Every year in Canada, hundreds of workers are injured during loading and unloading activities.

According to the Association of Workers’ Compensation Boards of Canada (AWCBC), transport and warehousing jobs accounted for over 11,000 workplace injuries in 2022—many involving slips, falls, and equipment mishandling at loading docks. 

Whether it’s a forklift striking a worker or a truck rolling away before it’s fully unloaded, these incidents are often preventable.

Loading and unloading practices are a critical part of daily operations in logistics, warehousing, and manufacturing. When done carelessly, they can lead to serious injuries, damaged goods, and costly delays. 

But with proper safety procedures, these tasks can become much more efficient—and far less dangerous.

Poor visibility, uneven dock surfaces, unsecured loads, and a lack of communication between drivers and warehouse staff all contribute to risk. 

And with the rise in demand for faster shipping and tighter delivery schedules, safety can sometimes be overlooked in the rush to move goods quickly. That’s where having the right safety practices in place makes a difference.

In this blog, we’ll walk you through 10 best loading and unloading practices to help reduce hazards, improve workflow, and ensure workers go home safe every day. 

Whether you manage a distribution centre, a factory floor, or a small loading bay, these tips are designed to be practical, cost-effective, and easy to apply across Canadian workplaces.

Why Loading and Unloading Safety Matters

Loading and unloading may seem like routine tasks in most industrial settings, but they’re some of the most dangerous parts of the job—especially when safety protocols are overlooked. 

Whether it’s a pallet sliding off a forklift, a driver moving too soon, or a worker slipping off a dock, the consequences can be serious.

Common Hazards

The risks during loading and unloading are varied and often underestimated. Here are some of the most common hazards:

• Falling cargo: Poorly secured or stacked materials can fall, injuring workers or damaging equipment.
• Vehicle and pedestrian collisions: Forklifts or trucks operating in tight spaces can strike workers or other machinery.
• Musculoskeletal injuries: Lifting heavy loads without proper technique or support can lead to back strains and repetitive motion injuries.
• Falls from heights: Workers may be required to climb onto trailers or containers, where a slip can result in a serious fall.
• Trailer creep or rollaway: If a truck is not properly secured during loading or unloading, it can move unexpectedly—causing crushing injuries.

Check out our online forklift operator training to keep everyone safe around you!

Canadian Safety Standards and Compliance

In Canada, Occupational Health and Safety Acts (OHSA) and CSA (Canadian Standards Association) standards require employers to provide safe working environments and procedures, including during cargo transfer operations. 

CSA Z1004-12, for example, provides guidance on safe use of ladders, which can apply to trailer access. Meanwhile, OHSA regulations emphasize the need for hazard assessments, proper training, and fall prevention systems.

Non-compliance with these rules can result in fines, penalties, or legal liability—not to mention the human cost of worker injury or loss of life.

Material Handling Protocols

Safe material handling is the foundation of safe loading and unloading practices. This includes:

• Using the right equipment: Forklifts, hand trucks, and hoists should be in good condition and operated by trained workers.
• Proper lifting techniques: Workers should know how to lift with their legs, not their back, and avoid twisting while carrying loads.
• Clear pathways: The area around loading docks must be free of obstructions to prevent tripping or collisions.

Cargo Transfer Safety

Cargo transfer refers to the movement of goods from one place to another—like from a trailer to a storage area. This process demands:

• Securing the vehicle: Wheel chocks or dock locks must be used to prevent movement.
• Communication between driver and dock staff: Miscommunication is a leading cause of early departure accidents.
• Even weight distribution: Loads must be evenly balanced to prevent tipping or collapsing.

Ultimately, loading and unloading safety matters because it protects people. 

It also improves operational efficiency and keeps businesses in compliance with the law. When done right, it’s a win for both safety and productivity.

10 Best Practices for Loading and Unloading

Ensuring safety during loading and unloading operations is vital for protecting workers, maintaining compliance with Canadian regulations, and enhancing operational efficiency.

Below are ten best practices designed to mitigate risks and promote a safe working environment.

1. Conduct Pre-Operational Safety Checks

Before commencing any loading or unloading activities, it's essential to perform thorough inspections of all equipment involved. This includes dock equipment, forklifts, trailers, and other machinery. 

Regular pre-operational checks help identify potential issues that could lead to accidents or equipment failure.

