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nrspp.org.au

February 2020 | 1

The Question

What is the issue and how do we reduce the risks?

This Q&A has been produced to help delivery truck drivers and their wider organisations reduce the safety risks at loading docks.

Scope of the problem

What is a loading dock? 1-5 Loading docks are the main arrival and departure areas in a warehouse for truck or van deliveries. A loading dock is where the loading and unloading of goods and equipment takes place and is therefore typically shared by trucks, forklifts and workers.

Loading Docks: Managing the safety risksQ&A:

Flush docks, where the opening is flush with the face of the dock

Saw tooth docks, where the driveway to the dock is on an angle

Depressed docks, where the driveway to the dock is sloped

Each kind of dock presents potential safety issues which need to be controlled for. For example, open docks are exposed to inclement weather and debris blowing onto the loading dock floor, which can create a slipping hazard. Depressed docks carry the risk of a truck driver colliding with the loading dock wall, due to the angle of driveway. However, while these specific dock types present their own unique challenges, all loading docks carry inherent safety risks which make them one of the most dangerous spots in a warehouse. This is due to the combination of hazards, number of activities and interactions between trucks, forklifts and people that occur in this confined area1.

Enclosed docks, where the truck parks inside to deliver goods

Open docks, where the sides of the dock are exposed to the air

There are several kinds of loading docks3:

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nrspp.org.au

February 2020 | 2

What safety technologies are available for my loading dock?

• Dock automation and management systems

• Vehicle restraints

• Dock bumpers

• Dock levelers

• Dock hoists

• Dock doors

• Dock shelters and seals

• Ramps

• Wheel and trailer guides

• Bollards and barriers

• Dock lighting

See www.safetech.com.au/ for more information

What are the safety risks in a loading dock?

Loading dock injuries make up some of the most serious and fatal of all warehouse injuries1. It is important for workers and managers alike to recognize these safety risks in order to manage them.

Trailer creep 1,6 Potentially one of most dangerous things to occur at a loading dock is trailer creep. When a truck parks in a loading dock, forklifts and workers drive in and out of the trailer to load or unload the goods. Trailer creep is where an unrestrained trailer drifts away from the dock during the unloading and loading process. If the trailer drifts too far from the loading dock, this can result in the forklift dropping between the dock and the trailer.

The truck can also separate from the loading dock when a driver pulls away while the truck is still being loaded/unloaded. This can happen when a driver is distracted or forgets to observe traffic lighting signals on a loading bay which prohibit the movement of the trailer.

Collisions between workers and vehicles 1-2,7 Loading docks can be a hive of activity, where trucks, forklifts and workers all share the same space. Where vehicles are reversing, loading and unloading goods, all workers should be mindful of the hazards around them in order to avoid injury. Collisions between workers and vehicles can occur due to poor visibility, traffic congestion, distracted workers, time pressure and inadequate safety management.

Trips, slips and falls 7-8 Loading dock floors – particularly open docks which are exposed to the elements – can easily accumulate water and other debris. If the floors are not kept clean and clear, they can quickly become a tripping, slipping or falling hazard. This includes hazards inside the trailer, which are easy to trip over in such a confined space, especially if the lighting is poor.

Falling from the edge of the loading dock is also a serious hazard for both forklift drivers and foot workers. This can be caused when the trailer unexpectedly separates from the loading dock, when workers unsafely jump from the dock, or when they are distracted. Some companies have also experienced their workers falling sideways off the tailgate of the truck where there are no barriers or falling backwards off the tailgate while rolling out dollies. This usually happens when the worker is concentrating on unloading instead of looking in front of them.

What are some safety measures for reducing these risks?

By implementing the appropriate safety measures in place, companies can take steps towards making their loading docks a safe working environment for all workers. After all, your workers are – above all – your most important asset.

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nrspp.org.au

February 2020 | 3

Restrain trucks for loading/unloading 1 It is important to prevent trailer creep by restraining all trucks when they stop at the loading dock. Trucks should be secured with a vehicle restraint system, such as wheel chocks and trailer locks, and forklift drivers should be required to visually inspect the restraint before driving onto the trailer. Any additional safety measures such as bumpers and mirrors can also help the driver to safety park their truck. This will ensure the truck is secure and prevent unnecessary falls from the loading dock.

Separate vehicles from people 7-10 The most effective way to prevent collisions between vehicles and foot workers is to work towards removing traffic hazards. The layout of the warehouse can be designed in a manner that keeps interactions between vehicles and people to a minimum.

A cost-effective way to do this is by marking the floor using a few rolls of black and yellow safety striping to indicate where the vehicles can go and where people can go. This is a simple, but effective way to provide visual warning signs for workers.

For exclusion zones where only vehicles are allowed, bollards or safety railings can prevent people from stepping out into oncoming traffic. This is especially important in areas where loading and unloading is taking place. In loading zones, only the driver and a spotter should be anywhere near the trailer while it is being secured in its designated area and then loaded/unloaded. The more people standing near the loading zone, the higher the risk that someone will be injured.

For an extra layer of safety, some companies may choose to invest in an Intersection Warning System for their loading docks. Intersection Warning Systems detect oncoming traffic at intersections and blind corners and alert approaching traffic of the danger ahead with LED lights.

Keep your dock well maintained 7,9 The loading dock should be kept well maintained to protect workers from injury due to trips, slips and falls.

The nature of some loading dock designs – such as open docks – means that they are exposed to inclement weather (e.g., rain, hail, dust, etc.). Wet floors due to inclement weather can cause workers to slip and injure themselves. It is therefore important for the floor to be kept clean and dry at all times. The dock floor should be treated with a non-skid coating if it is exposed to the outside weather.

