STANDARD OPERATING PROCEDURE File ref:

CONTAINER UNLOADING OPERATIONS

Version: 1.0
Issue Date:

STANDARD OPERATING PROCEDURE CONTAINER

UNLOADING OPERATIONS

Document No :
Document Type : Procedure

Submitted on
 STANDARD OPERATING PROCEDURE File ref:
CONTAINER UNLOADING OPERATIONS
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Contents
1. INTRODUCTION--------------------------------------------------------------------------------------------------- 3
1.1Purpose------------------------------------------------------------------------------------------3
1.2Scope---------------------------------------------------------------------------------------------3
2. RESPONSIBILITY------------------------------------------------------------------------------------------------- 3
2.1 Operations Manager------------------------------------------------------------------------3
2.2 Officer--------------------------------------------------------------------------------------------3
2.3 Supervisor/person in charge-------------------------------------------------------------3
2.4 Employees--------------------------------------------------------------------------------------4
3. Manpower & Equipment---------------------------------------------------------------------------------------- 4
3.1 Manpower---------------------------------------------------------------------------------------4
3.2 Equipment--------------------------------------------------------------------------------------4
4. PPE and Safety Equipment------------------------------------------------------------------------------------ 4
5. Hazard and Incident Reporting-------------------------------------------------------------------------------4
6. Prior to Commencing Container Loading and Unloading Operations--------------------------4
7. KEY PRINCIPLES FOR SAFE UNPACKING--------------------------------------------------------------5
8. UNLOADING PROCEDURE------------------------------------------------------------------------------------ 6
8.1 PLACEMENT OF THE CONTAINER FOR UNLOADING--------------------------6
8.1.1 WHAT IS THE ISSUE?-------------------------------------------------------------------------------6
8.1.2 HOW CAN I MANAGE THIS?--------------------------------------------------------------------6
8.2 BEFORE OPENING THE CONTAINER-------------------------------------------------7
8.2.1 WHAT IS THE ISSUE?-------------------------------------------------------------------------------7
8.2.2 HOW CAN WE MANAGE THIS?---------------------------------------------------------------7
8.3 BEFORE UNPACKING THE CONTAINER--------------------------------------------7
8.3.1 WHAT IS THE ISSUE?-------------------------------------------------------------------------------7
8.3.2 HOW CAN WE MANAGE THIS?---------------------------------------------------------------8
8.4 UNPACKING-----------------------------------------------------------------------------------8
8.4.1 WHAT IS THE ISSUE?-------------------------------------------------------------------------------8
8.4.2 HOW CAN WE MANAGE THIS?---------------------------------------------------------------9
Some Photos of How to Load/Unload Container--------------------------------------------------------11
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1. INTRODUCTION
1.1 Purpose
To ensure container unloading operations are completed safely and to eliminate the
potential for injuries where vehicle and people interaction occurs.
1.2 Scope
This procedure applies to all warehouse section employees, forklift operators and
other personnel involved in the unloading operations of container on the loading bay.
Cargo types could be including containers, lorries trailer and truck trailers for export,
local sales and intra-plant transfer.
This Standard Operation Procedure (SOP) is to be used in reference to the following
KPA SOP’s:

 Forklift Operations
 Personal Protective Equipment (PPE)
 Hazard and Incident Reporting Procedure

2. RESPONSIBILITY

2.1 Operations Manager

 Ensure this procedure is developed and reviewed with adequate consultation:
and
 Authorizing approval and amendment to this procedure.
2.2 Officer
 Implementing this procedure, including education regarding critical changes to
the procedure are communicated to supervisors, employees and relevant
trucking companies;
 Monitoring compliance with this procedure;
 Periodic review of this procedure; and
 Investigating reported non-compliances with this procedure

2.3 Supervisor/person in charge

 To ensure they and their team members comply with this procedure;
 To ensure that the forklift driver have a current license and are currently verified
as competent to operate the equipment;
 To ensure the unloading of trucks is conducted safely and in consultation with the
truck and forklift driver;
 To report non-compliances with this procedure to Management;
 To complete required documentation associated with unloading of trucks; and
 Periodic review of this procedure.
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2.4 Employees
 To comply with this procedure;
 To follow instructions from the supervisor or person in charge regarding this
procedure;
 To report all hazards and/or incidents to our supervisor as soon as possible
 To secure loads correctly
 To ensure that any specific loading requirements are passed on to the supervisor
in-charge of loading
3. Manpower & Equipment