Key Steps

• Inspect Dock Equipment: Ensure that dock levelers, bumpers, and plates are in good condition and functioning correctly. Look for signs of wear, damage, or misalignment.​
• Examine Forklifts and Other Machinery: Check for fluid leaks, tire conditions, brake functionality, and ensure all controls are operational.​
• Assess Trailers: Verify that trailer floors can support the load, doors operate smoothly, and there are no structural damages.​

Incorporating these checks into daily dockside operations not only enhances safety but also ensures compliance with Canadian safety standards, such as those outlined by the Canadian Centre for Occupational Health and Safety (CCOHS). 

Regular inspections can prevent equipment-related incidents and maintain a seamless workflow.​

2. Use Proper PPE and Train Staff Regularly

Personal Protective Equipment (PPE) serves as the last line of defense against workplace hazards during loading and unloading operations. Equipping workers with the appropriate PPE and providing regular training on its use is crucial for their safety.​

Essential PPE Includes:

• High-Visibility Vests: Ensure workers are easily seen by vehicle operators, especially in busy dock areas.​
• Safety Gloves: Protect hands from cuts, abrasions, and chemical exposures.​
• Steel-Toed Boots: Safeguard feet from heavy falling objects and provide slip resistance.​
• Hard Hats: Protect against head injuries from falling objects or low-hanging obstructions.​

Training Components

• Proper Use of PPE: Educate workers on how to correctly wear and maintain their PPE to ensure maximum protection.​
• Hazard Recognition: Train staff to identify potential risks associated with loading and unloading tasks.​
• Emergency Procedures: Ensure employees know the protocols for responding to accidents or equipment failures.​

Regular PPE training sessions reinforce safe practices and keep safety top of mind. 

In Canada, adhering to PPE requirements and providing adequate training aligns with Occupational Health and Safety (OHS) regulations, helping to prevent workplace injuries and ensuring legal compliance.

3. Secure Loads Before Transit and During Unloading

Properly securing loads before transportation and maintaining that security during unloading are non-negotiable aspects of safe material handling. 

Unsecured or poorly balanced loads can shift in transit, causing damage to products, vehicles, and—most importantly—injuries to workers. 

In Canada, unsecured cargo violations can also lead to heavy penalties under provincial and federal transport regulations, such as those enforced by Transport Canada and provincial Ministries of Labour.

Key Load Securing Techniques

• Use of Tie-Down Straps and Ratchets: Heavy-duty ratchet straps are essential for holding cargo in place, especially for large or irregularly shaped items. These should be rated for the load’s weight and applied tightly with no slack.
• Edge Protectors and Corner Boards: Edge protectors prevent damage to cargo and extend the life of straps by reducing abrasion. They’re also useful in keeping loads aligned and minimizing movement.
• Bracing and Blocking: Using wooden or metal braces within trailers or containers can keep loads from sliding or toppling. Blocking—placing chocks or other barriers at the base—adds an extra level of stability.
• Load Distribution: Ensure weight is evenly spread across the trailer or truck bed to prevent tipping and strain on axles. Uneven weight distribution is a major cause of vehicle instability.
• Load Restraint Systems: Built-in systems like anchor points, cargo bars, and netting should be inspected and used as needed. These systems are often overlooked but can significantly reduce risk.

Why It Matters

• Prevents Injuries: Workers are at risk of falling cargo during unloading if the load has shifted.
• Protects Equipment and Inventory: Damaged goods and broken pallets result in financial losses and work delays.
• Ensures Compliance: Meeting Canadian regulations for cargo securement is not optional. Violations can result in costly fines or even legal action.
• Supports Efficiency: When cargo is stable, unloading is smoother and faster, helping logistics teams stay on schedule.

By integrating securement checks into standard operating procedures, employers can significantly reduce the risks associated with load movement and improve overall safety.

4. Stabilize Vehicles Before Loading/Unloading

A vehicle that isn’t properly stabilized can move unexpectedly, leading to dangerous situations like falls, tip-overs, or collisions. 

In warehouses and on loading docks across Canada, one of the most common yet preventable accidents is known as “trailer creep”—a gradual shift in a trailer’s position as it's being loaded or unloaded, often caused by forklift movement.

