7. Basic safety regulations during loading and unloading operations

7. a. Risks related to the activity

  • Being struck by moving objects.
  • Being struck by motionless objects.
  • Being struck by falling objects.
  • Injury caused by flying particles.
  • Falls to different levels.
  • Collision of bridge cranes.
  • Being knocked down (by a forklift or another vehicle).
  • Entrapment by and between objects.
  • Being crushed.
  • Cuts, pricks, etc.

7. b. Materalisation of the risk

Immediate causes:

Unsafe actions

  • Standing in an area where there is a risk of handled materials falling.
  • Standing within the radius of action of a forklift/bridge crane while it is in movement.
  • Incorrect securing of racks or loads inside trucks.
  • Not controlling the load during the entire transport process.
  • Lifting the materials to remove the sling while standing in front of them.
  • Not cleaning the work area.
  • Not signposting the work area.

Basic causes: personal factors

  • The worker had experience in the job and had attended training courses on risks involved in his job, but the accident occurred despite all this. This could have been due to an excess of confidence on the part of the worker.
  • The worker was reading the loading instructions and did not calculate the forklift loading times correctly.
  • The load was not checked by either the foremen or the driver.
  • The driver did not check the load during transport.
  • Lack of attention during the operation, due to an excess of confidence (last operation of the day).
  • The operation did not consider the wooden dividers separating the slab packs.
  • The operation did not watch where he was walking.

Material factors

  • Old racks with no bar system to prevent overturning.
  • Area where the crane/forklift is working. Possible simultaneous use of two cranes.
  • New tensioners (efficiency not checked).
  • Load incorrectly secured.
  • Several lifting accessories hung from the crane hook.
  • Wooden dividers placed between the slabs to separate the loads.
  • Untidy work areas.

General provisions

  • Only staff authorised by the company can operate cranes or forklifts.
  • In the event of an anomaly or faulty operation of any piece of work equipment, the worker will report it immediately to his supervisor and, if necessary, put up a sign to indicate the failure and prohibit the use of the crane or forklift.
  • Workers must not accompany the load near rigid or fixed elements, as otherwise they could be crushed.
  • Hoisting and lowering of loads will be done slowly, without the load swaying, which could be very dangerous, when operating the bridge crane or the forklift.
  • It is forbidden to carry or lift persons, whether loaded or not.
  • It is forbidden to move loads by dragging them.
  • When operating a bridge crane or a forklift, move the load to a height that is sufficient to prevent it from colliding with obstacles. Do not leave loads in places of passage.
  • In the event of a failure in the work equipment, deposit the load on the ground and unhook it. If this is not possible, put up beacons to prevent other workers from walking below or near it.
  • When using the anti-tip bars, before starting to separate the slabs, make sure the bars are correct adjusted (inserted as far as they will go, with not clearance). Otherwise, the reliability of the anti-tip system is not guaranteed, and the load could overturn.
  • The work area must be kept clean, and all wooden dividers, pieces of detached material, tools not in use, etc. must be removed from it.
  • Pay special attention to coordination between bridge cranes when the use of various cranes at once is inevitable.
  • When loading with forklifts, the work area must be properly marked and signposted, to prevent other people from entering this area.
  • Pallets and small boxes that are also loaded on trailers (flooring, samples, marketing products, etc.) must not be secured to the truck frame for transport. In the case of elaborated parts (which are larger in size) such as worktops, counters, etc., they must be secured to the frame with belt
    tensioners.
  • In the event of doubt, ask the warehous foreman.

Corrective actions:

  • Continue the specific training programme in operating elevation equipment and transport of materials.
  • Implementation of mechanical systems to increase safety measures in the transport and storage of materials. Replacement of old racks.
  • Visual control of the work area when moving work equipment.
  • Routine control of accessories used during work operations.
  • Routine control of loading processes and of completed loads.
  • Clean or tidy the work area during work operations (not afterwards).

Other actions

  • Define areas used for stockpiling and for the passage of workers by marking the ground.
  • Install wireless push button panels on all cranes in which this is technically possible.
  • Keep work areas clean and tidy.
  • Install signs indicating main risks and basic safety guidelines in shipment areas.
  • Mark off loading areas, to prevent access by unauthorised persons.
  • Possible construction of loading bays in the loading warehouses.
  • Use of non-slip elements beneath racks on trailers in which this is necessary.

Example of signs in shipment areas:

  • Always be alert and within the visibility of the driver/vehicle moving into the warehouse.
  • Never stand in an area where you cannot be seen clearly!
  • Only authorized personal within the area of unloading/loading.
  • Safety bars on A-trames to be used at all times.
  • Do not walk or stand under suspended loads at any time.
  • Do not walk or stand in the travelling path of slabs once they are lifted and are being moved.
  • Do not handle or attempt to open the slab bundle inside the vehicle. Opening of the slab bundle is to be done once the slabs are clear of the vehicle and safety positioned.