Best Practices for

Loading Dock Safety

+ Safety Checklist

This report is sponsored by IRONguard, a company

that manufactures and distributes a comprehensive line
of loading dock and warehouse safety products.
T
he loading dock or loading bay is often one of the busiest places in a
warehouse or distribution center. They’re typically recessed inlets where
trailers can be loaded and unloaded, and they’re found in just about every
warehouse, manufacturing facility and commercial and industrial building. Day
and night, trucks come and go as materials, employees, and equipment move in
and around the warehouse floor and the docks.

With all that traffic and activity, it’s not surprising that loading docks come with
their specific set of occupational health and safety hazards. It’s critical that em-
ployers recognize these and take the steps required to keep employees safe
while working in these areas.

To understand the best practices surrounding loading dock safety, we must first
understand the parts that make up a loading dock, the hazards they create and
the risks that loading dock employees face.

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What makes up a loading dock?
Loading docks can be complex areas with a variety of key components. These
parts work together to allow for efficient loading and unloading of semi-trucks,
but they can also pose risks to the employees who spend their time in the area.
Some of the key safety features implemented in loading docks to help reduce the
risk for dock attendants include:

»» Bumpers protect the docks from truck damage and can be used as a guide
for truck drivers backing up to the dock

»» Dock levelers and lifts are adjustable platforms that bridge the gap between
the docks and the trucks

»» Vehicle restraint systems connect the base of the dock to the trailer and pre-
vent it from rolling away during loading or unloading operations

»» Indicator lights tell truck drivers when it’s safe to back in or pull out

Loading Dock Hazards

Loading docks are inherently busy places. From products and employees to ma-
terial handling equipment and trailers, it’s not hard to understand why the areas
in and around these docks are hotspots for accidents.

Each year sees numerous loading dock injuries and even fatalities. One of the
most common involves the trailer leaving the bay unexpectedly, causing the lift to
fall to the ground. There are two main reasons this could happen:

1. In many situations, it is caused by the truck driver mistakenly leaving the load-
ing bay before the loading or unloading is complete – a human error incident
known as drive away. This can cause the vehicle loader, machinery, or prod-
ucts to fall from the vehicle and poses a danger to anyone working in the area.

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2. Trailer creep can also cause the vehicle to move away from the edge of the
loading dock. As the lift truck enters and exits the trailer to deposit or remove
goods, its heavy weight can cause the trailer to shift significantly – even if the
parking brake is on. Several other factors can exacerbate this problem:

»» Uneven or deteriorating landing leg area

»» Height difference between vehicle bed and loading dock

»» Positioning and thickness differences between dock and trailer buffers

Trailer tip occurs when a trailer is resting on the landing legs (rather than attached
to the cab) and too much weight is placed towards the front, whether by a prod-
uct load or the use of equipment like a forklift. Those working in and around the
loading dock can fall from the vehicle or dock or be hit by the load or machinery
when the trailer tips forward.

Water in the loading dock area creates a slip and fall hazard for employees in the
dock area. While most loading bays have some sort of weather shield, ill-fitting
seals or aerodynamic trailer designs may cause water to run backwards into the
loading area.

Musculoskeletal injuries can occur from improperly lifting and carrying heavy
loads, while injuries resulting from careless behavior around machinery and
equipment are also possible.

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Best Practices in and Around the Loading Dock
These hazards don’t have to be an everyday part of the work experience. By
developing systematic processes and procedures based on loading dock best
practices, you can manage these risks and ensure the site is a safe, healthy place
to work.

BEST PRACTICE #1: PREVENT TRAILER MOVEMENT WITH

WHEEL-BASED OR AUTOMATED RESTRAINTS

Wheel chocks are an important component to preventing accidental movement

in a loading dock. However, these can slip or deteriorate over time, leading to un-
intended trailer movement. That’s why it’s best practice to use a secondary re-
straint as well. Wheel-based restraints are usually mounted to the dock approach
and engage with the rear trailer tires, preventing them from moving forward
during the loading process. This type of restraint is flexible and can accommo-
date different types of trailers.

Automated restraints are another option. They are mounted outside, under the
dock opening, and extend to wrap around the rear-impact guard on the trailer.
This secures the truck and prevents it from creeping forward.

BEST PRACTICE #2: USE A SECONDARY SUPPORT TO PROTECT

AGAINST TRAILER UP-ENDING OR LANDING GEAR COLLAPSE

The typical trailer landing gear simply isn’t reliable enough to ensure against trail-
er up-ending, collapse, or the teeter-totter effect and the injuries that would no
doubt accompany these dangerous scenarios. Using a secondary support sys-
tem like a portable trailer stand gives the front end of the trailer significantly
more support while it’s parked in the loading bay area, protecting those working
both inside it and out.

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Trailer stands come in a variety of options, from ones suitable for heavyweight
and high traffic loading docks to those suited for lightweight, quieter ones. They
are easy to position and simple to level, and while it’s an extra step in the loading
and unloading process, it’s one that ensures your loaders aren’t taking a huge risk
every time they venture to the front of the trailer.

Workers responsible for setting up and removing trailer stands must be thor-
oughly trained on safe procedures, as they are exposed to hazards that include
moving vehicles and safe handling and positioning issues.

BEST PRACTICE #3: DEVELOP AN EFFECTIVE

VISUAL COMMUNICATION SYSTEM

When communication breaks down, accidents happen. There should be a quick

visual communication system in place around the loading dock to help drivers
and employees understand how to safely operate together. Most important-
ly, there should be a clear signal to indicate when the trailer restraint process is
complete and it is safe for loaders to move forward.

BEST PRACTICE #4: DESIGNATE SAFE ROUTES

AND ACTIVITY ZONES FOR PEDESTRIANS

With loading docks full of product and machinery, pedestrians are constantly
facing potentially dangerous situations.

