Safety alert issued after fast food employee struck on the head by falling boxes

WorkSafe Victoria recently issued a safety alert about the health and safety risks of stacking boxes in cold rooms following an incident in which a young employee was struck on the head by falling boxes.

The employee, who was restocking a cold room in a fast food restaurant, suffered a concussion and needed medical treatment. The boxes of frozen fries and patties weighed up to 16kg each and were stacked about 2 metres high.

Restocking boxes in cold rooms can lead to a risk of injury, and the safety alert noted that, without the appropriate controls in place, there’s a risk of hazardous manual handling, which can cause musculoskeletal disorders (MSDs), and/or being struck or crushed by falling boxes.

Furthermore, handling boxes in cold rooms can become hazardous manual handling as employees are:

• using repeated and high force
• putting their body in awkward postures
• working with boxes stacked above shoulder height
• working with boxes that are hard to grip
• working in cold temperatures, which can restrict mobility and grip

The alert provided a number of recommended ways to control risks associated with restocking cold rooms. 

• Place smaller orders to avoid overstocking cold rooms. This will also lessen the amount of manual handling needed per delivery.
• Regularly check shelves to make sure they’re sound and stable.
• Work with suppliers to design boxes that are easier to handle. For example, boxes with cut-out handles.
• Make sure the boxes can fit on shelves without sticking out.
• Put frequently used boxes somewhere easy to access. Use raised platforms or shelves to make it easier to access boxes.
• Put heavier boxes at a height that is easy to access. Employees shouldn’t need to reach up or crouch down to access a box.
• If possible, add another cold room to reduce the amount of stock in one room.
• Talk to suppliers to see if delivery drivers can help store away boxes using mechanical aids. This will mean less double handling of boxes.
• Have clear pathways in cold rooms.
• Use mechanical aids like trolleys when restocking shelves.
• Provide protective gear, such as thermal gloves, to employees who go into cold rooms.

Employers also have duties under the Occupational Health and Safety Regulations 2017. These include:

• Identifying any hazardous manual handling an employee has done or will do.
• Eliminating any risk of MSDs associated with hazardous manual handling, so far as is reasonably practicable.
• If it is not reasonably practicable to eliminate the risk of MSDs, reducing the risk so far as is reasonably practicable by:
  • altering the workplace layout, environment or systems of work
  • changing the things used in hazardous manual handling
  • using mechanical aids
  • combining any of the above risk control measures