Published: July 2025

Wherever people and high-power equipment intermingle, the likelihood of accidents shoots up exponentially. Loading docks are among the highest accident-prone locations in industrial handling. 

Baldwin and Lyons Inc. reported that 25% of the total industrial accidents occur on loading docks and loading bays. According to the BHHC Safety Center, 200,000 employees reported accidents taking place on or near the loading dock in 2018. In the whole of 2024, OSHA investigated 17 loading dock accidents– all of which were fatal.

By reading this article, supervisors and industrial workers can gain better awareness of the hazards of loading docks and the federal safety standards that are required by law. 

Why Loading Docks Are High-Risk Zones

• Limited visibility and congested space
• Multiple moving vehicles (trailers, pallet jacks, forklifts, pedestrians)
• Weather and lighting conditions
• Time pressure from shipping/receiving schedules

Common Forklift-Related Hazards at the Dock

• Trailer creep (movement away from the dock)
• Blind spots when reversing out of trailers
• Slips, trips, and falls on dock plates or edges
• Collisions with other forklifts, workers, or structural elements
• Load shift or tip-overs on uneven dock transitions

OSHA Requirements and Safety Standards

• OSHA 1910.178 (forklift operation standards)
• MHI 2025 OSHA Loading Dock Safety:
  
  • Properly secured trailers
  • Clear communication between drivers and loaders
  • Attention to “near-miss” incidents
• Dock lock systems and trailer restraint devices
• Dock edges, wheel chocks, and signage
• Training standards and refresher training for high-traffic zones

Best Practices for Forklift Safety at the Dock

1. Use of Restraints and Dock Locks

• Preventing trailer separation and trailer creep
• Verifying proper engagement before entry

2. Visual Communication Systems

• Mirrors, floor markings, warning lights, and dock sensors
• Clear signals for “safe to enter” or “do not enter”

3. Safe Loading and Unloading Protocols

• Staging loads properly
• Checking for uneven floors or debris
• Avoiding quick movements or sharp turns near edges

4. Forklift Operator Training for Dock Environments

• Site-specific training for working in docks and trailers
• Hazard recognition and defensive driving in tight spaces

5. Pedestrian Awareness & Separation

• Marked pedestrian zones and dock area restrictions
  
  • Black and yellow stickers on the floor
• Clear communication between dock workers and operators
• High-visibility vests
• Worker awareness training

Maintenance and Inspection Protocols

• Daily inspection of dock plates, bumpers, and locking devices
• Ensuring forklifts have working lights, brakes, and backup alarms
• Regular training refreshers for all dock workers

OSHA Incidents: When Things Go Wrong

Inspection: 1750976.015

An employee was run over by a slow-rolling semi truck that did not have wheel chocks or a trailer stand. At the time the truck started slow-moving, the employee jumped from the loading dock to stop it but tripped and fell in the path of the wheels.

Inspection: 1793944.015

An employee was run over by a forklift on the loading dock. The operator’s view was obscured from ice on the windshield. The incident resulted in the employee’s fatal injuries. 

Inspection: 1729977.015

An employee was pinned between a tractor trailer and a loading dock. The employee at the time was preoccupied with picking up D-cell batteries which had fallen out of a box.

Inspection: 1692516.015

An employee backed a forklift off the edge of a loading dock and fell with the forklift to ground level. He incurred fatal traumatic injuries. The company accrued ~$16K in serious violation fines.

Rounding Out

Between an unexpected trailer creep and the hasty oversights of a busy workday, it’s just not worth it to overlook critical safety on a loading dock. Simple habits like utilizing wheel chocks and checking equipment sensors can save human well-being and thousands worth in violation fees with minimal effort. Maintaining training and refreshers can ensure employees feel more secure in their jobs and drastically reduce workplace anxieties.

Maintaining training and safety checks is not only a smart strategy for supervisors; it’s the best strategy for all industrial workplaces.

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