Stabilization Techniques

• Use of Wheel Chocks: Wheel chocks are wedge-shaped devices placed behind and/or in front of the wheels to prevent accidental rolling. These are a legal requirement in many facilities and a practical safety must.
• Dock Lock Systems (Vehicle Restraints): These hydraulic or mechanical systems secure the trailer to the dock, preventing it from pulling away while loading is in progress. They’re especially important in busy distribution centres.
• Brake Checks: Drivers should engage trailer brakes and confirm they’re holding before any loading/unloading begins. It’s a good practice to include brake checks in your driver safety training.
• Trailer Stands or Jacks: These are used to support the front end of a trailer when it’s not attached to a tractor. It prevents tipping forward during forklift entry and exit.
• Inspect Dock Plates: Before use, ensure the dock plate or leveler is securely in place and capable of handling the load’s weight. A faulty or misaligned plate can lead to slips and falls.

Why It Matters

• Prevents Equipment Damage: A shifting vehicle can damage forklifts, cargo, and dock equipment.
• Protects Workers: Stabilization reduces the risk of falls, rollaways, and crush injuries.
• Reduces Liability: Following proper stabilization procedures aligns with Canadian Occupational Health and Safety (OH&S) requirements and minimizes the risk of legal consequences.

Incorporating a stabilization checklist into your standard procedures—and training both drivers and dock workers on it—helps create a consistent safety culture. 

These steps may seem routine, but they’re critical in preventing serious, sometimes fatal, workplace incidents.

5. Use Clear Communication and Signalling

Effective communication during loading and unloading operations is vital for safety, especially in busy or noisy environments like warehouses, construction sites, and distribution centers. 

When teams work around moving vehicles, forklifts, and heavy cargo, the risk of injury increases if workers are not aligned in their movements. 

Using consistent hand signals, radios, and signage ensures everyone is on the same page, reducing confusion and keeping operations running smoothly.

Core Communication Tools

• Standardized Hand Signals: Hand signals are an essential non-verbal communication tool, especially when visibility is limited or verbal instructions can't be heard. Every worker involved in cargo movement should be trained on a standard set of signals for start, stop, lift, lower, and emergency halt.
• Two-Way Radios and Headsets: Radios provide real-time, instant communication between team members, especially in large facilities or across multiple loading bays. Wireless headsets allow hands-free operation and quick response to changes in the loading/unloading plan.
• Visible and Durable Signage: Use color-coded signs to designate areas for staging, restricted zones, and direction of movement. Signs should be weather-resistant if used outdoors and updated regularly to reflect changing workflows.
• Pre-Operation Briefings: Before each shift or major loading task, hold short “toolbox talks” to go over the job scope, roles, and emergency signals. This reinforces coordination and clarifies who is in charge of directing the task.
• Spotter System: Assign a spotter whenever visibility is restricted or when trucks and forklifts are backing up. The spotter must maintain visual contact with the driver and use clear, agreed-upon signals.

Why Communication Matters

• Prevents Accidents: Misunderstood or missed instructions can lead to collisions, drops, or pedestrian strikes.
• Enhances Cargo Transfer Safety: Coordinated communication ensures the timing of lifting, moving, and placement is precise.
• Improves Efficiency: When everyone knows their cues and roles, the job gets done faster and with fewer interruptions.
• Fulfills Compliance Requirements: Canadian Occupational Health and Safety standards encourage effective communication protocols as part of workplace safety systems.

Whether it's a small warehouse or a large-scale logistics operation, maintaining strong communication practices is essential for protecting people and property.

6. Follow Proper Material Handling Procedures

Proper material handling is about more than just lifting things safely—it’s a system of practices designed to reduce injury, minimize damage, and streamline logistics. 

Every year, Canadian workers suffer thousands of preventable injuries related to poor material handling.

These include strains, sprains, and crush injuries from improper lifting techniques or unsafe equipment use.

Key Elements of Safe Material Handling

Manual Handling Techniques:

• Employees should always be trained in safe lifting:
• Keep the back straight and lift with the legs.
• Avoid twisting while lifting or carrying.
• Limit weight to what can be handled safely—team lifting for heavier items.

Use of Tools and Equipment:

• Where possible, workers should use mechanical aids such as:
• Dollies, pallet jacks, and carts to move smaller items.
• Forklifts and powered stackers for heavy or palletized goods.
• Conveyors or gravity rollers in fixed facilities to reduce manual carrying.

Material Handling Protocols:

Protocols include step-by-step guides for how to safely load, store, and transport goods. These documents should be standardized, easy to access, and regularly updated to reflect new hazards or equipment.

