Loading docks are inherently dangerous, says WSPS Warehouse Specialist Norm Kramer. “The mix of trailers, workers, pallets, forklifts, and fast-paced loading and unloading can present many hazards.” These include risk of falls, vehicle collisions, struck-by injuries, crushing injuries and more.

“This is why the loading dock requires close and careful scrutiny during workplace inspections by your joint health and safety committee,” says Norm. And, not all hazards may be immediately obvious.

Norm provides a checklist that will help you identify hazards and gaps in five crucial areas of loading dock safety. 

Loading dock checklist

“These five aspects of loading dock safety are often linked to worker injuries and require special attention,” says Norm.  Once identified, you’ll be able to put control measures in place to protect your workers.

1.  Vehicle securement. “Trucks and trailers parked at your loading dock can leave the dock prematurely, even during loading/unloading operations, putting workers at risk for catastrophic falls,” says Norm.

• Is vehicle securement adequate, and if so, is it being used?
• Has the dock lock restraint mechanism been maintained within the last year, or more frequently based on the manufacturer’s recommendations?
• Is the mechanism attached to the Rear Impact Guard (RIG) of a truck or trailer to enhance safety during loading and unloading operations?
• If the RIG cannot be secured – for example, when a liftgate makes it inaccessible – are there other suitable restraints, such as wheel chocks, placed in front of the rear tires? “Ensure the wheel chocks are in good condition, not hidden by snow, and accessible,” says Norm.
• Another effective way to prevent unwanted movement of dropped trailer loads is to use a glad hand device to prevent brake release and premature departure. 

2.  Truck movement. Drivers of trucks reversing toward loading docks have minimal visibility and many blind spots, putting outdoor workers at risk of struck-by incidents. “Take a moment to observe vehicle movement outside the loading dock from a safe location,” suggests Norm.

• Are trucks backing in squarely towards the loading dock?
• Are there painted lines on the pavement or other means, such as directional lighting, to guide drivers to optimal locations?
• Are there any workers taking short cuts by walking between reversing trucks and the loading dock?
• Are outdoor workers wearing appropriate high visibility apparel that makes them easily seen by drivers?
• Are the dock bumpers in good condition to absorb the shock of a vehicle striking the building?

3.  Housekeeping. “Take a close look at the interior loading dock,” says Norm. “It is not uncommon to see pallets dropped off in lift truck paths if the staging area is full, space is limited, or operators are not following storage best practice. The interior loading dock often turns into a chaotic obstacle course filled with pallets, lift trucks, and workers, increasing the risk of struck-by incidents.”

• Is there a way to increase space around the dock to permit pallet staging?
• Are pallets unloaded to the staging area or moved away from the dock to minimize obstructions?
• Are there enough operators to move pallets to a designated storage in a timely manner?
• Can existing space be optimized? “For example, some businesses have installed two level racking directly above the loading dock to use as overflow for lighter pallet loads,” notes Norm.

4.  Smooth transfer of pallets to and from the trailer. “Lift truck operators are continuously moving back and forth from the loading dock to transport truck trailers to move pallets. Gaps or uneven surfaces can put both forklift equipment and operators at risk,” says Norm.

• Are dock levelers at the same height as the trailer to ensure safe and efficient movement of materials between the loading dock and the transport vehicle?
• Has the driver/shunter dropped the air ride suspension on the trailer prior to setting the brakes at the dock? This action lowers the trailer height, reducing the chance of the trailer walking forward during loading and reducing the forward forces on the trailer landing gear, so there is less chance of collapse. If an air ride trailer is too high in relation to the dock height, the lift truck operator will have less steering control, and will experience a bump at each pass causing discomfort and possibly permanent musculoskeletal damage.
•  Are the forks of the lift trucks properly positioned before entering the trailer? If the forks are pointing downwards or are too low, they may make unwanted contact with the dock leveler.
• Is there a risk that workers will get their feet crushed at the edge of the dock leveler? Fit dock levelers with toe guards to reduce this risk. 

5.  Pedestrian movement. “In general, the closer people walk near the loading dock doors, the greater the risk they will be struck-by a lift truck operator with limited vision. While it may be impossible to eliminate all pedestrians, the loading dock shouldn’t be a throughway,” explains Norm. 

• Is there a walkway situated directly through loading zones with high equipment traffic? It’s better to direct people onto a path that is away from a busy loading dock area.
• Are transport truck drivers walking through the loading dock area? “Many businesses keep truck drivers away from danger areas by restricting their movement with a barrier, while providing access to a comfortable rest area,” says Norm.

How WSPS can help

 Consulting

WSPS consultants are on hand to help you identify and address hazards on loading docks and improve your health and safety programs.

Resources

• Loading Docks and Warehouses (guide)
• Safety Tips: What should employees know about loading and unloading a truck or trailer safely? (video)
• Loading and unloading trailers safely (article)
• Fines & Penalties in Warehousing & Distribution (pre-recorded webinar)

 The information in this article is accurate as of its publication date.