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Most injuries that occur at the loading dock area are the result of direct exposure to hazards, and there are few exceptions. Loading dock accidents can have serious consequences for any company, resulting in physical injuries, business disruptions, risk of prosecution and financial penalties. Yet, in almost every case, they can be prevented with proper safeguards and training.
What are the hazards at loading docks and how do we control them?
Risks at loading docks
1. Premature trailer departure
Forklifts driving off the dock because a truck leaves before loading or unloading is completed.
2. Trailer creep and trailer walk
Trailers creeping away from the dock as forklifts continually move in and out during loading or unloading, creating a dangerous gap between the trailer and dock.
3. Landing leg collapse
Collapse of trailer landing gear due to the constant rocking motion of forklifts moving in and out during loading.
4. Dock roll-off
In a busy loading dock, an open, unprotected dock opening is an accident waiting to happen. Personnel, goods and equipment can inadvertently fall off the loading dock.
5. Hazardous work environment
Poorly lit and non-ventilated trailers are hazardous working environments. Fumigants used in shipping containers to control pests are toxic.
When considering how best to tackle the known risks, you need to consider applying the safety hierarchy of controls as is now an industry standard and used by the relevant WorkCover authorities around the country. Whilst elimination and substitution are the most effective solutions, in the case of loading docks this is not practical.
Therefore you have the options of personal protective equipment (PPE), administrative controls, and engineered controls. In the case of typical loading dock risk, PPE would have a minimal effect and would not remove the potential for falls or crushing.
Likewise, administrative controls can reduce the risk but are reliant on the human element and are therefore considered often as interim solutions (in, for example, WorkSafe Victoria recommended codes of practice). Administrative solutions require continual policing and training but are at their weakest when new employees join the business or supervision wanes or business imperatives overtake safety (shortcuts, productivity pressures).
Engineered solutions remove much of the human element and at their highest level actually prevent unsafe actions being taken in the first place, isolating the hazard from the employee.
Engineered controls: solutions for common loading dock risks
1. Premature departure
The hazard is controlled by the use of powered vehicle- and wheel restraints. Vehicle restraints are generally mounted to the concrete roadway and secure the trailer via the rear underrun bar (ICC), or if the presence or condition of the ICC can not be guaranteed, a wheel restraint is used. These are available in flush and surface-mounted versions, and they secure the vehicle by the wheel and clamp the truck or trailer in position.
Both systems can be interlocked with other dock functions such as building security, door operators, and dock levellers to prevent operation unless the vehicle is secured safely, with the aim of separating people from moving trailers. Other systems such as locking air lines or taking truck keys from drivers provide only a limited management of the risk, and often fail as soon as the procedure is not followed.
2. Trailer creep and trailer walk
Until recently, manual rubber wheel chocks were the only things available to hold trailers at the dock. However, compared to modern restraints, its easy to see why chocks are now the least effective restraint method:
• Chocks are easily lost or stolen, thus unavailable to use.
• Chocks are hard to use and to position snug against a wheel.
• Chocks slip and slide on gravel and dirty or wet concrete.
The engineered solution is the use of powered vehicle restraints and wheel chocks.
3. Landing leg collapse
The use of trailer stands prevents injuries due to trailer landing leg collapse, which can be caused by rusted or faulty landing gear failing when the trailer is not connected to a prime mover. In some cases loading trailers with heavy freight can also move the centre of gravity and tip the trailer forward.
4. Dock roll-off
Boom gates and barriers help prevent fork trucks, pallet jacks and pedestrians from falling off a loading dock. Many facilities leave dock doors open to help with ventilation in the summer months, inadvertently introducing another risk to the workplace. Available in manual and powered options, barriers can be interlocked with other dock equipment for sequencing and ensuring the separation of people from moving trailers.
5. Improving the dock loading environment
Trailer lamps and air circulation fans improve the work environment, increasing safety, comfort and productivity.
Australian standards (AS 1680.1.2006 Interior and Workplace Lighting) require all workplaces to be adequately illuminated. Poor lighting levels can lead to serious workplace incidents.
Venting of containers to remove fumigants through the use of ventilation equipment is an acceptable method of controlling the risks associated with exposure to toxic chemicals used in shipping containers to control pests (Australian Government: OH&S Hazard Instruction and Guideline: Fumigants, 2007).
The use of poorly maintained LPG forklifts in poorly ventilated spaces also poses significant health risks.
With the increasing number of successful prosecutions, many employers now choose to use integrated loading dock safety solutions to minimise the risk.
For more information contact Tieman Industries on (03) 9305 2255, email sales@tieman.com.au or visit www.tieman.com.au.
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