Safe Loading and Unloading of Lorries and Trucks

Date: 2025-09-18

Duration: [DURATION] minutes

Presenter: [PRESENTER NAME]

Location: [LOCATION]

Objective

To ensure all personnel understand and follow safe procedures for loading and unloading lorries and trucks, including nearside operations and hiab crane usage, to prevent injuries and damage.

Introduction

Loading and unloading lorries and trucks are high-risk activities. This toolbox talk will cover key safety points to minimize these risks, focusing on both general procedures and specific considerations for nearside operations and hiab crane usage.

Key Points

Pre-Operation Checks: Before commencing any loading or unloading activity, inspect the vehicle, loading area, and equipment. Ensure the vehicle's brakes are engaged and wheels are chocked to prevent movement. Verify that the trailer's landing gear is fully supporting the trailer if it is not coupled to a vehicle.
Safe Positioning: Position the vehicle on a level surface, free from debris and obstructions. Ensure sufficient clearance around the vehicle for safe movement of personnel and equipment. For flatbed trailers, ensure the surface is stable and free of depressions or mounds. [2]
Communication: Maintain clear communication between the driver, forklift operator, and any other personnel involved. Use hand signals or radios to coordinate movements, especially when visibility is limited.
Load Evaluation: Evaluate each load before lifting. Do not lift unstable or improperly secured loads. Ensure the load is balanced and within the weight capacity of the forklift or hiab crane. [2]
Hiab Crane Safety: When using a hiab crane, ensure the operator is properly trained and certified. Conduct a thorough inspection of the crane before use, checking for any defects or damage. Follow the manufacturer's guidelines for safe operation, including load limits and operating procedures.
Nearside Operations: Nearside loading and unloading present unique risks due to proximity to traffic. Implement additional control measures such as barriers, warning signs, and traffic management plans to protect personnel from passing vehicles.

Hazard Identification

Loading and unloading activities involve several hazards that can lead to serious injuries. Being aware of these hazards is the first step in preventing accidents.

Vehicle Movement: Uncontrolled vehicle movement during loading/unloading can cause collisions, crushing injuries, or run-over accidents.
Falling Loads: Unsecured or unstable loads can fall, causing serious injuries to personnel and damage to equipment.
Crushing Hazards: Workers can be crushed between vehicles, loads, or equipment during maneuvering.
Slips, Trips, and Falls: Slippery surfaces, obstructions, and uneven ground can lead to slips, trips, and falls, resulting in injuries.
Hiab Crane Malfunctions: Crane failure or improper operation can cause dropped loads, equipment damage, and severe injuries.

Control Measures

Vehicle Restraints: Engage vehicle brakes, use wheel chocks, and, if available, utilize a trailer restraint system to prevent movement during loading/unloading. [1] [1] [1]
Load Securing: Ensure all loads are properly secured with appropriate straps, chains, or other securing devices before lifting or moving.
Exclusion Zones: Establish and enforce exclusion zones around loading/unloading areas to keep unauthorized personnel away from potential hazards.
Traffic Management: Implement a traffic management plan to control vehicle and pedestrian movement in and around the loading area, especially during nearside operations.
Equipment Inspection: Regularly inspect all equipment, including forklifts and hiab cranes, to ensure they are in good working condition. Remove any defective equipment from service immediately.
Training and Competency: Ensure all personnel involved in loading/unloading activities are properly trained and competent in their roles. Provide refresher training as needed.

Personal Protective Equipment (PPE) Requirements

High-Visibility Clothing: All personnel must wear high-visibility clothing to ensure they are easily seen by vehicle operators and other workers.
Safety Footwear: Wear safety footwear with steel toes and slip-resistant soles to protect against foot injuries.
Gloves: Use gloves to protect hands from cuts, abrasions, and impacts when handling loads and equipment.
Hard Hat: Wear a hard hat to protect against head injuries from falling objects or impacts.

Real-World Example or Case Study

A worker was seriously injured when a forklift truck tipped over while unloading a lorry. The investigation revealed that the vehicle's brakes were not engaged, and the load was not properly balanced. This incident highlights the importance of following pre-operation checks and safe loading procedures.

Group Discussion

Discuss the following questions:

What are some common challenges you face during loading and unloading operations?
How can we improve communication between drivers, forklift operators, and other personnel?
What additional control measures can we implement to enhance safety during nearside operations?

Emergency Procedures

In case of an accident, immediately stop work and secure the area.
Provide first aid to any injured personnel and call for medical assistance if needed.
Report the incident to the supervisor and complete an incident report.

Questions and Answers

Now, let's take a few minutes to address any questions or concerns you may have about safe loading and unloading procedures.

Q: What should I do if I see a load that is not properly secured?

A: Immediately report it to your supervisor and do not attempt to move the load until it is properly secured.

Q: What is the procedure for reporting a damaged piece of equipment?

A: Remove the equipment from service and report the damage to your supervisor immediately.

Summary

Recap of main points:

Always perform pre-operation checks on vehicles and equipment.
Ensure loads are properly secured and balanced.
Maintain clear communication and follow safe work procedures.
Wear appropriate PPE at all times.

Action Items

Specific actions participants should take:

Review and understand the site-specific loading and unloading procedures.
Report any hazards or unsafe conditions to your supervisor immediately.
Actively participate in safety briefings and training sessions.

Remember: Safety First: Load Smart, Unload Safe!

Report all hazards, near-misses, and incidents to your supervisor immediately.