Tailor your controls accordingly.
Common Causes of Floor Hazards in Production Areas
A disorganised floor isn’t always due to carelessness. Sometimes it’s systemic. Below are typical sources of hazards:
• Inadequate Storage Space: When staff don’t have anywhere to put items, they leave them on the floor. Overflowing shelves are a red flag.
• Temporary Tools and Equipment: Tools used on-the-go often get set down "just for a moment"—and then stay there.
• Poor Waste Management: If bins are full or not clearly placed, rubbish ends up on the floor. That includes shrink wrap, packaging foam, and food waste.
• Trailing Cables and Hoses: Unsecured cords are one of the most common causes of workplace falls. Even short-term use requires proper cable management.
• No Safety Culture: When floor safety isn’t enforced, workers tend to stop noticing clutter. The norm becomes dangerous.
Spotting the cause helps direct the right fix. Skipping this step usually means the hazard returns later.
Staff Awareness and Training
Rules don't work if no one knows them. Every worker who uses the floor needs to be told exactly what’s expected. That includes:
• What must never be left on the ground
• Where tools and materials belong
• Who to notify if there’s a hazard
Training doesn’t need to be lengthy. Short, clear sessions followed by visible reminders often work best. It’s also worth reinforcing that safety is a shared responsibility.
A workplace with trained staff needs fewer warnings. People move smarter when they know what’s at stake.
Cleaning Schedules and Accountability
A cleaning schedule is more than a chore list. It creates structure and accountability. Use it to set clear times for hazard checks, tidy-ups, and bin disposal.
Each task should be assigned to a specific person. A rotation helps spread responsibility without overloading anyone. Include a final check at the end of each shift.
Here’s a basic example:
| Time | Task | Responsible Person |
| 08:00 | Clear all accessways | Shift Leader A |
| 12:00 | Empty waste bins | Floor Worker B |
| 16:30 | Check emergency exits | Safety Officer |
When the schedule is followed consistently, floor hazards have less chance to build up.
Designated Storage and Organisation
Tools, boxes, and machinery all need a home. If staff have to guess where things go, items get left wherever there’s space.
Consider these storage upgrades:
- Wall-mounted tool holders
- Stackable containers with labels
- Shelving that fits around equipment
- Floor markings to indicate drop zones or no-go areas
- High-visibility signage for all storage zones
A small investment in better storage often prevents repeat hazards.
Temporary Hazard Management
Some hazards can’t be removed, but they can be controlled. That’s where temporary safety solutions help.
- Cable covers protect foot traffic from exposed cords.
- Anti-slip tape increases traction on problem surfaces.
- Portable mats help with spills and water-prone zones.
- Barrier cones or signs alert workers to short-term risks.
The key is visibility. Hazards that are clearly marked are less likely to catch someone off guard.
Waste and Rubbish Management
Bins must be available in the right places. Staff shouldn’t need to walk far to dispose of waste. Each area should have a bin suited to the type of rubbish it generates.
- Cardboard and plastic wrap near unpacking areas
- General waste bins beside workstations
- Spill kits or oily rag containers in maintenance sections
Overflowing bins often mean they’re too small or emptied too rarely. Fix both, and rubbish won’t make it to the floor.
The Role of Matting in Floor Safety
Mats aren’t just for entrances. When selected properly, they support safety in multiple zones:
| Area | Recommended Mat Type | Purpose |
| Wet zones | Rubber safety mat | Drainage and slip resistance |
| Standing workstations | Anti-fatigue mat | Reduces strain and fatigue |
| Entrances | Absorbent entrance mat | Keeps dirt and moisture out |
| Temporary setups | Interlocking or safety runners | Quick coverage, easy removal |
High-quality matting prevents slipping, absorbs moisture, and improves comfort. It's one of the simplest ways to improve floor safety.
Signs Your Workplace Needs a Safety Upgrade
Still unsure if things are under control? These warning signs point to bigger problems:
- Repeated near-misses or trip reports
- Tools regularly left on the floor
- Workers complaining about clutter or unsafe areas
- Overflowing bins or full walkways
- Wear patterns in floor surfaces or mats
- Mat edges lifting or sliding out of place
Each sign points to an area worth reviewing. Waiting for an accident isn’t worth the risk.
When to Consider a Redesign or Storage Upgrade
Sometimes, the floor layout or storage setup can’t keep up with demand. If workers keep running out of space, it’s time to rethink the setup.
Indicators include:
- Storage areas constantly full
- Equipment blocking movement zones
- Materials stored in improvised locations
- Poor access to bins, shelves, or exit paths
In some cases, reorganising current storage is enough. In others, it may call for shelving upgrades, off-site storage, or even layout changes.
Getting input from staff helps. They see what doesn’t work long before management does.
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Some areas to focus on when assessing floor hazards are:
- Access: Obstacles make access more difficult, and sometimes even dangerous. The risks are compounded by the fact that people tend to get stuck in accessways where there are obstacles. The number of people using an area is directly related to the level of risk, which is why obstacles in high traffic entranceways are the most dangerous hazards.
- Trip hazards: One fall in the workplace can lead to a list of legal problems that nobody wants to confront. Anything on the floor, particularly cabling or work-related materials that often accumulate, are serious risks.
- Materials hazards: Some materials and types of equipment are serious safety hazards, particularly if the materials are combustible or the equipment relates to industrial safety issues. Putting some materials in the wrong places can also be a breach of industrial safety regulations.
- Safety and emergency exits: Anything that obstructs an emergency exit is not only dangerous but illegal. Even a simple food wrapper on the floor is a breach of safety regulations as it could cause someone to fall while using the exit. Blocking an emergency exit with floor obstacles is a serious offence that often ends in prosecution.
- Busy work zones and temporary floor obstacles: Although these areas are usually kept clear by those using them, the fact is that the busier an area is, the less clutter you want. Even temporary floor obstacle can be real trouble.
- Training: Ensure all users of the floor are aware of the requirement to keep it free of obstacles. Spend time going over exactly what is expected and reiterate that it is their legal obligation to comply. Use training to ensure that workers are not bringing any materials onto the floor without knowing exactly where it will be stored.
- Make a schedule...and stick to it: A schedule will let everyone know what needs to be done and when, as well as making sure someone is accountable if those things aren't done. The schedule should assign each job to a single person and include someone each day to make sure everything has been done at the end.
- Delegate a person to keep an eye on the problem: Once you have your schedule made, you will know who is in charge of each aspect of the cleanup. You should also delegate someone to be in charge of keeping the schedule updated and being a point of contact for employees. This could be your OHS person or someone senior who is aware of OHS issues in detail.
- Check for any temporary floor hazards: Cables and mobile equipment are common temporary hazards that must be guarded against. Areas must be fully secure and no risk to foot traffic or industrial vehicle movement. Any cables that need to trail across the floor should be covered with a cable cover - even if they are only there temporarily.
- Provide proper storage: Make sure your workers know where to return items when they are done, whether that's putting machinery back or stacking boxes in a certain place. Storage isn't just important for tools, too. Bins are important for keeping floors clear, as they provide storage for rubbish and mess. Lastly, make sure all storage units are clearly signposted, so workers still follow your regulations when you aren't there to guide them.
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