3.1 Manpower
 Skilled Site Supervisor
 Safety Officer
 Forklift Operator
 Crane Operator
 Required nos of Skilled and semiskilled labor
3.2 Equipment
 Forklift (as required capacity)
 Crane (as required capacity)
 Different type of hand tools
 Wire rope

4. PPE and Safety Equipment

All forklift driver involved in the loading and unloading process must wear appropriate
such as;
 Safety Shoes
 Safety Vest
5. Hazard and Incident Reporting
 If we identify a hazard:
 if possible, remove or eliminate the hazard;
 make the work area safe e.g. barricades, tag out
 alert our colleagues and report it to supervisor
6. Prior to Commencing Container Loading and Unloading Operations

Warehouse officer or supervisor plan for the task of loading and unloading container
with workers. The process must be followed to;
 Goods first in first out (FIFO) and;
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 Order booking closing date (ETD)

The following are general loading and unloading procedures for trucks:

 Trucks may be loaded and unloaded either manually, by forklifts or loader

(Pallets).
 The use of forklift is determined by the KPA Supervisor/person in charge.
 Loading/unloading cargo by forklift is to be done by the delegated competent
forklift
 Operator utilizing safe zones and work areas as per Forklift SOP.
 Never stand under the load.

7. KEY PRINCIPLES FOR SAFE UNPACKING

 Always establish a plan for safe unpacking before doing anything else.
 If the load has shifted or appears precarious or unsafe, don’t enter the
container.
 Never allow workers inside the container if there is any risk of objects
moving and trapping them.
 Never allow workers inside the container if there is a chemical spill.
 Never allow people and mobile plant to operate inside containers at the
same time.
 Avoid working alone inside containers.
 Continue to assess the load for risks as we unpack. If conditions change,
don’t risk it. Stop, conduct a risk assessment and replan the work taking
all reasonable precautions.
 Never stand near a load that is unsecured. For example, sheet material
on an A-frame.
 Where practicable, use mechanical aids over manual handling. For
example, a conveyor.
 Ensure workers who are unpacking containers are trained, supervised and
competent. This will help them to select the right work processes that have
the lowest risk, choose appropriate equipment and know when to call for
assistance if safety
 is unclear or jeopardized.
 Ask for help if we don’t have the equipment or expertise to safely unpack a
container.
 If necessary, engage specialists to do the unpacking.
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 Ensure workers wear appropriate PPE when
emptying the container.

8. UNLOADING PROCEDURE
8.1 PLACEMENT OF THE CONTAINER FOR UNLOADING
8.1.1 WHAT IS THE ISSUE?

Placement of a container in an inadequate location onsite can lead to a number of risks

including:
 electrocution
 slips, trips and falls
 falls from height
 collision of people and plant
 physical fatigue
 musculoskeletal disorders
 risk of being hit by unrestrained items or falling loads.

8.1.2 HOW CAN I MANAGE THIS?

The risk of injuries arising from the placement of the container can be eliminated or
significantly reduced by:
 consulting with workers who will be unpacking the container
 consulting with other site users prior to placement of the container on common
property
 considering the proposed container site prior to its arrival, including the path
of navigation to its resting place. For example, are there obstacles, overhead
power lines or any other dangers?
 selecting a suitable area for unpacking on level undamaged ground with
sufficient space to open doors and provide safe access
 paying close attention to the stability of the container if it is positioned at a
height to access a loading dock. We should consider lowering the landing
leg of the trailer to sure this up
 ensuring the site has adequate space to operate plant in and around the
container and to set down a load outside of the container (this should be
considered in Traffic Management Plan)
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 ensuring there is sufficient lighting in and around the container for

unpacking and operating plant
 considering the environmental conditions of the site, for example, heat, rain
and ventilation; and the appropriateness for workers unpacking in these
conditions.

8.2 BEFORE OPENING THE CONTAINER

8.2.1 WHAT IS THE ISSUE?

Loads within a container often shift during transportation or may move as a result of
inadequate packing. Goods may be pushing against container doors. This can lead to
uncontrolled opening of the doors. Workers are at risk of being hit by unrestrained items
or falling loads.
8.2.2 HOW CAN WE MANAGE THIS?
 The risk of injuries arising from the opening the container can be eliminated or
significantly reduced by:
 never assuming the load is secured in a safe manner when we are opening a
container door
 using a suitable restraint, such as a short rope, net or barrier, on the door to
prevent the items resting on the doors from forcing the doors open without a
control in place
 opening the right-hand door cautiously first, only when safe, proceed with the left
 checking to see if the goods have shifted when the doors are partially opened
 consulting with workers to develop and implement a safe method of unpacking
(using a safe work method statement) if the goods have shifted
 checking for any notices or labels (such as dangerous goods labels), or notices
concerning the contents.

