Safety in and around loading and unloading docks: 'It seems simple, and it actually is'

'When the calf has been drowned, the well is closed'. A well-known proverb, which unfortunately still applies all too often in and around loading and unloading docks. At least 250-300 injury accidents occur here every year, including several fatal ones. This makes the loading and unloading dock the riskiest area of the warehouse. "To reduce the number of accidents here, safety must be given (even) higher priority," believes Wim Zwikker, Managing Director Benelux & UK at Rite-Hite. "Awareness is indispensable for this, which we are very happy to provide."

Rite-Hite is a leading manufacturer and supplier of loading dock safety systems. "We like to act as an intermediary or consultant between warehouse employees and purchasing/management departments," says Zwikker. "We are convinced that companies have their employees' best interests at heart; after all, they are their greatest capital. But do they have visibility into all possible hazards? In the logistics sector, it is mainly efficiency and functionality that counts. Safety in and around loading and unloading docks is a bit lower on the agenda, because this is not a production-increasing investment. Moreover, most accidents are caused by haste, inattention and carelessness. Not surprising, since many operations are repetitive and performed on autopilot. This always goes well, until one time it goes badly wrong. And it is precisely that one time that we want to prevent. That is why we like to map out the current situation as well as possible challenges, gaps and risks. How great is the danger? How much activity is there around the various docks? And do you use your own drivers or external transporters? On this basis, we will make a proposal for ensuring safety, including an accompanying calculation and ROI calculation.

How far are you willing to go?

To increase the safety of the dock environment, small and large(er) modifications are possible. From walkway protections, physical separations between moving traffic and pedestrians and fall-through protections in pallet racks to more specific dock equipment. "Clear guidelines have been established for all these categories," Zwikker knows. "Yet this is often not sufficient. The same applies to legislation in this area. For example, in many situations you may use a wheel chock to stop the truck. Electrical blocking devices with light signals are also frequently used. Both are often false safety solutions in practice. After all, a wheel chock really doesn't stop a truck moving away too early. And sometimes the stoplight system does not work properly either. More specific and stricter legislation in this area is therefore desirable."

Immerse yourself in your tenants!

"In the year 2021, most warehouses will still be equipped by default, with a light 6-ton dock leveller, a dock shelter of about 700-800 euros and a set of standard wheel swings. If a tenant then enters this that transports big bags, for example, you have a serious problem. Not for nothing are we frequently involved in existing buildings, where there are significant safety issues." Zwikker is keen to prevent situations like this by getting around the table with the property owner, architect and logistics provider at an early stage. "Get to know your tenants!" he advocates. "What requirements do they have for dock products? For example, in terms of efficiency, ergonomics and safety? In new construction projects, logistics equipment is often only 3-4% of the total investment. Is that really smart? My experience says not."

Maximum security of the forklift operator

To ensure proper positioning at the dock and maximum security for the forklift driver, Rite-Hite supplies, among other things, the Dok-Lok truck-locking system. This patented system originated in America in 1985 and initially consisted of a hook arm that blocks the truck. "For Europe this system was not suitable, because our trucks do not have a unified bumper at the rear. So in 1996 we introduced a system variant, which is still used successfully today and is the only product in the market to meet the highest safety class (FEM 3)," says Zwikker. "Thanks to the Dok-Lok, premature truck departure is prevented. Moreover, during loading and unloading, the truck can never again slide away from the loading dock."

Simple, but effective

Also high up in Rite-Hite's product range is the Dok-Guardian. This simple but effective safety barrier consists of two pillars with a fiberglass mesh curtain between them, which prevents forklifts, pallet trucks and pedestrians from falling off the 1.2-meter-high loading dock when the dock door is open. "For those with high sustainability or hygiene ambitions, we also offer our Eclipse loading dock seal, which ensures that the dock seal completely seals the opening. And so there are numerous other solutions possible."