Inside, creating a dedicated zone for pedestrian activities (like packing and sort-
ing) keeps them clear of equipment traffic and out of harm’s way. Similarly, it’s
essential that they have safe “travel” routes between various locations in the
warehouse.

Outdoors, clear, safe routes should be marked and there should be a system in
place to prevent pedestrian traffic from moving around while trailers are arriving,
departing, or being repositioned.

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BEST PRACTICE #5: KEEP DOCK DOORS CLOSED
AND SECURED WHEN NOT IN USE

Open dock doors invite accidental falls or security/supply-chain breaches. When

a loading bay is not in use, the doors should be kept closed and secured. If a door
must be left open, appropriate fall protection, such as a guardrail system, must
be used to prevent possible injury to workers in the vicinity. Dock barriers allow
workers to easily identify the loadings bays that are open but not currently in use.
They must, however, be able to withstand the weight of a moving, loaded forklift.

BEST PRACTICE #6: PROVIDE WORKERS WITH

TRAINING ON PROPER LIFTING TECHNIQUES

To reduce the risk of musculoskeletal injuries, all employees working in and

around the loading dock should receive comprehensive training on how to prop-
erly lift heavy loads. Refresher training should be provided at regular intervals
and following any incidents.

BEST PRACTICE #7: ESTABLISH A PREVENTATIVE

MAINTENANCE PROGRAM

Faulty or worn equipment and machinery can result in unnecessary risks to work-
ers in the loading dock area. Regular preventative maintenance should be con-
ducted on dock levelers, restraints, bumpers, doors, lights, communication sys-
tems, flooring, and dock seals/shelters to ensure everything is in good working
order. Equipment that is excessively worn or found to have defects should be re-
moved from service immediately until it is repaired or replaced.

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Planning and implementing best practices
There are nine key steps that businesses and organizations should take to imple-
ment and manage safety control systems in the workplace.

CONSULT
»» Speak to anyone affected by risks and control measures that may be put in
place (loaders, drivers, supervisors, IT staff, suppliers)

»» Explain the “why” behind these new initiatives

DESIGN
»» Create control measures and safety systems in consultation with relevant
parties

BUILD
»» Begin with work locations that pose the greatest risk

»» Consider how to mitigate disruptions to operations while work is taking place

TRAIN
»» Provide training to all employees affected by operational changes

»» Consider including various teaching methods, such as posters, handbooks,

procedure documents, and classroom sessions

IMPLEMENT
»» Implement operational changes in stages to allow you to give adequate at-
tention to each group of employees while minimizing disruption

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SUPERVISE
»» Provide adequate supervision at all times

»» Escalate and investigate any issues that occur

MAINTAIN
»» Establish a regular maintenance routine for equipment and machinery

»» Provide refresher training for staff

AUDIT
»» Conduct audits at regular intervals to assess the compliance and suitability
of the safety system

REVIEW
»» Conduct reviews of risk assessment and safety control measures at a set pe-
riod after the implementation, and following any incidents or near misses

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 Evaluating Your Loading Dock
Safety Practices
As you consider how these best practices can be implemented into your organi-
zational context, it’s important to begin by conducting an audit to determine the
state of your current safety practices.

LOADING Are dock approaches in good condition and free from potholes?
AREA
Are dock bumpers in place, properly spaced and in good working condition?

Are there clear markings to indicate proper trailer positioning?

Are truck engines turned off while in the loading bay?

Are secondary (wheel-based or automatic) restraints used to prevent

trailer movement during loading and unloading?

Are secondary supports used to stabilize the front end of trailers?

Are dock levelers in good working order?

Are bays kept closed and secured when not in use?

Are dock barriers used where appropriate? Are they sufficient to withstand
the weight of a moving, loaded forklift?

Do workers and visitors wear appropriate PPE while in and around the
loading dock (e.g. footwear, gloves, hearing and eye protection, hi-vis
apparel)?

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LOADING DOCK
EQUIPMENT Does all motorized equipment have working lights, a horn, brakes,
operating manual and safety checklist?

Are there designated paths for motorized equipment to move along?

Are there procedures in place to protect pedestrians while motorized

equipment is in use?

Do dock levelers, restraints, bumpers, doors, lights, communication

systems, and dock seals/shelters receive regular preventative
maintenance? How often?

WAREHOUSE Are floors kept free of debris and swept on a daily basis?
HOUSEKEEPING Are caution signs or barriers used in areas that are slick?

Are floors inspected on a regular basis for signs of wear and tear? Are any
shortcomings repaired in a timely manner?

EMPLOYEE Do loading bay workers receive general health and safety training?
TRAINING
Are written health and safety training documents and procedures made
easily accessible to workers?

Are workers trained on proper heavy lifting and manual handling

techniques?

Are workers trained on the proper use of motorized and non-motorized

equipment (forklifts, pickers, pallet movers)?

Are workers trained in the proper use of wheel chocks and wheel
restraints?

Are workers trained in the proper use of dock levelers and bridge plates?

Are workers trained on how to properly place and adjust secondary

supports, like trailer stands?

Is refresher training on all of the above provided on an annual basis?

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Conclusion
The consistent flow of people, products, and equipment through loading docks
makes them inherently risky places for warehouse employees. The best practic-
es outlined in this document will help you manage the hazards and mitigate the
risks, creating a safe workplace for trailer loading and unloading activities to be
carried out.

While every workplace is different, using the evaluation checklist provided above
will give you a good idea of where your business currently sits in terms of safe
loading dock practices. Remember that even once you have a functioning safety
program, the work isn’t done: annual audits and reviews should be carried out to
keep your practices current and ensure they address all identified risks in your
loading bays.

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