Warehouse dock safety 2013


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I am seeing many dock accidents at warehouses and industrial plants. I made this powerpoint with the help of Bryan Haywood and Misette Kobler.

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  • Read more here: http://www.kansascity.com/2013/11/20/4636136/person-pinned-between-truck-and.html#storylink=cpy
  •  LOADING DOCK FATALITY Gardner man dies in Shawnee FedEx accident (a man, 62, who was injured at a loading dock has died just before 7 a.m. - he suffered critical injuries when he was pinned between a trailer and a loading dock at the company's plant and was transported to a Medical Center where he later died from his injuries - in March, a worker, 31, was killed after falling under the wheels of a truck in an accident at the same facility)LOADING DOCK Serious Accident involving UPS Worker (worker, 19, was taken to a hospital WITH LIFE-THREATENING INJURIES after he was crushed by a truck around 6:30 - it appears that he was probably assisting or engaging a truck coming to the loading bay - he was caught in the middle between the truck and the loading bay walls or doors which caused him to be crushed)FORKLIFT AMPUTATION Marina Worker Loses Legs In Forklift Accident (a marina worker, 54, lost both of his legs after a boat forklift overturned - the forklift was approaching a seawall when it struck the worker who was standing on the dock - the forklift fell into the water, where it had the worker pinned against a fence - worker was airlifted to a nearby trauma center in critical condition)FORKLIFT FATALITY Forklift accident costs Saegertown teen his life ( a worker, 17, was killed when a forklift fell on him at a Forest Products logging company - he was reportedly moving lumber inside the shop around 1 p.m. when he backed the forklift off a loading dock, supposedly ejecting him from the operator’s seat - the forklift then rolled on top of him - County Coroner pronounced the teen dead at 1:30 p.m. from multiple blunt force trauma - he had not been wearing the forklift’s seatbelt, corner said)LOADING DOCK FATALITY Worker's death at Brooklyn Center post office ruled an accident (a worker, 58, who was hit by a mail truck June 18 at a post office has been ruled an accident - he was struck in the loading dock at the post office and suffered numerous injuries)LOADING DOCK FATALITY Police: Postal employee killed in Brooklyn Center (a postal employee has been struck and killed at a post office at about 7:30 a.m. - a semi driver was backing up to the loading dock when a postal worker was struck and killed)LOADING DOCK FATALITY Worker killed at distribution center (an employee, 30, died while trying to repair a loading dock plate at a distribution center - the plate fell on him, who was pronounced dead at a hospital - investigators are trying to determine whether safety mechanisms on the plate were used correctly or were functioning properly)LOADING DOCK FATALITY Worker dies from injuries (a worker, 29, suffered serious injuries after begin pinned between a tractor-trailer and loading dock at a Warehousing facility - he was at the loading dock when a transport truck reversed into the dock and struck him - paramedics attended the scene and the worker was transported to a Hospital for treatment)LOADING DOCK FATALITY – DOCK PLATE Worker Dies in Accident at West Columbia Bakery (a worker, 47, at a bakery died in an accident - she had entered the loading dock to unload a truck, and she was found beneath the loading dock plate - she was pronounced dead at the scene)LOADING DOCK FATALITY OSHA investigating accidental death of Greensboro industrial worker (an industrial worker, 43, was killed in an accident - he was found pinned between a commercial carrier cab and its trailer around 10:30 a.m. - he was pronounced dead at the scene - a preliminary investigation revealed that he got into the path of the backing vehicle as the driver was attempting to connect the trailer)LOADING DOCK FATALITY Driver dies after accident at postal facility (a truck driver, 46, died one day after he was reportedly run over by his own rig at a distribution center - he reportedly jumped onto his truck to stop it after it slipped out of gear and started to roll through the parking lot at the Distribution Center - he then lost his balance and the truck ran over his arm - he died from his injuries shortly before 9 p.m.)LOADING DOCK FATALITY Construction worker in fatal big rig accident ID'd (a worker, 48, was killed in an accident involving a tractor-trailer at a distribution warehouse - he was standing behind the big rig on a loading dock at the distribution center shortly after midnight, preparing to help unload a shipment, when the vehicle lurched backward - the doors of the trailer hit him in the head, knocking him to the ground, where he apparently struck the back of his head - paramedics tried in vain to revive him before pronouncing him dead at the scene)TRUCK UNLOADING Worker pinned when steel rolls off truck at Beaver County plant (a worker was hurt after a load of steel rolled off of a truck and pinned him against a loading dock - the man was flown to a hospital to be treated for his injuries - no word on his condition)
  • Wheel chock in place on 53 foot trailer.
