The ramp, or inclined plane to you engineers out there, is one of six classic simple machines.
These are machines so fundamental to technology that they impact nearly every day of our lives. Among them, the ramp is arguably the most important when it comes to loading dock safety. The humble ramp connects two areas of different heights, allowing the smooth passage of materials. Every time you move products between your loading dock and a tractor-trailer, you use a ramp.
After all, a dock leveler is really just a ramp with cooler features.
The dock leveler serves the same function as its ancestor, but technological improvements have elevated it from a tool for access to one for safety. In modern warehouses, dock levelers are a vital asset for protecting workers and goods. Yet, they hide a hazard for the uninitiated, and what you know about your leveler’s maintenance could very well save a life or end one.
Read on to learn:
In the simplest terms, a dock leveler is a mechanical bridge.
The gap between your loading dock and trailers is one of the most dangerous places in your warehouse. Slips, trips, and falls account for roughly a quarter of all workplace injuries and 15% of warehouse deaths. Worse, falling from a loading dock in a forklift is frequently lethal for the operator.
Dock levelers play a vital role in preventing these catastrophes.
They span the gap from your loading dock to a trailer, creating a seamless transition. This allows your team to safely move products between the two using productivity-enhancing equipment such as portable conveyors or forklifts. Levelers even account for any differences in height, meaning a trailer bed that sits higher or lower than your loading dock poses no obstacle.
In other words, dock levelers make your loading dock safer while also improving productivity.
Dock plates and dock boards functionally fill this gap. However, these options are rarely suitable for competitive warehouses. For example, dock plate construction uses lightweight aluminum to make them easier to lift. Aluminum is fine for foot traffic and lightly loaded pallet jacks. However, it deforms under the weight of lift trucks.
Dock levelers, on the other hand, feature steel construction, allowing them to withstand heavy machinery like a fully loaded forklift.
Dock boards are sturdier than dock plates, but lack the security of levelers. A dock board sits on top of the loading dock and the trailer bed without fixed attachment points. Lacking permanent anchors, the board shifts slightly every time a forklift traverses it. Without careful monitoring, this movement can dislodge the board over time.
Levelers are permanent fixtures and do not shift beneath forklift traffic.
Consequently, dock levelers have become the gold standard for high-throughput loading docks. Their construction features powerful, durable components capable of supporting heavy pallets and the forklifts carrying them. Combined with their creep-resistant anchoring, levelers serve as both essential loading dock safety equipment and crucial productivity boosters.
Ultimately, these benefits make levelers a highly reliable mainstay of any busy warehouse.
Loading dock safety equipment makes loading docks safer, not safe.
That’s a critical distinction if you want to protect your team. Loading docks are inherently dangerous. The vast majority of warehouse accidents occur on the loading dock. Even a dock decked out with all the latest engineering controls is only as safe as the workers using it.
Let’s look at an actual OSHA incident as an example.
That November night was pleasantly cool in McAllen, Texas.
After an 80-degree day, the temperature dropped to the mid-60s with the setting sun as a southeasterly breeze brushed sweat from laboring brows. A stock handler, who we'll call Carl, probably welcomed the cooler weather as he collected the load locks within a tractor-trailer. His imminent danger was, by all indications, the furthest thing from his mind. After all, the dock leveler was set. Unfortunately, the trailer restraints were not. As Carl stepped onto the leveler, the trailer lurched forward. His foot found empty air, and the asphalt rose to meet him.
Bruised and scraped, Carl pulled himself from the ground.
At the age of 59, we can only imagine how his bones must have ached after such a tumble. He'd likely be sore for days. Yet Carl could still walk, and, finding himself in the danger zone between dock and trailer, he tried to dart away.
That’s when the driver put the truck in reverse.
The trailer closed the gap in a matter of seconds, pinning Carl against the concrete dock. His body offered no resistance against the trailer's force. Its superior mass smashed his ribs and pelvis and lacerated his organs. We can't know what Carl's final thoughts were as 40 tons of steel and crated fruit crushed the life from him. Yet, we do know his death was preventable. A lack of safety equipment didn't kill Carl; it was the mishandling of that equipment that did.
Ultimately, both the equipment your associates use and how they use it will determine loading dock safety.
Your dock leveler is a prime example of how a safety tool can become a hazard with improper training.
As discussed above, levelers can help prevent dangerous falls when used in tandem with other loading dock safety equipment, like trailer locks. Levelers are durable and dependable, but they still require maintenance. Docks are portals between your warehouse and the outside world. Consequently, levelers are constantly exposed to weather, dust, and debris.
This exposure makes daily inspections vital.
Every day, or even every shift, workers must give the leveler a visual inspection to ensure it’s undamaged and free of debris. They should check the hydraulics and electrical connections for leaks and frays. Finally, the inspecting workers should cycle the whole leveler to ensure proper function. While all of that seems fairly routine, there is a hidden danger: most of those steps involve looking under the leveler.
Working with anything under the dock leveler’s deck is incredibly hazardous.
Most levelers weigh between 1,000 and 2,000 lbs., enough to crush anyone beneath it. To prevent a horrific accident, dock workers need to know how to conduct the inspection safely. This requires training on how to prevent unintentional closures by isolating the power and securing the deck with appropriate supports. For inspections, basic leveler safety training is often enough.
However, service and repairs are a whole different animal.
Service and repair involve more thorough precautions.
For starters, technicians performing these tasks must spend extended periods of time beneath the leveler’s deck. The longer they work down there, the higher the likelihood that someone or something will accidentally release the deck. Additionally, service and repair involve disassembling and reassembling various leveler components, some of which can cause the deck to fall without additional safety measures.
Expert technicians have the training and tools to safely tackle these dangerous situations.
In-house technicians may seem up to the task, but it’s a serious gamble. There is no margin for error with a ton of steel hanging over your head. Putting inexperienced technicians in that situation creates a very real risk of an on-the-job fatality.
No amount of saved money or time is worth the death of a team member.
Don’t put your associates in danger. Go to the experts instead.
The SST team offers all the loading dock safety equipment your facility needs, and we have the experienced technicians to safely and quickly repair your loading dock leveler. Our loading dock maintenance plans make service painless. We work on your schedule to prevent unnecessary downtime and costly repairs.
We improve safety, save you money, and eliminate needless delays. What more could you ask for from a maintenance plan?
To learn more about dock levelers and loading dock safety, contact us online or visit one of our locations:
Florida
Jacksonville
Lakeland
Ocala
Orlando
Tampa
Winter Haven
Georgia
Albany
Macon
Columbus
Valdosta
Further Reading
Loading Dock Safety Checklist: How To Save Lives and Money
How To Extend the Life of Your Loading Dock Equipment
Driven to Safety: Loading Dock Safety Essentials