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Drivers and Control of Non-Driving Injuries

Injuries to drivers often occur while they perform non-driving tasks. Freight loading/unloading activities account for a large number of non-driving injuries within the trucking industry. Such injuries may occur in yards, near loading docks and in maintenance shops. Moving freight is labor-intensive and entails a lot of material handling. As a result, driver injuries due to lifting are common and expensive.

The amount of additional freight a motor carrier must haul to cover the costs of a compensable injury can impact its bottom line and long-term future. In addition to workers’ compensation costs, injured drivers cannot move freight. According to 1998 Bureau of Labor Statistics data, 25 percent of truck drivers who sustain lost-workday injuries are away from work an average of 31 days, with a median of 10 days. That means a lot of freight simply may not move, aggravating the already critical driver shortage.

NON-DRIVING INJURIES

Injury Type & Incidences

According to the 1994 Trucking Research Institute (TRI) study, slips, falls and lifting account for 40 percent of all injuries in trucking, which represent almost half of all workers’ compensation claims. Slips and falls accounted for 22 percent of all driver injuries and 18 percent of all vehicle repair worker injuries.

Getting In And Out Of The Cab

On or away from the employer’s premises, truck drivers fall frequently and for many different reasons. Conventional or cab-over-truck cabs can be several feet off the ground, and a driver can sustain serious injuries if he/she falls while entering or exiting the truck. Transitioning out of the cab and onto slippery, greasy or oily surfaces can cause slips and falls. Oil and grease can accumulate on yard surfaces and be transferred to the driver’s shoes. In winter weather, snow and ice can accumulate on the truck decking that leads into/out of the cab. Another factor in falls is that the driver’s legs may “fall asleep” during long periods of driving.

To reduce these exposures, consider:

  • Use of foot and handholds, as well as non-skid decking, can help prevent such falls.
  • Drivers should maintain a “three-point stance” during truck ingress and egress. That is, they should have two feet on the steps and one hand on the handhold, or two hands on the handhold and one foot on the step. This stance should also be used when climbing up and down or between the cab and trailer to connect brake and light lines.
  • Drivers should be aware of which leg they lead with when climbing into and out of the cab. Based on the design of the steps, leading with the left or right leg can reduce the amount of twisting of the torso and increase the ease of maintaining a three point stance.
  • Furthermore, the driver must be aware that jumping from cabs, trailer bodies or loading platforms is an unsafe and prohibited practice.

Loading & Unloading Freight

Drivers are often expected to load and unload freight; such manual lifting can stress the back and lead to injuries. Using forklifts, dollies and other material handling devices can reduce the potential for injuries. Overexertion injuries are another concern, particularly when drivers who have been traveling for an extended time are expected to move freight. Hand injuries are also common. To prevent these injuries:

  • Drivers should be trained in proper lifting techniques to avoid injuries.
  • Drivers should seek help when lifting heavy objects.
  • Evenly distribute loads within the trailer. Proper tandem adjustment and use of landing gear or stabilizer bars are ways to prevent accidents from unstable falling loads. However, their use can be strenuous, which increases the risk of injury.
  • Proper staging (placement) of freight can help reduce injuries associated with manual materials handling as well. For example, heavy objects should be placed in areas that are easily accessible.
  • Proper palletization can help reduce the risk of back and shoulder injuries.
  • Some carriers use portable adjustable platforms, which can be placed at different heights inside the trailer. This not only better stabilizes the load, it also provides for easier access.
  • Drivers and dockworkers should avoid pinch points of the latching mechanisms on trailer doors that either swing back or open overhead.
  • Wearing gloves can help workers avoid cuts and scrapes from sharp edges and pinch points.

Falling & Leaking Freight

Falling and leaking freight expose drivers and dock workers to additional hazards. Consider these controls:

  • Swingback doors should be opened slowly and workers should be cautious of freight that may be leaning against the door. To avoid injury, workers should keep the door between themselves and the trailer’s contents as a shield against falling freight.
  • Overhead doors should be raised slowly until workers are sure that no freight will fall. Before entering the trailer, they must also pause for a moment to ensure that the door will stay up.
  • Drivers should use the ropes or straps provided when closing an overhead door; these should be long enough to permit drivers to pull the door down while standing on the ground. If a door must be closed while standing on the vehicle, drivers should pull down far enough so it can be closed from the ground, then dismount the vehicle and finish the task. Drivers must also be warned to never pull the rope and dismount at the same time.
  • Dockworkers should be alert for signs of leaking freight, especially if it contains hazardous materials. If employees suspect a release, they should immediately exit the trailer and notify personnel who have been trained to respond to such incidents.

Load Securement & Tie-Downs

According to federal regulations, all freight must be secured while in transit. Achieving this can be physically taxing - i.e., it brings another injury risk into play.

  • Training drivers how to safely use load-securement devices, such as chains, tarps and binders, will reduce their risk of injury.
  • Handling tarps in windy conditions is extremely dangerous and should be avoided.
  • In some cases, a driver harness tie-off is necessary for safe load securement duties.
  • Systems that allow drivers to make adjustments from the ground further reduce the risk of injury. Making adjustments while standing on the vehicle or its load presents a fall hazard, especially if the load shifts or if the securement device fails. The best practice is to avoid standing on any part of the load when applying or releasing tie-downs.

