File ref: OSH103/1227861

STANDARD OPERATING PROCEDURES

TRUCK LOADING AND UNLOADING Version: 3

Broome Port Services OPERATIONS Issue date: Aug 2017

Current version number: 3 File reference: OSH103/122786 Original issue date: April 2013

Maintained by: Harbourmaster/Operations Manager Last review date: Aug 2017

Next review date: Aug 2019 Procedure: non-core Review period: 2yrs

Roles: Operational employees and truck drivers

1. INTRODUCTION

1.1. Purpose

To ensure truck loading and unloading operations are conducted safely at the Port of
Broome to eliminate the potential for injuries, particularly as a result of vehicle and human
interaction.

1.2. Scope

This procedure applies to all Kimberley Ports Authority (KPA) employees, truck operators
and other personnel involved in the loading and unloading operations of all trucks and
trailers in Port controlled areas including the wharf, irrespective of the nature of the goods.

1.3. References

 Loading, Unloading Exclusion Zones Guidelines (LUEZ) V1 November 2010. Safety

Assist;
 Load Restraint Guide, 2nd Edition 2004, National Transport Commission Australia;
and
 Marine Order Part 32, (Cargo Handling Equipment,) 2011.

This Standard Operating Procedure (SOP) is to be used in conjunction with KPA’s OSH
Management System and in particular the following KPA Policies and SOPs:

 OSH Policy;
 Crane Operations; and
 Forklift Operations.

2. RESPONSIBILITIES

OSH responsibilities are outlined in KPA’s OSH Policy. The following area specific
responsibilities relating to truck loading and unloading operations.

2.1. Supervisor/person in charge

It is the responsibility of the Supervisor or person in charge to:

 ensure appropriate consultation with the truck driver;

 ensure that a member of their team (eg the dogman or forklift operator) is responsible
for confirming with the truck driver:
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OPERATIONS SOP
Broome Port Services Issue date: Aug 2017

- the location of the safe zone;

- when cargo operations have been completed; and
- when it is safe to move from the safe zone.

2.2. Employees

Employee’s responsibilities include:

 in regards to reversing trucks, check that a spotter is in place and where required
actively be a spotter.

2.3. Truck Operators

Truck Operator responsibilities include:

 all truck operators to comply with this procedure;

 to ensure a spotter is in place at all times and on all occasions when reversing;
 to ensure that any specific loading requirements are passed on to the supervisor in
charge of loading;
 to wear correct PPE including gloves when undertaking manual handling tasks
including securing the load;
 to report any hazards or incidents to a KPA supervisor;
 to comply with directions from KPA employees in regards to this procedure; and
 to secure loads correctly prior to moving the truck.

3. DEFINITIONS

Load restraint: Load restraint includes lashing/unlashing, tie down, twistlock

locking/unlocking for the purposes of ensuring a load is secured to the truck to meet the
performance standards in the load restraint guide or unsecured in preparation for removal.

Safe zone: is an area free of interaction between equipment/machinery and people. The
safe zone will usually be identified by green for example green safety cones.

Spotter: A person acknowledged by the equipment or vehicle operator to provide assistance

for maneuvering and in particular reversing the equipment or vehicle.

Work Zone: Also called the exclusion zone, is an area where operational tasks occur e.g.
crane/forklift operations for truck unloading/loading. Only operationally critical personnel can
enter the work zone, as approved by Supervisor.

4. PPE AND SAFETY EQUIPMENT

All KPA Employees and Port Users are required to wear the minimum PPE requirements.
For information on what requirements are to be met (see Appendix 1). KPA employees can
refer to the KPA PPE sop for more detailed information.

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OPERATIONS SOP
Broome Port Services Issue date: Aug 2017

All KPA employees and truck operators involved in the loading and unloading process must
wear appropriate gloves, unless they are operating equipment e.g. crane, truck or forklift.

To comply with KPA’s safe hands program the hierarchy of risk controls is to be considered
when planning tasks for example consider if a crane, forklift, stiffy sticks or tag lines can be
used prior to using hands (with gloves). In addition, consideration must be given to the
potential stored energy of the object being lifted.

Stairs or platforms are to be used to access truck trailer decks when rigging/unrigging loads.

Appropriate equipment such as traffic cones, flags and/or bollards, are to be used to mark
the exclusion zone around the work area and safe zones. For example, red/orange/yellow
traffic cones for work/exclusion zones and green traffic cones for safe zones such as PPE
free zones.

5. STOP WORK AUTHORITY AND HAZARD AND INCIDENT REPORTING

All KPA employees and port users have the right to stop the job if they believe; there is an
unsafe situation, condition or that an unsafe act is being performed.

Except when there is an immediate risk of injury or harm, the stop work should be
coordinated through the supervisor or manager. . A Stop Work Order will only be lifted by
the person in charge of the work following an appropriate review and implementation of any
remedial action necessary to undertake and complete the work safely.

If you identify a hazard:

 if possible remove or eliminate the hazard;

 make the work area safe e.g. barricades, tag out;
 alert your colleagues;
 report it to you supervisor;
 that is not able to be resolved and you are still exposed to an unsafe situation then
cease work (a Stop Work Authority is activated) until the matter is resolved; and
 report the hazard by filling out a hazob.