    OSHA is currently not citing wheel chocking of CMV’s. However, in the absence of a dock lock system, may be BSP for prevention of driver pullaway.
    Driver pullaway could be a 5(a)(1) hazard
    Chock should be approx. 1/5 wheel height, and may be placed in front of either front or back rear tire.
  • 1910.23©(1)
    Employer guarding of unused open dock door, 4 ½ feet high.
  • Mechanical dock leveler (cont’d)
    Leveler springs must strike a delicate balance. Too much spring tension and leveler may not walk down easily. Too little and the platform may not rise or the lip may not extend. Excess friction will upset the balance. Housekeeping important – biggest problem is dirt particles get in and foul up front and rear hinges, springs, roller, latches and linkages.
    Check for “drooping lips”, caused by failing latches. Inexperienced ee’s may not report drooping lips and will sometimes play dangerous game of “chicken” – e.g., one ee holds lip out while the other walks the ramp down. Serious hand injuries can result.
    Other problem: The hold down is a pawl with teeth that engages a ratchet bar. If the teeth are ground down by dirt, or dirt prevents proper engagement, the ramp will not stay down in the truck bed. Or teeth can engage but be jarred loose by the impact of a pit entering the truck. The leveler can spring up and the pit driver cannot hear it above the noise of his engine. He may then back out and strike the raised platform.
    Need preventive maintenance program by qualified mechanics.
    Hydraulic levelers are the most reliable.
    Always have a safety strut in place when servicing levelers.
    More and more dock levelers are being installed in combination with loading dock safety devices called truck restraints or vehicle restraints.
    A typical restraint has a hooking mechanism mounted on the dock face tht holds the trailer to the dock by engaging the underride guard (ICC bar). A dock worker activateds the engaging device from a control panel inside the dock door.
    The restraint also includes a communication system of warning lights and signs. Lights inside the dock tell PIT drivers when a truck is secured and may be safety loaded. Lights outside tell truck drivers when loading is completed so they can depart without endangering dock personnel.
  • Dock leveler with lip extended properly (altho it looks a bit short).
  • Dock leveler where lip did not open a plate is being lowered after chain pulled.
    This is where accidents happen if ee on trailer and lifting lip by hand and another one steps on plate.
  • Best Safety Practice
    Courtesy of Rite-Hite Corporation
    Shows how dock restraints (Dok-Loks) work
    Mechanical means of securing truck or trailer to a loading dock is considered equivalent to wheel chocks (per STD1-11.7).
  • Section 5(a)(1)
    Recommended use: One T-frame style jack (approx. 36 inch wide center bar) under trailer front or two post-type jacks) prior to loading/unloading by PIT. Greater hazard in pup trailers (less than 30 feet) or in larger trailers if loaded to capacity.
    Important: Bes rue that the capacity of the jack is appropriate for the trailer’s load. Normal capacity of a 53 foot trailer is roughtly 80,000 lbs. That’s 17,200 lbs. Per axle (34,400 lbs) and gross weight of load a little over 40,000 lbs. (17,200 lbs per axle is a STA (surface transportation act) requirement.
    Michigan OSHA standards require that uncoupled trailers less than 30 feet in length entered by PIT’s SHALL be provided a support capable fo sustaining the load at the front.
    Some trailer have additional “fixed jacks” on front like nose cones, that fold down as needed as additional stabilizers. These are unusual.
    OSHA 1910.178 states “fixed jacks may be necessary to support uncoupled trailers during loading.” Since few trailers come with fixed jacks, an “auxiliary” jack is bsp.
    See handout on this topic.
  • Section 5(a)(1)
    Commonly referred to as “nose cones”.
    Can be used like 36 inch T-style jack to prevent downturning of trailers. If rusted out, like these, will not be used properly.
  • Section 5(a)(1) – Another protection against driver pullaway.
    “Deadlining a trailer.” Guarding against truck pullaway with a lockout device. Lock is applied to the emergency brake (red) connection of the trailer. The lock must be removed before the air line from the trailer can be connected and thereby release the emergency brakes on the trailer. At this company, the forklift driver kept the lockout device key in his possession and the truck driver waited inside the warehouse, not in the cab of the truck.
  • See previous slide for description.
  • OSHA TIB on suspension-type trailers (see handout). Also available on OSHA website.
