The Ultimate Guide to Loading Dock Safety: Tips and Best Practices

Loading docks can be an extremely dangerous place for employees if the proper protocols are not in place. From falling off the dock to pedestrians getting hit by forklifts, it’s up to you as a safety manager or as the business owner to keep everyone safe on the job. 

Loading docks are used in a variety of industries, including manufacturing, retail, hospitality, food and beverage, and more. They’re one of our key points of commerce in the United States. In 2018 alone, loading docks handled an estimated 18.6 billion tons of goods worth nearly $19 trillion, according to the Bureau of Transportation Statistics.

Loading docks are in a flurry of constant movement of goods and the warehouse personnel who facilitate their handling. This constant motion can pose numerous threats to your staff’s safety. In fact, the National Safety Council estimates that out of the 4.6 million workplace injuries that occur in the United States each year, up to 25% of all industrial accidents occur at the loading dock.

Let’s take a look at the most common hazards that occur on the loading dock and how you can implement strategies to keep your employees safe.

The loading dock, also referred to as the loading bay, is an integral part of any warehouse, manufacturing facility, or distribution center–it’s where goods are loaded and unloaded. Loading docks are designed to be able to meet the height of the truck bed, with the help of dock plates or dock boards, so that loading and unloading are less burdensome to the carrier and dock loaders.

Forklift Accidents

From driving a forklift off the loading dock edge to falling off a dock board, preventing forklift accidents should always be top of mind. 

Loading Dock Separation Accidents

If dock boards or dock plates are not properly placed or if trailer creep occurs, accidents can occur for dock loaders and forklift operators.

Heavy Lifting Injuries

Cargo is often heavy, and without the use of lifting aids such as dollies and forklifts, injuries are common. 

Trailer Creep

Trailer creep occurs when trailers gradually move away from the dock due to the constant motion of forklifts entering and exiting them.

Collisions Between Workers 

Without constant communication between forklift operators, those working on the floor, and carriers, collision injuries are inevitable. 

Slips, Trips, and Falls

Without proper protocols, floors can be obstructed by packing supplies, tools, or goods. Inclement weather, oil, or accidental spills can cause floors to be slippery. The edge of the dock always poses the threat of falling.

Train Workers in Ergonomics and Use Ergonomic Material Handling Equipment

Manually lifting heavy loads can injure your workers. Make sure they know how to properly lift items (bending at the knees, not the back) and that they don’t lift items without assistance. Employees should always wear proper PPE, including high-grip gloves and footwear. 

There are also plenty of options to take the strain off of your workers with material handling equipment, including manual or electric pallet trucks, forklifts, pallet stackers, and ergonomic work positioners. 

Use Safety Markings and Fall Protection

Make sure to mark the edge of your dock in bright yellow tape or paint to help prevent falls. In addition, mark where it's unsafe to walk due to forklift traffic. When the dock is not in use, safety railings can also help prevent falls. 

Only Allow Certified Drivers to Operate Heavy Machinery

It is imperative to train and certify your drivers on the specific vehicles they operate. Forklifts have different controls from other industrial vehicles, and drivers are required to undergo extensive OSHA training. 

Establish Safe Standard Operating Procedures (SOPs)

Develop and enforce SOPs to ensure the safety of all employees. Some relevant SOPs to develop include: 

• Inspect and ensure loads are secure before handling.
• Do not enter the trailer until the light on your vehicle restraint system has signaled.
• When trailers are not attached to the dock, use a safety barrier.
• Remove pallets from rotation when they become damaged. 

Pad Sharp Corners

Frequently moving goods in and out of a facility can cause employees to accidentally run into sharp edges. Put some padding around those edges to prevent injury. 

Secure Loose Product

Make sure all of your product is secure before moving it. Smaller, loose product can cause tripping and falling, while larger goods can cause injury as your employees strain to lift the load.

Visual Communication Signs

Posting signs to remind employees of the safety protocols is a great way to keep safety top of mind throughout their shifts. 

Keep the Loading Dock Clean and Organized

Rain, snow, ice, oil, spills, and debris can cause slipping hazards on your loading dock. It’s imperative to keep floors clean and dry at all times. If spills occur, they must be cleaned up immediately. Make sure garbage receptacles are close by so that packing materials are disposed of quickly.

Invest in Reliable Vehicle Restraints

Vehicle restraints for your loading dock are a much more reliable solution than vehicle chocks. While OSHA may require wheel chocks, vehicle restraint systems can actually secure a trailer to the dock. Lights are used to inform truck drivers when it’s unsafe to move and inform forklift drivers when the trailer is secure and safe to board.

OSHA has strict requirements around loading dock safety. To learn more about OSHA’s requirements, take a look at guidance from the National Safety Council.

Zoro has all the products and equipment your business needs to ensure you’re OSHA compliant.

Dock Boards	Dock Plates	Dock Levelers	Dock Signaling Devices
Guarding (Dock Barricades, Guard Rails)	Bollards	Loading Nets	Caution Tape

Zoro has all the personal protective equipment your employees need to stay safe on and off the loading dock.

Head Protection	Eye Protection	Hearing Protection	Gloves

Loading dock safety can save your employees from potentially life-altering injuries. Start developing your loading dock safety plan today and hold frequent refresher courses for your employees. Find everything your business needs from the front office to the assembly line to the loading dock at Zoro.

Product Compliance and Suitability

The product statements contained in this guide are intended for general informational purposes only. Such product statements do not constitute a product recommendation or representation as to the appropriateness, accuracy, completeness, correctness, or currentness of the information provided. Information provided in this guide does not replace the use by you of any manufacturer instructions, technical product manual, or other professional resource or adviser available to you. Always read, understand, and follow all manufacturer instructions.