The dock floor should also be kept clear of debris, such as materials and packaging. Goods for loading/unloading can become tripping hazards or cause forklifts to maneuver around goods which have been haphazardly placed on the floor. Goods for loading/unloading should be placed inside a designated marked zone and any debris outside of the marked zone should be kept clean and clear.

The structure of the loading dock itself should also be maintained to prevent injury. For example, the floors should be checked for cracks and uneven surfaces, the dock doors should be inspected, identified hazards such as sharp corners or overhead beams should be clearly marked, and guard rails should be maintained to protect the dock drop off. Guard rails can also be attached to the sides of truck tailgates to prevent workers from falling sideways.

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nrspp.org.au

February 2020 | 4

Improve visibility 8-10 Good visibility is essential in and around loading docks, for both drivers and foot workers.

The loading dock area should be well-lit so that workers can see what they are doing and avoid potential hazards before they cause an injury. Not only should the loading dock area be well-lit, but the approach to the loading dock area should also have good lighting for the driver to see their approach, and the inside of the trailer should also be well-lit. This includes the edge of the loading dock, which presents the most danger to workers.

Not only is good lighting important in and around the loading dock, but so is blind spot visibility. A trained spotter can provide assistance to forklift and truck drivers by guiding them as they back up, enter and exit the trailer and pass other vehicles. However, it is important for spotters to be standing at a safe distance from the vehicle to prevent injury to themselves. Some companies may choose to replace spotters with driver assistance technologies such as blind spot detection, collision warning systems and reversing cameras. Flashing lights and reversing alarms can also be utilized to alert other drivers and foot workers of the approaching hazard.

To protect foot workers, it is also essential for them to wear safety clothing such as reflective vests to make them more visible to others. Every single person in the loading zone should be visible to others before loading/unloading can begin. Simple changes in procedure can also improve how workers see the hazards surrounding them. For example, training workers to unload trucks in a forward facing direction instead of backing out can prevent unnecessary trips and falls.

Continuous monitoring and improvement 9 The safest companies in the world are continuously monitoring and improving their knowledge, training and technology. An effective safety management system not only has the best policies and procedures written on paper, but it also emphasises a positive safety culture, encourages communication between workers and managers, ensures workers are appropriately trained and certified, and does not hesitate to improvise on their guidelines when something isn’t working.

Continuously monitoring and improving on safety measures at your loading dock will ensure your employees are working in a safe environment. Working in a safe environment will enhance worker morale and wellbeing, productivity and the overall effectiveness of your organization.

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nrspp.org.au

February 2020 | 5

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“We don’t manage all of the loading docks we use – how can we ensure the safety of our drivers?”

A common issue for companies delivering to shared loading docks is that they are often managed by a corporate body and they have little say in the safe design of these loading docks. Common issues at these loading docks which may be difficult to change include the following:

• Inadequate maintenance

• Traffic congestion

• Poor lighting

• Blind spots

• Rushing

• Frustration

How then can we maximise the safety of our workers if the design and operations of the loading dock cannot change?

• Arrange a meeting between the loading dock users and the owner of the dock to discuss the safety issues. You may find that the loading dock owner had little awareness about the safety issues and may be willing to compromise on some improvements. These discussions should be ongoing.

• Invest in a fleet of trucks with in-built safety features, such as reversing cameras, blind spot detection and collision avoidance.

• Adequately train all of your workers in loading safety and ensure they can identify safety issues which arise at shared loading docks so they can be communicated to management.

• Ensure your own company’s safety management system is up-to-date and is continuously improving based on the experience of your workers.

2 years in the making, 5% grater than B double, 50% more capacity than standard single trailer, fixed Mez deck, new loading process…

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nrspp.org.au

February 2020 | 6

References

1. Prahler, M 2012, Loading dock safety, Retrieved from https://www.supplyht.com/articles/96524-loading-dock-safety

2. Verge Safety Barriers 2019, 10 Tips that Make Loading Docks Safer for Your Workforce, Retrieved from https://www.vergesafetybarriers.com.au/10-tips-that-make-loading-docks-safer-for-your-workforce/

3. Adaptalift Group 2013, Different types of loading docks, Retrieved from https://www.aalhysterforklifts.com.au/index.php/about/blog-post/different_types_of_loading_docks

4. National Institute of Building Sciences 2019, Loading dock, Retrieved from http://www.wbdg.org/space-types/loading-dock

5. Whole Building Design Guide 2016, Loading dock, Retrieved from https://www.wbdg.org/space-types/loading-dock

6. Verge Safety Barriers 2019, How to properly layout your work area, Retrieved from https://www.vergesafetybarriers.com.au/how-to-properly-layout-your-work-area/

7. McCrea, B 2015, Protecting workers at the loading dock, Modern Materials Handling, vol. 70, no. 12, pp. 36-39.

8. Rite-Hite 2019, Loading dock safety: 10 vital tips to maximize safety at the loading dock, Retrieved from https://www.ritehite.com/en/am/news/2018/blog/loading-dock-safety_10-vital-tips-to-maximize-safety-at-the-loading-dock

9. Poulter, B 2014, Improve loading dock safety: 6 key tips, Food Manufacturing, Rockaway

10. Verge Safety Barriers 2019, Exclusion zones, Retrieved from https://www.vergesafetybarriers.com.au/exclusion-zones/

NRSPP acknowledges the contributions of:

• Kurt Clark – ANZ HSE Manager – Tip Top

• Andrew Starr – Managing Director – ALDI Derrimut