Key risks and safeguarding measures for safe access to automated warehouses
How a combination of safeguarding devices lead to safer access
Automated warehouses use stacker cranes, conveyors, shuttles, lifts, and automated storage and retrieval systems (AS/RS) to move goods with limited human intervention. Because these systems can operate automatically inside enclosed aisles, personnel access for inspection, fault recovery, cleaning, or maintenance must be carefully controlled.
The main risks include crushing or trapping by stacker cranes and transfer equipment, unexpected automatic restart, restricted visibility inside long warehouse aisles, multiple access points, and manual intervention inside areas normally operated automatically.
What safety devices do we recommend?
A typical safe-access concept combines machine guarding, coded key access, safety interlocks, and light curtains.
Machine guarding creates the physical boundary, key switches and interlocks control authorized entry and safe machine state, light curtains detect access where needed, and trapped or personal keys help prevent restart while personnel remain inside.
Together, they create a sequenced safety system that controls access, reduces unexpected start-up risk, and provides stronger protection than relying on a single safeguard.
Practical application of safety devices to automated warehouses
Manual faucet operation.
Recessed key switch
De-activation of the manual faucet operation.
Light curtains for body detection.
safety interlock
with control buttons
The key from the switch
is used for access request.
Automated storage and retrieval systems typically have access points at the ends of aisles and, in some cases, at mid-aisle locations. To comply with EN BS EN 528:2021+A1:2022, automatic operation must be switched off from outside the guarded area using a key switch.
Once automatic operation is disabled, the released key is used to unlock the door interlock and gain access to the aisle. The same key can also be used to enable manual crane operation from the cab where required.
Machine guarding defines the protected area, while light curtains can provide additional presence detection at selected access points. Normal automatic operation can only be restored after the access sequence has been completed and the key returned.
How has safety improved after the application of these devices?
After applying the combined safety devices, access to automated warehouse aisles becomes controlled, sequenced, and easier to verify.
The main improvements are:
- Automatic operation is disabled before entry, reducing the risk of unexpected movement.
- Access is restricted to authorized personnel through keyed or interlocked entry points.
- Safety interlocks link the access door to the machine safety system, so normal operation cannot resume while access conditions are not met.
- Light curtains and other detection devices add presence monitoring where open access points require additional protection.
- Manual crane operation can be controlled separately during maintenance or fault recovery, rather than allowing unrestricted automatic operation.
- Machine guarding clearly separates personnel from hazardous movement, creating defined safe and hazardous zones.
The result is a safer access process for inspection, maintenance, and fault recovery, with fewer opportunities for uncontrolled entry or unexpected restart.
Safeguarding standards and regulations for automated warehouses
Safety requirements for S/R machines
BS EN 528:2021+A1:2022
Addresses hazards linked to automated movement, aisle access, load handling, transfer points, and interaction with surrounding warehouse systems.
It is particularly important for defining the safeguarding approach around stacker cranes, automated aisles, access points, and maintenance intervention.
Guidelines for safety interlocking devices
ISO 14119:2024
ISO 14119 applies where guards, doors, or access points are fitted with interlocking devices.
It defines principles for selecting and designing interlocks so that access to a hazardous area is controlled and machine operation is linked to the status of the guard.
For automated warehouses, this is especially relevant for controlled aisle access, safety doors, and keyed access systems.
Safe use of work equipment
Directive 2009/104/EC
Focuses on the safe use of work equipment by employees during operation, inspection, servicing, and maintenance.
It is particularly relevant where personnel enter automated warehouse areas for fault recovery or maintenance and need protection from hazardous machine movement or unexpected operation.
Products used in this application:
Machine Guarding
Machine fencing ensures a physical barrier around machine and installations.
Light Curtains
Light curtains detect people entering machines and installations
Frequently asked questions about safeguarding warehouses for safe access
Automated warehouses can expose personnel to hazards from stacker cranes, conveyors, shuttles, lifts, AGVs, and other automated handling systems. The main risks include crushing, trapping, collision, entanglement, and unexpected machine movement during access or intervention.
Safe access is essential because automated systems can restart or move with little warning. Controlled access helps ensure that personnel can enter for inspection, fault recovery, cleaning, or maintenance only when the relevant equipment has been placed in a safe state.
Different devices control different parts of the risk. Machine guarding creates the physical boundary, interlocks and key switches control access, light curtains detect entry where needed, and trapped or personal keys help prevent restart while personnel remain inside.
Safety interlocks are installed on access doors and gates to link entry to the machine safety system. Access is only permitted when the required safety conditions are met, and automatic operation cannot normally resume until the access point has been secured again.
Machine guarding separates personnel from hazardous automated movement. It defines the protected zone around stacker cranes, conveyors, and other equipment, while designated access points allow controlled entry when required.
The system should be brought to a safe state before access, with automatic operation disabled and the access sequence controlled through appropriate interlocking or isolation measures. The objective is to prevent hazardous movement from resuming while personnel are still inside the safeguarded area.
Key references include BS EN 528:2021+A1:2022 for rail-dependent storage and retrieval machines, ISO 14119:2024 for interlocking devices associated with guards, and Directive 2009/104/EC for the safe use of work equipment.
Controlled manual operation may be required during fault recovery, inspection, testing, or maintenance. In these situations, access and operating mode should be managed through the safety system so that automatic operation remains disabled while controlled intervention takes place.
