Forklift Safety Tips: Loading and Unloading Trailers

In 2021, workplace injuries cost American businesses $167 billion. Warehouse workers, in particular, are more than twice as likely to be injured at work, and according to OSHA, 25% of all warehouse injuries take place on the loading dock. That makes loading dock safety the highest priority for anyone looking to safeguard their employees and business from incidents.

Thankfully, most accidents during the loading and unloading of trailers are preventable by following simple safety protocols and using loading dock safety equipment. Read on to learn five tips for a safer loading dock.

Create a No-Clutter Culture

Between 2021 and 2022, slips, trips, and falls caused 144 workplace deaths and 275,660 days away from work. This kind of accident is the fourth most common injury source and is all the more severe when it happens on a loading dock.

However, you can help prevent these accidents by creating a no-clutter culture in your warehouse. In a no-clutter culture, everything has a place, and every worker is responsible for returning items to their proper place as soon as they are no longer needed. For example, empty pallets are immediately moved to their designated home, as are plastic wrap and ties. Eliminating clutter reduces the likelihood of workers tripping in the loading dock area, thus preventing serious injury or death.

Dry out Slick Surfaces

The loading dock is your warehouse's portal to the outside world, and with that access comes rain, sleet, and even snow. Precipitation creates slick surfaces in your loading dock and invites dangerous falls. During periods of inclement weather, keep your floors dry by making brooms, mops, snow shovels, floor fans, and dryers available as needed. Ensure your team has the necessary training to clean up spills common to the loading dock area as well. Wet floors are a severe hazard to both pedestrians and material handling equipment. Simple loading dock safety procedures like this dramatically affect loading dock safety.

Get Rid of the Creeps

The motion of a forklift entering and exiting a trailer can cause the trailer to shift away from the dock. This is known as trailer creep, and it poses a serious risk to forklift operators. This creep is difficult for the forklift operator to spot before the gap is large enough for the forklift to fall from the dock. In fact, trailer creep is a significant contributor to 15,480 days away from work caused by forklift injuries between 2021 and 2022.

However, there are engineering measures you can put into place to help prevent trailer creep. Dock levelers and dockboards help cover the gap between the trailer and the loading dock. They also ensure a smooth, stable ramp for forklifts. Additionally, dock locks physically secure the trailer to the loading dock. These are the best tools for ensuring the trailer does not slip away and are one of the mechanical means approved by OSHA for preventing trailer creep. Your facility's safe trailer loading procedures should dictate that loading only begins once the trailer is secured to the dock.

Say No to Premature Departure

Human error remains a significant contributor to loading dock accidents. Among the most dangerous culprits is the premature departure of the trailer. The segmentation between truck driver and loading dock team often creates imperfect communication. This can cause the driver to mistakenly pull away from the dock when a forklift is entering or exiting the trailer. Such instances almost always result in serious injury for the forklift operator.

Dock locks are one mechanism to help prevent this. However, they don't stop the truck driver from trying to drive off. That's where dock light communication systems come in. These simple systems show green inside the dock when the team is cleared to load and unload while showing red outside so the truck driver knows not to pull away. When loading is complete, the lights switch, showing the truck driver they are clear to vacate the dock. Work communication systems such as these into your trailer unloading safety procedure to improve loading dock safety.

Protect Pedestrians

One of the loading dock's most dangerous aspects is the proximity of pedestrians to forklifts. Indeed, as much as 80% of forklift accidents in the US involve pedestrians. While the presence of pedestrians and heavy material handling equipment is vital during loading and unloading, there are procedures that can help protect both.
First, never allow pedestrians inside the trailer with a forklift. The confined space increases the likelihood of a fatal accident. Second, establish pedestrian safe zones where workers can stand out of the way of a moving forklift. Block these spaces off with railings or other physical barriers to ensure the separation of pedestrians and working forklifts.

Your Partner in Loading Dock Safety

Being in the material handling business is also being in the business of safety. With over 45 years of experience, Mid Columbia Forklift has the expertise you need to keep your loading dock the safest in your industry. Our experts can help you select the perfect loading dock safety equipment for your facility. To learn more about loading dock safety or to request a quote, contact us online or visit your local Mid Columbia Forklift.

Auburn 253-854-5438
Pasco 509-547-7413
Wenatchee 509-663-9009
Yakima 509-457-5137

Further Reading
Dock Leveler Troubleshooting and Repair
4 Simple Ways to Prevent Loading Dock Accidents
5 Loading Dock Products That Instantly Boost Safety and Profitability