Why Stairway Safety Matters in Warehouses

Warehouses experience high foot traffic, equipment movement, and frequent material handling. Stairways used by forklift operators, pallet carriers, and maintenance crews are especially vulnerable to slips when liquids, dust, or debris accumulate. OSHA reports indicate that falls on stairways are among the leading causes of lost‑time injuries in industrial settings. This makes selecting the right anti‑slip surface critical — not just for compliance but to protect workers and maintain productivity.

What Are Fish Eye Plates?

Fish eye plates are metal sheets with raised indented “fish eye” patterns that create multiple contact points between footwear and surface. These textures significantly increase friction coefficients compared to smooth surfaces, even when wet. Studies indexed by Google Scholar demonstrate that mechanical traction textures maintain higher slip resistance under lubricated conditions than many surface coatings or tapes. When used on stair treads and landings, fish eye plates enhance safety without compromising durability.

Materials and Design Considerations

Choosing the correct material and design for fish eye plates depends on environmental exposure and load expectations:

• Stainless Steel (304/316) — Durable and corrosion‑resistant for wet or chemical environments.

• Aluminum Alloys — Lightweight and strong for indoor dry applications.

• Galvanized Steel — Cost‑effective for standard warehouse stairways.

Design parameters such as raised pattern height, open area ratio (for drainage), and plate thickness impact traction performance. ASTM International’s standards on surface texture and slip resistance testing provide benchmarking methods to verify performance before installation. Refer to ASTM International for detailed specifications on testing protocols.

Internal Resource Links

For related applications and design guidance, see:  Maintenance Area Anti‑Slip Metal Panels,  Perforated Metal Panel Design Guide,   and Textured Sheet Solutions for Extreme Environments.   These articles cover engineered textures, installation strategies, and performance criteria applicable to stairway safety.

Case Study 1: Warehouse Stairway Retrofit in Midwest Distribution Center

A large distribution warehouse in the U.S. Midwest noticed an increase in slip incidents on back‑of‑house stairways used by order fulfillment staff. Traditional non‑slip tapes wore off within weeks due to heavy use and exposure to spilled liquids. The safety team recommended fish eye plates for stair treads and landings, fabricated from marine‑grade stainless steel. Following installation, slip incident reports fell by 74% in the first quarter, and custodial staff reported easier cleaning due to the drainage capability of the patterned surface.

Installation Best Practices

Successful installation of fish eye plates on stairways involves several important steps:

• Preparing existing stair surfaces by removing loose coatings and debris.

• Ensuring the substrate is level and secure before plate application.

• Using corrosion‑resistant fasteners that match the plate material.

• Maintaining flush transitions at tread edges to prevent trip hazards.

Proper prep work and installation reduce long‑term maintenance and enhance surface performance, especially in high‑traffic warehouses.

Case Study 2: Cold Storage Warehouse Stairway Upgrade

A cold storage facility in Canada experienced frequent slips on stair landings due to condensation and icy conditions. Standard tread covers and gritted coatings failed to maintain traction, leading to several near‑miss incidents. Management installed fish eye plates with textured raised patterns and increased open area for drainage. Post‑installation testing showed significant improvement in slip resistance, lowering incident rates by 81% during the first winter season. Workers reported greater confidence navigating steps, particularly in colder conditions.

Standards and Compliance

Warehouses must align safety upgrades with recognized frameworks. OSHA walking‑working surface standards emphasize traction systems that exceed minimum friction requirements. ISO guidance on surface performance benchmarks helps define measurable slip resistance goals. Verified surface friction using ASTM test methods provides data for compliance documentation, strengthening audit outcomes and reducing liability exposure.

Maintaining Traction and Durability

Even engineered surfaces require maintenance to sustain performance. Regular cleaning removes built‑up debris and ensures open patterns remain clear for drainage. Scheduled inspections should check for plate loosening, wear, or corrosion, especially in areas exposed to frequent liquid contact. Low‑pressure washdowns and manual brushing keep surfaces performing at peak levels.

Comparing Alternatives: Tapes, Coatings, and Engineered Plates

Temporary solutions like anti‑slip tapes, abrasive coatings, or paint textures offer short‑term traction but generally deteriorate quickly under heavy use. Studies on performance surfaces indexed on ScienceDirect show that textured metal plates provide more consistent friction and resist wear under industrial loads. Engineered plates also avoid the frequent reapplication costs associated with coatings or tapes.

Return on Investment

While fish eye plates may have higher upfront costs than temporary alternatives, the long‑term benefits — reduced slips, fewer injury claims, lower maintenance, and improved worker confidence — often result in measurable ROI. Facilities that invest in engineered traction systems typically see cost savings through incident prevention and reduced downtime.

Future Trends in Stairway Safety

Emerging designs in surface engineering explore hybrid composite plates and nano‑textured surfaces that further enhance traction and cleanability. Integration with sensor systems to monitor surface wear and environmental conditions offers a proactive approach to safety maintenance in busy warehouses.

Conclusion

Fish eye plates offer a reliable, engineered solution for improving stairway safety in warehouses. By providing enhanced traction, drainage, and durability, they significantly reduce slip risks and support compliance with industry safety standards. Proper installation and maintenance ensure lasting performance that protects workers and improves operational reliability.

Contact & Call to Action

If your warehouse needs a reliable traction upgrade for stairway safety, contact our team for custom design and installation guidance.

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