Load Planning:

Arrange cargo in a way that prevents shifting or overloading. Lighter items should go on top of heavier ones, and frequently accessed items should be placed for easy retrieval.

PPE and Ergonomic Supports:

Use gloves for grip, back braces for heavy lifting, and steel-toed boots for foot protection. Adjustable carts and anti-fatigue mats are great additions in areas where workers stand or lift frequently.

Why It Matters

• Reduces Musculoskeletal Injuries: These are among the top causes of lost-time claims in Canadian workplaces.
• Improves Productivity: Workers can move more efficiently and with less fatigue when they follow proven handling methods.
• Lowers Equipment Damage: Correct use of handling tools reduces wear-and-tear and breakage.
• Ensures Compliance: Material handling is regulated under Canadian OHSA guidelines, including CSA Z1004 for ergonomics.

By establishing clear handling procedures and ensuring consistent training, businesses can significantly reduce workplace injury rates and improve operational flow. 

Adopting and enforcing these practices also shows employees that their well-being is a top priority.

7. Keep Dock and Aisle Areas Clean and Uncluttered

A tidy workspace is a safer workspace—especially in fast-paced environments like warehouses and loading docks. Slips, trips, and falls are among the top causes of workplace injuries in Canada, and cluttered aisles or wet floors often contribute to these incidents.

Key Tips

• Routine Housekeeping: Assign staff to conduct regular cleaning rounds during and after shifts. Use checklists to ensure key areas like loading zones, dock plates, and aisles are kept free of debris, spills, or obstructions.
• Anti-Slip Surfaces: Apply anti-slip coatings on dock floors and ramp edges. This is especially important in winter when snow and ice increase slip hazards.
• Proper Storage: Use designated shelving or pallet racks to store goods rather than leaving them on the floor or in walking paths.
• Lighting and Visibility: Keep the area well-lit to spot spills or obstacles quickly. Bright paint or floor tape helps define lanes and hazard zones.

Warehouse loading and unloading tips often emphasize mechanical safety, but clean, organized environments form the base of safe material handling. An uncluttered dock is also more efficient—less time wasted navigating hazards means more focus on safe loading and unloading practices.

8. Use Proper Loading Techniques to Avoid Overloading

Overloaded trailers and transport vehicles pose serious risks—tipping, jackknifing, cargo shift, and even structural damage to the vehicle can occur. For workers and drivers alike, maintaining balance and respecting load limits is a non-negotiable part of workplace safety.

Best Practices for Safe Loading

• Know Your Limits: Refer to the manufacturer’s weight limits for vehicles, forklifts, and racking systems. Never guess—use certified scales when needed.
• Even Distribution: Load heavier items at the bottom and center of the trailer or pallet. This reduces the chance of the vehicle tipping and keeps the center of gravity low.
• Use Load Bars and Dunnage: These tools keep cargo from shifting in transit. Load bars, straps, and edge protectors are essential for tight, secure stacks.
• Avoid Stacking Too High: High stacks reduce visibility and increase fall risk. Follow guidelines for stack height and stability.

Proper loading techniques aren’t just for compliance—they directly prevent injuries and property damage. Following best practices makes unloading easier and safer, especially at destinations where you can’t predict dock conditions.

9. Verify Cargo Documentation and Labels

Before moving or accepting any load, always check the paperwork. This is more than just good logistics—it’s a critical safety step, particularly when dealing with hazardous materials.

Why Verification Matters

• Avoid Handling Errors: Cargo that’s mislabelled or undocumented can contain hazardous or fragile items that require special handling.
• TDG Compliance: In Canada, the Transportation of Dangerous Goods (TDG) Act requires accurate documentation and labeling. Non-compliance can result in fines or even criminal charges.
• Protect Workers: Knowing what’s inside a container helps workers prepare with the right PPE, equipment, or handling method.

Verification Checklist

• Match shipment with the Bill of Lading or manifest
• Check for required TDG labels, placards, or Material Safety Data Sheets (MSDS)
• Confirm container integrity—no leaks, broken seals, or missing labels

Verifying cargo not only improves safety but also enhances operational accuracy. For companies dealing with chemicals or flammable goods, TDG certificate training ensures staff are confident and compliant.

10. Implement Emergency Protocols and Reporting

Even with the best planning, incidents can still happen. That’s why having clearly defined emergency protocols is just as important as preventing accidents in the first place.