If there is an incident resulting in injury, damage or a near miss the job should be stopped
and the incident reported to the supervisor. The supervisor should then advise a
management representative immediately. Priority must be given to any injured personnel
and rectifying or isolating any hazard resulting from the incident to ensure others are not put
in any danger. Where it is safe, employees and truck drivers must remain at the location of
the incident, until authorisation to leave is given by a KPA Management Representative.

Note: Serious incidents may require the authorities to conduct an investigation. In this case
the site will need to be left in the same condition as when the incident occurred until they
attend the site. This requirement is not to restrict or impede any rescue efforts or
environmental pollution controls.

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OPERATIONS SOP
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6. PRIOR TO COMMENCING CARGO OPERATIONS

6.1. Traffic Management

A traffic management plan for the task is to be discussed between the involved parties, for
example at a toolbox talk, prior to loading and unloading. A trucking operator representative
may attend this toolbox meeting. The traffic management plan will be discussed and
appropriate controls to be implemented, including traffic cones designating specific work
areas and safe zones.

Specific traffic management requirements, such as oversize loads, must be communicated

to appropriate KPA personnel such as the Gatehouse and third parties to ensure the traffic
plan is understood.

No more than 2 trucks per cargo vessel are to be in the Maritime Security Zone and where
possible heavy vehicles should drive forward into position.

Refer to the Traffic Management SOP for further information.

6.2. Work Zones

When identifying the work zones it is important to consider the following:

 Other pedestrians not related to the specific job;

 Driver safe zone;
 KPA employee safe zone;
 Effective system of communication; and
 Effective loading and unloading operations in progress warnings; e.g. spotter,
barricades and signage.

See photo below for example of driver safety zone and work zone.

Photo 1: Driver Safe Zone and Work Zone

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6.3. Mobile Phones

Mobile phone use is to be limited and restricted to operational needs only and must not be
used within the work zone. It is recognised that Supervisors are required to use mobiles
more frequently for operational reasons. Supervisors must ensure it is safe to take the call
and they must leave the work area and/or take the call in the marked safe zone.

6.4. Cargo Manifest

The supervisor must have a copy of the cargo manifest or other cargo documentation from
Port Operations or the Drilling Logistics Coordinator (DLC)/Agent, clearly identifying by
volume, weight and distinguishing marks the cargo to be handled before commencing the
discharge/backload operations to or from a truck.

The Supervisor must positively identify each of the goods /cargo to be handled and verify the
weight marked on the goods corresponds to the manifested weight..

7. GENERAL LOADING AND UNLOADING TRUCK PROCEDURES

The following are general loading and unloading procedures for trucks.

General requirements:

 Never stand under the load;

 Be aware of pinch points and crush hazards during the loading and unloading
process. Keep hands away from cargo and truck trailer during loading and unloading
and avoid touching the load with your hands while it is moving or suspended.
Utilising hands free tools and tag lines for assisting load control is appropriate;
 Truck drivers are not to walk into the work area during cargo handling operations
unless authorised by a KPA employee;
 Truck drivers must stay in the safe zone, for example next to the cab, until the load
has been loaded or unloaded and/or the truck driver has been authorised to leave the
safe zone by the KPA dogman or forklift operator;
 Truck drivers to remain with their vehicles unless there is an operational requirement
to do otherwise;
 If trucks are required to reverse on Port Lands and/or the wharf then a spotter is
required at all times during the reversing operation. It is the responsibility of the truck
driver to ensure that a spotter is in place. The spotter could be a KPA employee,
another truck driver, a competent vessel crew member. Reversing alarms must be
installed and in good working order on all trucks. In addition, it is recommended that
truck trailers have reversing beepers. Note: the requirement for a spotter is for all
articulated trucks or any truck that has an obstructed view;
 Any loads or items placed on the wharf from a vessel or truck must be placed in a
planned methodical way considering good housekeeping practices and well clear of
the hazard line to maintain sufficient room for any mooring or unmooring that may
arise. No items are to be stored on or inside the hazard line. In addition, trucks must
park away from the hazard line to ensure that the driver does not need to enter the

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OPERATIONS SOP
Broome Port Services Issue date: Aug 2017

hazard zone to exit/enter the cab, unless a safety control is in place (i.e. PFD or
safety rail in place).

Loading/unloading requirements:

 Trucks may be loaded and unloaded either by cranes and/or forklifts. The use of the
crane or forklift is determined by the KPA Supervisor/person in charge. Forklift/crane
operations may be simultaneous but each trailer to have only one item
loaded/unloaded at a time;
 Loading/unloading cargo by forklift is to be done by the delegated competent forklift
operator utilising safe zones and work areas as per Forklift SOP;
 KPA employees must not stand on truck trailers during placement or removal of
loads by cranes or forklifts. Access to truck trailers should be avoided where
possible and only occur with the authorisation of the supervisor/person in charge,
once the load is landed and settled on the truck and where an adjacent platform, for
example a trailer, work platform or stairs, is in place. Stairs need to be controlled by
another person while in use. See photo 2 for example of trailer access; and
 Lifts are to be checked off the manifest and any discrepancies noted and advised
immediately to the superintendent
 Goods/Cargo are not to be lifted if there is a discrepancy between the manifested
weight and the weight marked on the goods until the discrepancy is resolved.
 If there is a weight that is re-declared as a result of a discrepancy, ensure that the
appropriate persons are notified, including truck operators who may need to adjust
the truck load plan and load restraint parameters.