  • Warehouse dock safety 2013

    1. 1. Dock and Trailer Safety John Newquist Draft 11 30 2013
    2. 2. Nov 2013 • A FedEx worker died Wednesday after he got pinned between a truck and a loading dock in Shawnee • In March, a man died in that parking lot after being crushed under a trailer. Witnesses said the victim fell under the wheels of a trailer pulling out of the FedEx lot.
    3. 3. How Bad is the Problem? • 11 of these dock fatalities have occurred this year – Bryan Haywood • www.safteng.net • LOADING DOCK Serious Accident involving UPS Worker (worker, 19, was taken to a hospital WITH LIFETHREATENING INJURIES after he was crushed by a truck around 6:30 - it appears that he was probably assisting or engaging a truck coming to the loading bay - he was caught in the middle between the truck and the loading bay walls or doors which caused him to be crushed)
    4. 4. General Rules • “If I can't see their mirrors = they can't see me.”
    5. 5. General Rules • • Back up alarms in most cases are a FALSE sense of safety. Many trucks backing up to many doors at most of these loading docks AND when the horn is on the tractor some 50' away from the back of the trailer, they are often challenged to hear them with the background noise emanating from the warehouse. • These back-up alarms become nothing but "nuisance alarms" to workers when they hear them all day on trucks and forklifts thus the brain begins to filter out these tones as merely background noise. – Bryan Haywood
    6. 6. • General Rules • • • I think the best approach is a comprehensive dock safety program tailored to a specific facility's needs and traffic patterns. Actual verification by the driver or reliable communication to the driver by another means that no one is in the danger zone when a vehicle is moving or has the potential to move is critical. The problem with a marker is that it can be moved or pulled in error - which unfortunately • • • Many backing up crush accidents have occurred because the person at the dock was trying to see or communicate with the driver and doesn't appreciate the hazard of their own position. In my opinion, it is not an intuited danger, and workers need to be shown/taught the hazard. Kind of like teaching kids not to run out between parked cars. But with a good program, they should not be allowed in the danger zone to begin with. – Misette Kobler
    7. 7. IL Accidents – Struck by Trailer • August 4, 2003 • Temporary employee was killed when his head was pinned and crushed between the back of a 53-foot trailer and the wall of a loading dock. What is your procedures to back up trucks?
    8. 8. IL Accidents - Liftgate • April 20, 2000 • Unloading a 1400 lb. computers from truck to the lift gate. • Pallet truck wheel goes over the lift gate causing the computer to tip. • Temporary worker tried to push it up onto lift gate and is crushed. What is your procedure to unload heavy boxes?
    9. 9. IL Accidents – Forklift Leaves Dock • November 1, 2000 • An employee was driving a forklift truck in reverse. She backed off of the receiving dock and was pinned under the forklift. Operator was not wearing seatbelt and the forklift didn't have a overhead guard.
    10. 10. IL Accidents – Storage Rack Collapse • January 16, 2002 • Company wants to clean up fallen batteries on upper storage rack. • Employee rides a pallet to top. He loses balance on unsecured grating and falls through the storage rack. What could be done differently?
    11. 11. IL Accidents – Struck by load • October 21, 2001 • An employee was moving a load from the dock to the warehouse driving a lift truck with two pallets of material weighing 1,176 pounds. He took the turn too fast in reverse and the material fell off the forklift truck striking an employee. What facts would you want to know in this case?
    12. 12. IL Accidents – Tanker Truck Fall • February 21, 2001 • Employee #1 was working on top of a tanker truck about 12 feet off the ground. He was monitoring the washing of the inside of the tanker truck. Employee #1 fell from the top of the tanker truck and suffered severe head injury. Access platforms prevent fall from trailers.
    13. 13. Dock Lights • Dock lights will add visibility in the trailer.
    14. 14. Wheel Chocks • Wheel chocks should be ¼ of the wheel height.
    15. 15. Dock Bumpers • Dock bumpers must have slots in them to allow dockplates inserted. • Inspect bumpers for wear. • Violation: No way to insert dockplate if truck was flush to dock bumper.
    16. 16. Inside Control How a Dock Trailer Restraint System Works (used with permission by RiteHite Corp.) DOK-LOK Outside Lights
    17. 17. Future
    18. 18. Further • Thanks to Misette Kobler in the Aurora OSHA office for all her investigations and help. She is one of the best in the dock safety area. • Bryan Haywood contributed the recent fatalities and thoughts on Facebook. • Find me on Facebook, Twitter, Linked-in, and Slideshare.