Key Elements of Emergency Protocols

• Injury Response Plan: Staff must know how to respond to injuries, including where first aid kits and eye wash stations are located, and how to call for emergency help.
• Spill or Fire Protocols: For chemical or flammable goods, ensure procedures are in place for containment and evacuation.
• Rescue Plans: If your facility uses confined spaces or vertical storage areas, emergency rescue procedures should be practiced regularly.

The Role of Reporting

• Encourage reporting of all incidents—including near-misses. These are valuable learning tools.
• Provide anonymous or easy-to-use digital reporting systems.
• Regularly review reports during safety meetings to spot trends and improve training.

Culture matters. Workers are more likely to report hazards or incidents when they trust the process and see that action is taken. Our Incident Investigation Training can help you create a reporting culture that leads to long-term safety improvements.

Industry-Specific Considerations

While the fundamentals of safe loading and unloading apply across industries, specific environments and cargo types require tailored approaches. 

Whether you're operating in a bustling logistics terminal, a food delivery chain, or a retail loading dock, understanding your industry's unique demands is essential to minimizing risk and improving workflow.

Logistics Terminals

In large freight terminals and distribution centres, speed and volume are key. These high-traffic zones often deal with tight schedules and multiple vehicles at once.

Best Practices

• Use standardized dock schedules and lane assignments to prevent bottlenecks.
• Employ dock locks and trailer restraints to prevent unexpected vehicle movement.
• Digitally track load times and cargo inspections for efficiency and accountability.

Food and Beverage Delivery

This industry requires careful attention to cleanliness, temperature control, and damage prevention. Loading areas are often cleaned frequently, increasing the risk of slippery surfaces.

Best Practices

• Ensure food cargo is loaded quickly to maintain cold chain compliance.
• Use clean, insulated dollies or pallets for perishable items.
• Train staff to avoid stacking fragile food items or liquids in unstable ways.

Warehouses and Distribution Centres

These facilities handle a wide variety of goods and often rely on racking systems, conveyors, and forklifts.

Best Practices

• Mark out safe pedestrian zones in warehouse aisles.
• Provide fall protection training for elevated loading areas.
• Integrate real-time load tracking with warehouse management systems.

Retail Stores and Shopping Centres

Retail locations often receive shipments through smaller loading bays with limited space. Deliveries may occur during operational hours, introducing customer safety concerns.

Best Practices

• Schedule deliveries during low-traffic hours whenever possible.
• Use signage and barricades to separate unloading zones from customer walkways.
• Train employees on manual handling techniques for lighter goods.

Adapting to Canada’s Climate

Canadian winters bring unique challenges to loading dock safety. Snow, ice, and freezing rain can cause slip-and-fall injuries, frozen dock equipment, and reduced vehicle control.

Cold Weather Safety Tips

• Install heated dock plates and use anti-slip mats or coatings.
• Regularly clear ice and snow from dock areas, steps, and vehicle paths.
• Use cold-weather-rated PPE, such as insulated gloves and boots with traction soles.

No matter the industry, adapting loading and unloading procedures to match your specific risks—both environmental and operational—is critical. 

Creating a tailored safety plan based on these variables is one of the most effective ways to keep teams safe and operations running smoothly.

Conclusion

Loading and unloading may seem routine, but without the right precautions, it’s one of the riskiest tasks in any industrial setting. 

This guide has walked through essential themes—preparation before the job begins, clear communication between team members, and strict adherence to safety regulations. These aren’t just best practices—they’re lifesaving habits.

To truly build a safe workplace, it’s important to go beyond written policies. Hold regular toolbox talks focused on dock safety, vehicle stabilization, and proper lifting. 

Walk around inspections should be frequent, especially in high-turnover or high-traffic areas. These moments help reinforce expectations and keep small hazards from becoming big incidents.

Consistency is what transforms guidelines into culture. Supervisors and frontline workers alike must be held accountable for following and promoting safety protocols. 

Encourage peer feedback, and celebrate teams that complete operations without incidents or near-misses.

Digital tools can be a game-changer here. Whether it’s a mobile app for pre-operation checks or a load-tracking dashboard that flags risky patterns, technology helps ensure that loading and unloading practices remain both efficient and compliant.

In the end, safety isn’t just about avoiding injury—it’s about showing every worker that their wellbeing matters. And that starts with staying alert, prepared, and committed to doing things right—every single time.