Don’t overlook one of the most hazardous areas of your warehouse

It’s Monday morning, and you have been selected to perform a safety inspection of the loading dock area and report back at the next health and safety committee meeting on your findings.

As you walk by the loading dock, everything appears to be fine. But be careful not to skip over this area too quickly—there may be hazards that are not immediately obvious.

Pay special attention to these areas:

Vehicle securement

Trucks and trailers parked at the loading dock can leave prematurely, even during loading and unloading, putting workers at risk of catastrophic falls.

• 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 the truck or trailer to enhance safety during loading and unloading?
• If the RIG cannot be secured—for example, when a liftgate makes it inaccessible—are 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.
• Another effective way to prevent unwanted movement of dropped trailer loads is to use a glad-hand lock to prevent brake release and premature departure.

Truck movement

Drivers reversing toward loading docks have minimal visibility and many blind spots, putting outdoor workers at risk of being struck. Take a moment to observe vehicle movement outside the loading dock from a safe location.

• Are trucks backing in squarely toward the loading dock?
• Are there painted lines on the pavement or other guiding mechanisms, such as directional lighting, to help drivers position properly?
• Are any workers taking shortcuts 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?

Housekeeping

Take a close look at the interior loading dock. 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 practices. The interior loading dock often turns into a chaotic obstacle course filled with pallets, lift trucks and people, increasing the risk of 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 designated storage in a timely manner?
• Can existing space be optimized? Some businesses have installed two-level racking directly above the loading dock to use as overflow for lighter pallet loads.

Smooth transfer of pallets to and from the trailer

Lift truck operators are continuously moving back and forth between the loading dock and transport trailers. Gaps or uneven surfaces can imperil both equipment and operators. Look at the following:

• Are dock levelers at the same height as the trailer to ensure safe and efficient movement of materials?
• Has the driver or shunter dropped the air-ride suspension on the trailer before setting the brakes at the dock? Lowering the trailer height reduces the chance of the trailer shifting forward during loading and minimizes forward forces on the landing gear, reducing the risk of collapse. If an air-ride trailer is too high in relation to the dock, the lift truck operator will have less steering control and will experience bumps at each pass, leading to discomfort and possibly permanent musculoskeletal injuries.
• Are the forks of the lift trucks properly positioned before entering the trailer? If the forks are pointing downward 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.

Pedestrian movement

In general, the closer people walk near loading dock doors, the greater the risk of being struck by a lift truck operator with limited vision. While it may be impossible to eliminate all pedestrian traffic, the loading dock shouldn’t be a thoroughfare.

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