Top Forklift Safety Practices at Loading Docks│ 2025 OSHA Guidelines
Guest blog from MHI Member GMR Safety, Inc.
Every year, National Forklift Safety Day serves as a powerful reminder of the responsibility we all carry to protect forklift operators and warehouse personnel, especially around one of the most dangerous areas in any facility: the loading dock.
Forklift-related accidents remain one of the leading causes of serious workplace injuries in distribution centers, warehousing and logistics facilities. But what’s most troubling is that many of these incidents are preventable. With the right combination of ongoing training, enforced safety procedures, and modern equipment, lives could be spared, injuries avoided, and operations made safer and more efficient.
The Real Risks
Loading docks are dynamic, high-traffic areas where split-second decisions and movements can have life-or-death consequences. According to OSHA, roughly 25% of all warehouse injuries occur at the loading dock. Even more alarming, over 70 lives are lost annually in the U.S. alone due to forklift-related incidents, many of which take place during material handling at the dock.
Several dangerous scenarios can unfold quickly, especially when trailers are not properly secured. One of the most common and catastrophic issues is trailer creep: the gradual movement of a trailer away from the dock due to repeated forklift entry and exit. When this happens, a dangerous gap can form between the trailer and the dock leveler. A forklift operator might not see this gap until it’s too late, leading to a fall or tip-over that could cause severe injury or death.
Another frequent hazard is miscommunication between forklift operators and truck drivers. In the rush to keep operations moving, a driver might prematurely pull away from the dock, mistakenly assuming the loading is complete. If a forklift is still inside the trailer at that moment, the consequences can be devastating, the machine and its operator can be thrown from the trailer with incredible force.
Unfortunately, when no injury occurs, those near-misses are often brushed aside or never reported. But they are far from harmless. In fact, near-misses are red flags, early warnings of systemic issues waiting to escalate. A trailer that wasn’t quite locked in place. A dock light that was ignored. A forklift that nearly tipped. These are all signs that corrective action is needed. Treating near-misses as “non-events” is one of the biggest mistakes a facility can make, they are valuable indicators that the safety culture needs strengthening.
Compounding all these risks is the lack of modern dock safety equipment. Without proper vehicle restraint systems, visual indicators, and audible alarms, dock personnel and drivers are left to rely on assumptions and guesswork, conditions that lead to confusion, mistakes, and accidents.
6 Best Practices for Modern & Responsible Logistics
In today’s fast-paced logistics landscape, safety can’t be an afterthought, it must be integrated into every step of your operations. Here are some best practices to enhance forklift safety at loading docks:
1. Implement Robust Wheel Restraint Systems
High-quality wheel-based vehicle restraints made with robust materials and composed of traffic lights, and audible alarms are essential. By restraining the vehicle by its sturdiest part, the wheel, they not only prevent trailer creep and early departures but also provide clear communication between forklift operators inside, and drivers outside the building
2. Train Continuously, Not Just Once
OSHA mandates that forklift operators be trained and evaluated at least once every three years, but training should be ongoing. Regular refreshers, toolbox talks, and drills keep safety top of mind and help reinforce safe habits. Also, training should extend beyond operators, to supervisors, dock staff, and even truck drivers who interact with the loading dock.
3. Establish and Enforce Dock Protocols
Create and enforce standard operating procedures (SOPs) for loading and unloading. For example, no trailer should be accessed until the restraint is engaged and the green light is on. Ensure everyone knows the sequence of operations, and that it’s followed without shortcuts.
4. Create a Safe Culture of Reporting Near-Misses
Encourage your team to report near-misses without fear of blame or punishment. Use this data to proactively identify weak spots in your process or equipment. Many serious injuries are preceded by multiple close calls, don’t wait for the worst to take action.
5. Conduct Regular Safety Audits
Walk your docks regularly. Inspect equipment, verify that protocols are followed, and look for signs of wear, damage, or non-compliance. Use these audits as coaching opportunities, not just compliance checks.
6. Invest in Ergonomic and Visibility-Enhancing Tools
Forklifts with rear-view cameras, 360-degree visibility systems, and anti-slip flooring improve operator awareness and reduce fatigue-related mistakes. Dock areas should be well lit and free from visual distractions.
It’s About People
Yes, safety measures reduce insurance claims, minimize downtime, and protect assets. But more than that, they protect people. Every forklift operator is someone’s partner, parent, child, or friend. When we talk about loading dock safety, we’re not just talking about procedures, we’re talking about real human lives.
This National Forklift Safety Day, take the opportunity to reassess your safety measures, listen to your team, review your near-miss logs, and invest in technology that can make a real difference. Let’s move beyond compliance and toward a culture of care, accountability, and prevention. Because safety should be more than a promise, it should be a commitment.