8.3 BEFORE UNPACKING THE CONTAINER

8.3.1 WHAT IS THE ISSUE?

Unpacking without a plan may lead to an unsystematic, adhoc approach. This can
ultimately expose our workers to risks.
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8.3.2 HOW CAN WE MANAGE THIS?

The risk of injuries arising from the opening of the container can be eliminated
or significantly reduced by:

 planning the order in which the items should be removed to avoid

remaining items becoming unstable and falling
 determining the number of workers required to safely unpack the
container
 determining the appropriate equipment to unpack the load safely. This
might include, but is not limited to, plant, conveyors and personal protective
equipment (PPE)
 considering the placement of the container, the movement of plant into
and out of the container, and the placement of load we are unpacking
when outside of the container
 considering risks that may arise during unpacking, and ways to minimize
risks by including control measures to either prevent or manage hazards.

8.4 UNPACKING

8.4.1 WHAT IS THE ISSUE?

Workers are at risk when they are unpacking heavy, awkward and unsecured items.

The systems used to unpack containers may include the manual handling of goods.
This can involve heavy lifting, using awkward postures and spending long periods of
time doing the same movements. Mobile plant can be used to eliminate the need to
complete hazardous manual tasks.

All of these can pose a range of risks to worker including:

 people being hit by unrestrained items or falling loads
 people being hit by mobile plant such as forklifts
 musculoskeletal injuries, such a sprains and strains
 slips, trips and falls when manually handling a heavy and awkward object.
Reaching those objects is also a risk.
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8.4.2 HOW CAN WE MANAGE THIS?

The risk of injuries arising from unpacking shipping containers can be eliminated or
significantly reduced by:
 only removing the restraints of the item to be immediately removed.
 bracing items temporarily with suitably rated restraint devices such as props,

braces or frames where there is a risk of the items falling

 keeping the area around the container clear of obstructions
 having an appropriate traffic management plan in place
 reducing manual handling by using mechanical loading and unloading
systems. This can include:
– unloading with powered mechanical aids such as a forklift or electric pallet
truck if the load was packed using bulk bags, pallets or slip sheets
– packing small items on a pallet to be removed using a pallet truck or a
forklift.
 If manual unpacking is necessary, we should:
– train workers in the safest system of work to unload the container
– ensure goods are handled between the knee and shoulder height by using
pallet jacks, pallet rollers, trolleys or adjustable conveyers.
 using PPE such as gloves, hard hats, safety glasses, and hi-visibility
clothing
 unloading with mobile plant. When doing so, we should:
– ensure appropriate traffic management measures are in place to
separate people and plant
– use a crane or forklift with attachments such as grabs, spikes or
slippers
use a tag line to guide loads being lifted using a crane – to keep away from the load
– ensure the attachments and slings are inspected and maintained
– ensure the ratings of any plant using attachments, such as fork tyne
slippers, are known to avoid overloading.
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 taking extra care when unpacking sheet material,
such as glass sheet, panels, stone sheets, and composite slabs. We can do this
by:
– strapping items to an ‘A’ frame or to the side of the container. Securing

each sheet using a separate strap means workers can only release the
sheet that is being removed – one at a time
– using mechanical aids to eliminate the need to manually handle goods
– ensuring individual sheets are secured as we unpack
– unpacking only in a designated area
– ensuring the load is secured in its final destination.
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Some Photos of How to Load/Unload Container

Photo 1: Container must be park close loading bay “Dock leveler”

Photo 2: Container stopper must be placed at tires before loading and unloading
operation.
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Phote 3: Check container condition (Inside & Outside) before loading and
unloading operation

Phot0 4: Use restraints to ensure doors can be opened safely

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Photo 5: Prepare and check goods condition before/after loading or unloading

operations

Photo 6: Use cargo net or plastic rope for tight the goods on the last row
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Photo 7: Example correct way of loading and unloading truck

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Photo 8: In case of Large Pallet, we will use multiple
Forklift Like this way.

Photo 9: In case of Open top or Flat Rack or heavy Pallet, we will use Crane Like
this way.
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Photo 10: In case of Pallet inner side of the
Container, we will use wire rope

n.b. Mobile Phones

Mobile phone use is restricted to forklift & Crane Operator during operation It is
recognized 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.
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