Fifth Wheel, Sliding Tandems & Landing Gears

  • These parts of a vehicle present many hazards associated with heavy lifting and awkward positioning. Sometimes, special techniques must be used to release equipment that may be “frozen” into position.
  • When unhooking a trailer, drivers must maintain a firm grip on the release lever of the fifth wheel.
  • It may be necessary to “rock” the unit to release the fifth wheel or locking mechanism on a sliding tandem. Proper adjustment, maintenance, and lubrication will reduce the potential for injury. Where possible, a “pin puller” should be used to release the fifth wheel.
  • Attaching or detaching the fifth wheel is a one person job. In no cases should a second person be positioned between the trailer and tractor when any vehicle movement is anticipated.
  • Manually operated sliding tandems present many similar problems, especially if one person must be under the trailer to pull the pins while another is behind the wheel to “rock” the unit. In these situations, employees must always block the wheels nearest the releasing mechanism. Pulling the wheels over the blocks provides additional warning and allows the person operating the mechanism more time to get clear. In all cases, the driver must be ready to stop.
  • The effort required to lower landing gear can lead to strain injuries as well. Proper maintenance and lubrication, along with two-person operation, can reduce these risks. Care must also be taken to ensure that the crank does not slip and injure the employee.

Handling Hoses

A significant amount of force is required to pull hoses from cradles, position them and connect them to the fittings. Some considerations for reducing the force and strain upon the back and torso include:

  • Install a counter balance wire at the main terminal to support the weight of the hose during loading of tankers.
  • At client deliveries, the following procedures should be reinforced with the drivers to reduce the strain during hose handling:
  • Align the truck so that the coupling is facing the driver.
  • Pull the hose partially off the cradle, and hook the end to the coupling on the truck; this will allow the cradle and coupling to hold part of the weight. Please note: Depending upon the deliverable, drivers may be required to hook into the delivery valve first, then to the tanker.
  • For trucks with hose tubes instead of cradles, assure the tubes are maintained so that crimps in the tube do not bind on the hose as it is pulled from the hose tube.
  • Some delivery hoses warrant wire counter balances at the delivery site to reduce the force required to maneuver the hose.

LOADING DOCKS & MAINTENANCE FACILITIES

Loading Dock

A loading dock is a busy area. Forklifts, dollies, carts, and employees usually intermingle continually with one another. As a result, the potential for injury is significant. Forklift tipovers and falls off loading docks can produce severe injuries. In some cases, a driver may unknowingly pull his/her truck away from the dock while the forklift is moving in between.

In addition, trailers may inch forward during forklift operations. This “trailer creep” can create a gap large enough for the forklift to fall into. Consider the following controls:

  • Proper communication or the installation of swing gates is important to reducing the potential for these types of injuries.
  • The use of properly maintained dock locks, spring-loaded braking systems, auxiliary air hoses, and wheel chocks can help prevent this problem.
  • The driver and loading dock personnel must also secure dock boards and bridge plates between the loading dock and trailer, and verify that these devices are strong enough to support the anticipated load.
  • Use of dock board levers and pry bars may also reduce the risk of back and shoulder strains.
  • Forklift operators must receive extensive training on how to safely operate the vehicle and be made aware of potential hazards that exist within the operating environment.
  • Dock workers must also make sure that hand trucks, dollies and carts are in good condition prior to use, and ensure that forklifts are properly maintained and used only within their specification limits.

Maintenance Shop

Vehicle repair, tire inflation, lube pits, battery storage and charging, and chemical use and storage are activities associated with maintenance shops in trucking facilities. Common hazards include exposure to hazardous chemicals, unguarded machinery and poorly maintained equipment. Some key points to remember:

  • Maintenance personnel must be properly trained regarding the potential hazards associated with these activities.
  • Drivers should be authorized to conduct repairs only in the areas in which they have specific training.
  • Falling forklifts or moving trucks can cause serious injury to vehicle repair workers. To prevent these injuries, forklifts should be secured while being repaired.
  • Trucks should be chocked and immobile during similar activities.
  • No equipment should be started unless the repair worker is clear of the area.
  • Tires must be placed in cages for inflation while removed from the vehicle and air pressure monitored.
  • Hoses must be capable of releasing pressurized air away from the inflation point.
  • Lube or grease pits should have chains or barriers around them to prevent falling hazards.
  • Workers must be warned not to jump across lube pits.
  • Areas must be free of combustible residues, properly ventilated and equipped with explosion-proof lighting.
  • Employees must be trained on the safe use and handling of hazardous chemicals.
  • All chemicals, including compressed gas cylinders, must be properly and securely stored.
  • All flammable or combustible waste must be removed daily.
  • Batteries must be stored in well-ventilated areas, and a supply of neutralizing agents placed nearby in case of leakage.
  • To avoid electrical hazards, precautions must be taken when charging batteries.
  • Forklifts must be de-energized if batteries are to remain on them during recharging.

Management Controls

To better understand and prevent injuries, management must investigate and determine the causal factors of accidents. Some common management considerations include:

  • Implement a safety shoe policy. For example, many truck drivers wear cowboy boots, which often have leather soles, pointed toes and heels that provide little slip resistance, cause restricted step contact and produce catch points. Therefore, management should discourage drivers from wearing any type of footwear that has leather soles.
  • Implement and monitor housekeeping programs. Such programs help ensure that debris and other unwanted materials do not accumulate and increase the chance of injury or fire hazard.
  • As noted, many injuries within the trucking industry occur away from the employer’s facility. Contracts should detail who is responsible for loading/unloading freight as well as the amount of freight to be handled.
  • Non-trucking employers must provide safe workplaces that are free of debris and other potential hazards.
  • Provide initial and periodic job and safety training for drivers.
  • Periodically monitor or observe drivers to discover hazards and areas for improvement.

This article contains excerpts from an article published in Professional Safety, November 2000, “Safety in the Trucking Industry: Non-Driving Incidents,” authored by Stuart Flatow.

XL Environmental • Risk Control Division • 505 Eagleview Boulevard, Suite 100, PO Box 636, Exton, PA 19341 • Phone: 800-327-1414 • Fax: 610-458-7285 • xlenvironmental.com


XL Environmental is a division of XL Specialty Insurance Company.
 
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