Write a risk assessment for Please prepare standard or safe operation procedure for Container loading and unloading activity with picker vehicle

A suitable risk assessment and safe operating procedure for container loading and unloading with a picker vehicle should be task-based and documented before work starts. The assessment should identify hazards such as struck-by, crushed-by, falling loads, trailer movement, unstable ground, poor lighting, blind spots, pedestrian interaction, overhead obstructions, adverse weather, manual handling strain, and inadequate communication. Controls should follow the hierarchy of controls: first eliminate or reduce the hazard through planning, site layout, equipment selection, guarding, restraints, and exclusion zones; then apply administrative controls such as procedures, supervision, signage, and training; and use PPE as the final layer of protection. [4] [6] [12]

Key hazards to identify

• Vehicle or trailer movement during loading/unloading
• Load shift, falling materials, or unstable containers
• Crushing between picker vehicle, trailer, dock, container, or fixed structures
• Pedestrian or spotter struck-by incidents in blind zones
• Ground failure, uneven surfaces, dock edge or ramp hazards
• Overhead contact with structures or power lines
• Manual handling injuries from chains, slings, dunnage, tarps, or repositioning cargo
• Poor visibility, lighting, weather, noise, or ventilation
• Failure of lifting accessories, hooks, slings, restraints, or dock plates
• Unauthorized persons entering the operating area

[2] [5] [15] Before starting the task, verify that the picker vehicle is the correct equipment for the load and site conditions. Do not use it for loads that are too large, unbalanced, poorly packaged, or otherwise unsuitable. Confirm the rated capacity of the vehicle and all lifting gear, the weight of the load, the lifting points, the travel path, and whether the trailer, dock, ramp, or ground can support the combined weight of the equipment and load. If the container or load cannot be handled safely with the picker vehicle, use a different method. [10] [5] [14]

Task-based risk controls and safe operating procedure

1. Plan the job: complete a documented JSA/JHA, confirm load details, assign roles, establish exclusion zones, communication methods, and emergency arrangements.
2. Prepare the area: use level, stable ground or a sound dock area; remove debris and obstructions; ensure adequate lighting, visibility, ventilation, and overhead/side clearance; suspend work in unsafe weather.
3. Secure the transport unit: engage brakes, shut off the vehicle if appropriate, chock wheels, use trailer restraints or stabilizers, post warnings not to move the vehicle, and keep the driver clear unless their role is defined in the procedure.
4. Inspect the load before disturbing it: check for shift, leaning, damaged packaging, inadequate fork or sling entry, loose items, and any condition that could cause the load to fall or roll.
5. Inspect the picker vehicle and lifting accessories before use: remove defective equipment from service and do not operate until faults are corrected.
6. Control the lift: verify load weight and capacity, center and secure the load, use suitable slings/hooks/attachments, keep the load as low as practicable while travelling, avoid sudden movements, and never allow anyone under a suspended load.
7. Manage people and traffic: isolate pedestrians, use barriers and signs, control intersections and blind spots, maintain a designated safe zone for non-essential personnel, and stop work if anyone enters the danger area.
8. Load/unload methodically: maintain load balance on the trailer or container, avoid pushing against adjacent freight in a way that could dislodge it, and reassess continuously if the trailer tilts, gaps form, steering changes, or conditions deteriorate.
9. Complete the task safely: place the load on stable ground or supports, confirm it is secure before disconnecting lifting gear, remove restraints only when safe, and restore the area to a safe condition.

