What safety precautions should you take using forklifts around elevated loading docks?

Loading docks are among the most hazardous areas within any facility. Around a quarter of all facility-related accidents occur at or around the loading dock as there are vehicles moving around, pedestrians and an elevated platform. These accidents include:

• Forklifts and pallet jacks going over the edge of the dock
• Vehicles backing up too hard to the dock
• People being trapped between a vehicle and dock
• Products being spilled off the dock
• Pedestrians falling off the dock ledge
• Bridge plate damage due to incorrect usage (e.g. load too heavy, bridge plate not secured, bridge plate not lapped over the dock far enough, etc)
• Reversing vehicles hitting other vehicles in the vicinity
• Vehicles hitting roller doors not raised high enough

Loading docks are often tight spaces with limited manoeuvrability. Forklift operators must navigate past other equipment, pedestrians, and numerous obstacles while safely loading and unloading materials. Additional challenges include:

• Temperature changes between inside the warehouse and outside lead to the fogging of glasses
• Light level changes between inside the warehouse and outside lead to the forklift operator squinting when operating outside
• Uneven surfaces such as the bridge plate can unsettle loads
• Time pressures, such as when unloading chilled products (i.e. not leaving the rear doors open too long) cause operators to rush
• The risk of falls from the dock or bridge plate.

These conditions pose significant risks to your workforce. Prioritising the safety of your employees not only protects them from harm but also helps your business avoid costly consequences and fosters a culture of responsibility and respect for human life and well-being.

Ensuring forklift safety at the loading dock is critical to preventing accidents and injuries. It’s also essential for maintaining the operational integrity of your loading dock, which is central to all business activities involving moving goods into and out of your facility.

Here is an expanded checklist of key safety measures, equipment recommendations, and tips to prioritise safety at the loading dock, prevent safety violations, and establish a robust safety management system:

1. Inspect and Properly Install Safety Railings: Safety railings, when installed at the correct height and resistance, can significantly reduce the risk of falls. Make sure that they are rated to withstand the impact of a forklift
2. Utilise Dock Levellers: Dock levellers are automatic bridge plates that bridge the gap between trailers and the loading dock, ensuring safe loading and unloading operations. Understanding the load capacity of your dock leveller is crucial; exceeding this capacity can lead to equipment damage, employee injuries, and product loss. Investing time upfront in these installations reduces the risk of operator injuries.
3. Install Trailer Restraints: Trailer restraints mitigate the common risk of trucks pulling away from the loading dock while personnel are still inside or prevent trailer tip-overs. Use these restraints in conjunction with wheel chocks to enhance crew safety.
4. Clean the Docks Frequently: Ensure the loading dock is free of debris, water, or ice before forklift operations begin to prevent sliding accidents. Remove any items that could get caught around wheels.
5. Conduct Comprehensive Risk Assessments: Regularly inspect facilities, equipment, and processes to identify potential safety hazards and take proactive measures to address them.
6. Implement Safety Policies and Procedures: Develop and enforce clear safety policies and procedures tailored to your workplace. Ensure all forklift operators are trained in safety protocols, hazard recognition, and the proper use of personal protective equipment (PPE).
7. Provide Adequate Training: Ensure forklift operators receive thorough safety training relevant to their roles and responsibilities, covering topics such as hazard communication, fall protection, machine guarding, emergency procedures, and equipment operation. Use toolbox meetings to remind them.
8. Promote a Safety Culture: Foster a workplace culture where safety is a priority. Encourage employees to report hazards, near misses, and safety concerns without fear of retaliation. Consider forming safety committees or designating safety representatives to facilitate communication, identify safety issues, and collaborate on improvement initiatives.
9. Conduct Regular Inspections and Audits: Schedule routine inspections and audits to monitor compliance with safety regulations and identify areas for improvement. Promptly address any deficiencies and implement corrective actions.
10. Allocate Sufficient Resources and Encourage Engagement: Invest in the necessary safety equipment, training materials, and tools to maintain a safe work environment. Involve employees in safety decision-making processes and encourage them to contribute ideas for improving safety practices. Recognize and reward employees for their commitment to safety.