Photo 2: Trailer access and crane/truck work zone

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Broome Port Services Issue date: Aug 2017

Restraint requirements

 For trucks the unlashing and lashing will be conducted by the truck drivers or trucking
company representative. All lashing on vehicles is to be in compliance with the Load
Restraint Guide;
 Trucks are to arrive and depart the Port Lands and the jetty with all items suitably
restrained by the transport company. If safe to do so, and in agreement with the
Supervisor, trucks can move to the lashing zone for restraining of a load;
 The trucking company is responsible for determining the appropriate restraint method
in line with the load restraint guide and the load placement location on truck. KPA
stevedores are required to bring to the attention of a truck driver when they believe a
load is not restrained in accordance with the Load Restraint Guide. Where you
believe an unsafe situation has not been addressed adequately then you are
required to notify your Supervisor immediately or elevate your concerns to a
Management representative; and

7.1. Specific Cargo Requirements for Trucks:

Some cargo may have specific safety considerations including, but not limited to, the
following:

 Tubular cargo is to be loaded and unloaded on trucks with suitable headboards and
sufficient bolsters in place to secure the load should the tubular items shift
 Containers:
o Slings on pre-slung containers must be long enough and be on the outside of
the container so they can be easily reached to avoid the need to climb into or
on top of containers or onto a truck trailer. Stingers should be used to ensure
slings are of adequate length.
o Containers are to be loaded onto trailer twistlocks where possible. The truck
driver is responsible for locking the twistlocks.
 Break bulk bags can have a separate lashing zone. Once bags are landed and
unhooked and personnel have left the work area the truck can be directed to the
lashing zone.
 When loading radioactive items on to trucks they should be loaded as far from the
drivers cab as possible to protect the driver from radiation exposure during long line
haul trips.

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OPERATIONS SOP
Broome Port Services Issue date: Aug 2017

VARIATION RECORD:

Version No. Version Date: Brief Description of Change:

This procedure has been separated from the Vessel loading and
1.0 April 2013
discharging operations SOP. A complete review occurred.
Minor updates including clarification of use of gloves and number of trucks
1.1 June 2013
on wharf during cargo operations.

1.2 June 2013 Changed wording of assessment question.

1.3 August 2013 Changed wording of assessment question.

KPA logo and position title changes. Minor additions including information
1.4 September 2014 on vessel manifest and information on unloading and loading dangerous
goods and loading livestock and fodder.

1.5 March 2015 Change to truck operators responsibilities.

2.0 September 2015 Include Hazard line and housekeeping plus full review.

Updated 7.2 Loading and unloading Tubular on Trucks to reflect new way
2.1 April 2016
of crossing over wire slings and securing through eye.
Clarification of simultaneous operations in section 7. Information on trucks
2.2 July 2016
parking away from the hazard line.
Clarification to 6.4 Suitability of pallets or bags on plastic shrink wrapping,
2.3 August 2016
addition of unitising to definitions.
Review of document with removal of repeated information throughout the
document and references made to other KPA documentation where
required. Major changes included:
Section 2: reference to OSH Policy for general responsibilities,
Section3: definitions reduced to SOP specific terms only
Section 6: removal of information about pallets as this is covered in KPA’s
3 August 2017 vessel loading SOP
Section 7: review of whole section and removal of repeated information
including rig tender example as this information is already covered in the
general guidelines. Clarification on the requirement and use of a spotter
when reversing, additional requirements for reversing beepers and
additional information on the procedure to access containers). Cargo
specific information reworded and summarised in section 7.1.

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OPERATIONS SOP
Broome Port Services Issue date: Aug 2017

ACKNOWLEDGEMENT

This written assessment must be completed by KPA employees and personnel involved in
the loading and unloading operations of trucks to ensure a good understanding of the
Procedure.

INSTRUCTIONS: All questions must be answered correctly; incorrect answers will require
you to demonstrate your understanding to the correct and fill in where indicated. Pass mark
is 100% correct

Questions:

1. How are the following areas marked?

a) The work zone:

b) The safe zone:

2. When slings are unable to be accessed from the ground, stairs or a platform, then
the container is to be:

a)
b)

3. Tag lines and hands free tools/ stiffy sticks are used to achieve what outcome?

4. Truck drivers will conduct all lashing/unlashing and locking/unlocking of loads. (Tick
true or false)

True False

5. Who is responsible for arranging a spotter for a reversing truck? (Tick correct one)

KPA Stevedore Truck Driver

End of Assessment
I have read and understood the content of the Policy/Procedure and agree to be
bound by the Policy/Procedure.

Full Name (please print):

Signature: Date:

Organisation:

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