[2] [5] [10] Operator competency is critical. Only trained, authorized, and competent operators should use the picker vehicle and any associated lifting attachments. Training should cover equipment-specific operation, load charts and rated capacity, pre-use inspection, load stability, blind zones, traffic rules, signaling, securing trailers, dock and ramp hazards, overhead hazards, emergency procedures, and the site SOP. Refresher training should be provided after incidents, near misses, unsafe acts, equipment changes, or when competency is in doubt. Spotters and ground personnel also need training in exclusion zones, signaling, and staying clear of suspended or shifting loads. [9] [13] [13]

Pre-use inspection

• Check tires, wheels, steering, brakes, horn, lights, alarms, mirrors/cameras, seat belt if fitted, hydraulic systems, forks/booms/attachments, and safety devices.
• Inspect hooks, safety latches, chains, ropes, chokers, slings, and other lifting accessories for wear, damage, deformation, missing tags, or defects.
• Verify warning labels are legible and the operator manual is available.
• Inspect the work area, trailer, container, dock plate, flooring, landing gear/stabilizers, and clearances before entry.
• Remove damaged or defective equipment from service immediately.

[2] [2] [14] Load stability must be treated as a primary control. Inspect every load before each lift. Do not lift leaning, damaged, poorly secured, or unstable loads. Ensure the load is properly supported, balanced, and engaged by the lifting device or attachment. Keep bystanders out of the opposite side blind zone of trailers and containers because freight can be pushed or fall unexpectedly. Never permit anyone to stand, walk, or work under a suspended load or beside a load that may shift. [5] [13] [2]

Traffic management should be formalized in the SOP. Separate pedestrians and mobile equipment wherever possible using designated routes, exclusion zones, barriers, and signs. Set speed limits, stopping rules, right-of-way rules, and horn/signal requirements. Control intersections and blind corners with mirrors, lights, alarms, radios, or spotters as needed. Ensure floors, aisles, ramps, docks, and passageways are clear and strong enough for the equipment and load. High-visibility apparel should be required where workers are exposed to vehicle movement. [15] [15] [1]

Lifting and material handling controls should include using appropriate equipment for heavy or awkward loads, minimizing manual handling, and adapting the task to reduce strain and crush hazards. Workers should not ride on loads or in material hoists. When manual handling is unavoidable, use team lifting or mechanical aids, maintain clear hand placement, and keep feet clear of pinch points. Secure all loose tools and materials so they cannot fall during transport or lifting. [1] [2] [8]

PPE requirements

• Hard hat where there is exposure to falling or shifting objects
• High-visibility vest or clothing where there is vehicle or equipment traffic
• Safety footwear with toe protection for crush and impact hazards
• Work gloves suited to the material and handling task
• Safety glasses as a minimum where impact hazards exist; goggles/face shield if splash or flying particles are present
• Hearing protection where noise exposure warrants it
• Fall protection only if a separate fall hazard assessment identifies a need

[2] [7] [6] Communication must be established before work begins. Use one designated signaler where visibility is restricted or where multiple workers are involved. Agree on standard hand signals, radio channels, horn signals, and stop-work commands. Maintain positive communication between the operator, spotter, and driver, and do not proceed if communication is lost. Non-essential personnel should wait in the cab or a designated safe zone, not beside or behind the trailer or container. [14] [1] [13]

Emergency response arrangements should be part of the SOP and risk assessment. Provide first aid resources appropriate to the work, ensure workers know how to summon emergency services, and establish rescue and incident response steps for crush injury, struck-by events, load collapse, fire, medical emergency, and hazardous material release if applicable. Stop work, secure the area, and do not attempt unsafe recovery actions. Emergency equipment such as fire extinguishers and communication devices should be available and workers trained in their use. [4] [14] [1]

For compliance, the employer should maintain a written SOP and risk assessment/JHA for loading and unloading operations, document operator authorization and training, complete and record pre-use inspections where required, enforce traffic management and PPE rules, and review the procedure after incidents or changes in equipment, loads, or site conditions. The program should align with applicable occupational health and safety legislation, powered industrial truck and materials handling requirements, and company safe work procedures. A documented loading dock or yard safety program should address responsibilities, traffic flow, signage, securing trailers, inspection and maintenance, housekeeping, environmental conditions, emergencies, and training. [9] [11] [3]