Choosing the correct Loading Bay to avoid risk.
In this article, we will shed some light on warehouse loading bays or as they are also known loading docks. Loading docks are commonly used in commercial, industrial and in particular warehouse environments allowing for the safe handling of goods from vehicles. We will look at the different types of loading bay and also the guidelines relating to their safe usage and operation. We’ll identify risks associated with vehicle/dock interfaces for the logistics sector and look at possible control measures.
The issues which exist when it comes to transferring goods to and from a vehicle can include the difference in height between loading bay and truck but also the gap from vehicle to bay. There is also some consideration to be given to the loading bay door to the building used for loading/unloading and any risk it poses from exposure to the elements. A loading bay should accommodate a number of different vehicle types and this is achieved by the loading bay being adjustable.
Loading Bay Component Parts.
The loading bay itself has a number of features that allow them to be universal in terms of the size and type of HGV it can accommodate. Materials handling via a loading bay can include goods to store, pallets to collect or can even be used to help with material offloading for maintenance work or site equipment.
Dock Leveller
The primary component within a loading bay is the loading dock leveller. Once a vehicle has reversed into position to begin the loading process it is of paramount importance that the operation can be undertaken as safely and efficiently as possible. Any dock leveller needs to interface with the vehicles without causing exposure to dangerous trip hazards or unnecessary obstacles.
The levelling element of a dock leveller is basically an adjustable ramp. The ramp is a large adjustable plate that hinges at the back allowing the front to either be lifted or lowered to suit the vehicle height. The front edge of the levelling ramp incorporates what is known as the lip or bridge plate. The lip is designed to extend in a cantilever fashion creating a bridge that rests on the rear of the vehicle. This creates an effective solution when dealing with the constant changing of delivery vehicles.
Most dock levellers incorporate a mechanism allowing accurate adjustments to be made to the position and angle of the lip or bridge plate when resting within the vehicle opening. Loading dock levellers are identified as either having telescopic lips or swing lips, swing lips can be either electronic or manual. The swing lip on a combi-dock leveller is segmented which allows for a narrow section designed specifically to work with vans to be extended. In this scenario, the dock leveller would be lowered to meet the reduced height of the van while the narrow section of the lip creates the bridge to gain direct access into smaller vehicles.
Loading Bay Shelters
A loading bay shelter is designed to act as a seal between the vehicle and the opening to the building. They help insulate against the weather and outside elements by reducing the heat loss and air changes to the loading area. As well as maintaining energy efficiency they also serve to protect the goods, workers and the building from rain and snow during the loading/unloading process.
Types are specified for specific use cases. Retractable dock shelters are ideally suited when the vehicle fleet consists of different types and sizes of vehicle. Being retractable means the framework is sprung and collapses back to the wall if the framework comes into contact with the vehicle. They are designed with head and side curtains and maintain a large opening in the middle. The vehicle reverses into the opening and the curtains brush up against the sides and top to form a loose-fitting seal.
Inflatable dock shelters are designed with a more specific purpose in mind. To improve the effectiveness of the seal, inflatable loading bay shelters inflate around the rear of the vehicle. The pressure created serves to greatly reduce any gaps and therefore they perform much better. Inflatable loading bay shelters are a popular choice for food manufacturers and cold store applications.
Another type of loading bay shelter in use is the cushion seal type. These are ideal to suit a dedicated fleet of similar-sized vehicles but can be installed with a specific fleet size in mind. The thermal properties in the foam cushion make them suitable for temperature critical warehouses.
Loading Bay Bumpers
To protect the building and vehicle from damage caused while reversing, dock bumpers are used to create a barrier between the loading bay and vehicle. Loading bay bumpers have to be incredibly strong to withstand the repeated impacts for HGVs. All dock bumpers have a mechanism to absorb the impact otherwise the force would transfer through to the building.
Although protection can also be provided by steel plates, these are not as effective in the long term. The most effective types of dock bumper are manufactured from either high-density rubber, spring-loaded, nylon or polyethene. An added benefit of using polyethene is the ability to be crushed into granules when they reach the end of life in order to be recycled.
Loading Bay Safety and risk factors.
When considering loading bay safety within warehouse environments there are a number of factors to consider. Being aware of potential issues and problems helps them to be avoided. Poor communication between drivers and warehouse staff as well as differing specifications for docks and vehicles all contribute to the increased risks associated with this type of activity. By looking at others in the sector it may be possible to adopt solutions to mitigate any risks involved.
All warehouse loading zones have safety controls in effect to reduce risk and increase efficiency. That is not to say these controls are the same from one site to another and any differences in these controls could confuse a visiting driver who is unfamiliar with a specific site.
Some sites may operate where a visiting driver parks at a goods-in bay and that same driver after unloading drives the vehicle off the bay. Other sites may have goods driven on and off bays by shunter drivers allowing trailers to be loaded whilst uncoupled from the tractor unit. These are just two situations where risks increase around the location of the loading bay.
The potential hazards on a warehouse site are multiple with some being of particular relevance to the dock loading area between the warehouse and vehicle. The risks created are of particular significance to workers loading or unloading the vehicle and if not properly managed could result in injury or death. By frequently undertaking risk assessments some of the more common dangers can be avoided.
Drive-away
A drive-away is when a vehicle or trailer is moved away from the loading bay too early. This can happen before the loading/unloading operation is complete. The vehicle loader, machinery or goods can fall from the vehicle, posing a danger to the loader or anyone working in the vicinity.
Vehicle creep
Vehicles can move (or creep) away from the edge of the loading bay as loading equipment jolts the vehicle or compresses its suspension. This can happen when moving between the bay platform and the vehicle. This can widen the gap between the loading bay and the vehicle and cause the dock plate/leveller, which provides a platform between them, to suddenly slip. Again the vehicle loader, machinery or goods can fall from the vehicle, posing a danger to people working in that area. This can occur even if the trailer has its park brake applied, due to the vehicle rocking on its suspension. Creep can also occur if the trailers landing leg point in the yard is uneven or is deteriorating, causing the trailer foot to rock forward when loads are transferred into/out of the back of the trailer
Load roll-away
The height of vehicle load platforms can vary significantly in relation to the height of loading docks. Also if a vehicle is either empty or full or the suspension and tyre pressure can all contribute and change the height of the vehicle. With double-deck trailers, there can be a difference in height when loading the top or bottom deck. An incline, either on the loading dock plate or within the trailer, can cause goods loaded in cages or dollies to roll either into or out of the vehicle.
Trailer tip
Trailers can sometimes be prone to tipping forward from the landing legs if too much weight is placed towards the front of the trailer. This is more likely to happen when the trailer is uncoupled from the tractor unit with the landing legs lowered. This can be caused by a heavy load or the use of heavy equipment, such as a forklift truck, within the trailer
Water ingress
Slip hazards can occur if water enters the dock loading area and can create a risk for both pedestrians and those using mechanical equipment. Most loading bays have canopies, curtains or shelters to create a weather shield. Poorly fitted seals or different vehicle and trailer designs, such as trailers designed to improve aerodynamics – known as ‘teardrop’ trailers can compromise the effectiveness of dock shelters. The sloping design means that water could run back into the loading area.
Conclusion
Loading Bays within the logistics sector facilitate the handling of goods between warehouses and delivery trailers. They are designed to allow a variety of vehicles to be used which in turn streamlines the whole procedure. They are available in different specifications and designs to suit certain applications. Different warehouse types can be accommodated including cold stores, fulfilment centres or distribution centres.
