Why Every Loading Dock Needs Fall Protection, Risks and Solutions

If you are running a warehouse or storage facility, then you know your loading dock is one of the busiest and most hazardous areas on-site.  With constant traffic from forklifts, delivery trucks and workers on foot, it is a high-risk zone, where one misstep can lead to serious injuries or worse.  

The WHS legislation is clear: as a Person Conducting a Business or Undertaking (PCBU), you are responsible for eliminating or minimising these risks so far as is reasonably practicable.

As most loading docks are not designed with people’s safety front of mind, they not built for efficiency and throughput.  But without proper fall protection, that efficiency can come at a devastating cost.

Loading Dock Incidents Occur Too Often

According to Safe Work Australia, falls from heights are one of the leading causes of fatalities and serious injuries across all industries.  In warehousing and logistics, loading docks are a key risk area, especially where raised platforms are left open during deliveries or changeovers.

The risk is heightened when:

• There are no guardrails or gates to stop a person or forklift from rolling off the edge.
• Workers stand too close to the edge while loading or unloading.
• There is poor visibility during night shifts or bad weather.
• Equipment like pallet jacks, trolleys or loads cause imbalance near dock edges.

It only takes seconds for a slip, misjudged step or lost balance to turn into a tragic incident.  Unlike controlled height work using harnesses or platforms, loading docks are often treated as ‘just another platform,’ until something goes wrong.

Legal Duties and the Cost of Ignoring the Risk

Under the Work Health and Safety Regulation 2017 (NSW), a PCBU must comply with the “Model Code of Practice: Manage the risk of falls at workplaces” from one level to another by implementing the most effective control measures.  If there is a risk of a fall of 2 metres or more, fall protection must be in place.

But even where the height is under 2 metres, the risk remains significant.  Serious head injuries, spinal trauma or fractures are common from low-level falls, especially where concrete surfaces, moving vehicles or uneven ground are involved.

The cost of ignoring this risk?

• Injured workers
• Lost time and productivity
• Insurance premium hikes
• Legal action and regulatory penalties
• Reputational damage that can take years to repair

For example, if you were prosecuted and your warehousing business was fined $200,000 after a worker fell off an unprotected dock edge while guiding a delivery vehicle.  Moreso, when it was preventable by installing a simple physical barriers or gates that could have changed the outcome. What impact would have on you, the workers and your reputation?

A construction company, Caelli Constructions (Vic) Pty Ltd, has been fined $70,000 and had a conviction recorded after a worker fell through a temporary mezzanine floor during construction at the Paula Fox Melanoma and Cancer Centre in Melbourne. Representatives for Caelli Construction (Vic) Pty Ltd did not attend the hearing. 

Effective Fall Protection Solutions for Loading Docks

There’s no one-size-fits-all approach, but there are proven systems that work.

Here are examples that can be implemented for clients across the warehousing and logistics sector:

1.  Dock Safety Gates

Install industrial-grade self-closing or rollover safety gates at dock edges.  These are especially effective for preventing falls when the dock is not in use.  

Gates should:

• Automatically close after pallet access
• Be highly visible and easy to operate
• Withstand regular forklift and pallet movements

2.  Guardrails and Edge Protection

Wherever practical, install fixed or removable guardrails that prevent forklifts, trolleys or pedestrians from approaching the edge unintentionally.

3.  Visual Cues and Warning Systems

Use high-visibility line markings, bollards and signage to create visual separation between vehicle paths and pedestrian zones.  Consider motion sensors or dock lighting systems to improve awareness during loading.

4.  Fall Arrest Systems (where needed)

If work must occur at heights or on elevated vehicles, use engineered fall arrest or restraint systems.  However, these are a last resort when physical barriers are not feasible.

5.  Training and Procedures

No system works without people understanding how to use it.  Induction training, toolbox talks, and routine safety refreshers are essential to reinforce safe loading dock behaviours.

Doing nothing is no longer defensible.  If you can foresee the risk, you are expected to act.

Loading docks will always be high-traffic zones, but they do not have to be high-risk.  By proactively investing in physical controls and embedding safe procedures into daily operations, you can prevent falls, protect your team and stay compliant.

Need Help?

Let’s Talk, do not wait for an incident

If your loading dock setup has not been reviewed recently or if you are unsure whether your controls meet current WHS expectations, reach out.  

We offer practical safety audits, system reviews and tailored recommendations that fit your warehouse layout and workflow. Contact our team today to discuss your safety concerns.