Best Practice Guidelines for Safe (Un)Loading of Road Freight Vehicles covering Technical, Behavioural, and Organisational Aspects
Issue 1 - December 2013 (Corrigendum Sept. 2021)
Table of Contents
- Introduction
- Scope and Objectives
- Part A: Organizational and Behavioural Aspects
- Part B: Technical Aspects
- Contact List
- Part C: Annexes
- Annex 1: Example Risk Assessment for Bulk Solids Unloading Sites
- Annex 2: Pictorial Examples of Access/Egress to the (Un)Loading Area
- Annex 3: Examples Behaviour Based Safety Observation Reports
- Annex 4: Roles and Tasks for Load Securing in Cargo Transport Units
- Annex 5: Hierarchy and Lists of Applicable Legislation
- Annex 6: Best Practice Guidelines
- Annex 7: Examples of Risks and Risk Mitigation for (Un)Loading Operations
- Annex 8: (Un)Loading Expressions / List in English
- Annex 9: Examples of Pictographic Loading Instructions
Introduction
Continuous efforts to improve safety during the transport and the associated handling of chemicals are part of the overall aim to improve safety performance of both the chemical industry and the transport industry. Statistical analysis shows that 80% of transport-related incidents occur during loading and unloading operations, with human factors being the root cause in 90% of these cases. Thus, increasing safety during these operations is essential.
Scope and Objectives
The objective of these guidelines is to assist in the prevention or elimination of unsafe conditions during (un)loading operations by promoting best practices and recognizing the need for interaction between different involved parties. These guidelines cover the loading and unloading of chemical products at production sites, storage terminals, warehouses, and customers, for liquid bulk, dry bulk, as well as packed goods.
Part A: Organizational and Behavioural Aspects
1. Behaviour Based Safety
Behaviour Based Safety (BBS) is a safety management practice originally used in the process industry to improve safety on the work floor. This guideline suggests applying this system to the (un)loading operation.
Key principles of BBS:
- Active involvement of management.
- Effectively observing and influencing worker behavior.
- Properly training participants.
- Working collaboratively across multiple parties involved in (un)loading operations.
2. Roles and Responsibilities
This chapter lists the roles and responsibilities of parties and individuals involved in the (un)loading operation. Any deviation must be agreed upon by both parties.
Parties involved:
- Principal: The party commissioning the transport company and/or the (un)loading site.
- Transport Company: Contracted by the principal.
- Site: The location where the (un)loading takes place.
- Driver: The person physically carrying out the transport.
- Operator: The site employee carrying out the (un)loading operation.
Responsibilities include equipment provision, competence assurance, site instruction communication, and emergency preparedness among others.
3. SQAS and ESAD
Assessing risks in the supply chain as described in this document can be complemented by qualifying and periodically reviewing transport companies through programs like SQAS (Safety & Quality Assessment Systems) and ESAD (European Single Assessment Document), providing a risk assessment tool and industry benchmarks.
4. Emergency Response Plan
An emergency response plan should address procedures for dealing with incidents such as loss of containment, fire, and explosion. Key elements include containing and controlling incidents, informing on-site personnel, and ensuring readiness of emergency equipment.
5. Applicable Legislation
Different types of applicable legislation are covered under Health and Safety, Process Safety, Environment, and Transport. The specific legislative requirements and standards are listed and described in detail.
6. Communication Skills of Drivers and Operators
Ensuring effective communication between drivers and operators is crucial. This can include using a fixed set of expressions in English, creating supporting means (e.g., leaflets, apps, handbooks), and using pictograms.
Part B: Technical Aspects
7. Technical Requirements (Un)Loading Sites
Examples of risks include overflow, over pressure, exposure to vapours, fire/explosion, among others. Appropriate technical measures depend on a risk assessment involving potential effects and probabilities.
8. SULID: Site (Un)Loading Information Document
SULID lists all practical technical and safety-related information about the (un)loading point. This document aids in identifying potential risks and provides a clear picture of existing situations.
9. Information, Instructions and Training for Drivers and Operators
Drivers must be properly informed of site safety requirements, (un)loading methods, product hazards, etc. Adequate signage and training should be provided to ensure compliance and safety.
10. Personal Protective Equipment (PPE)
Three different sets of PPE are specified based on risk assessments:
- For loading/unloading sealed packed goods.
- For bulk granulates or solid chemicals without danger classification.
- For bulk liquids and DG solids.
11. Unloading Scenarios Bulk Liquid
Four common scenarios for unloading bulk liquids include:
- Bottom unloading by pump and vapour return.
- Bottom discharge by pump without vapour return.
- Bottom unloading by compressed air or inert gas.
- Top discharge.
Each method has distinct advantages, disadvantages, and conditions for safe practice.
12. Couplings and Hoses for Bulk Liquids and Gasses
Multiple types of couplings including BSP, Flange, TW, Guillemin, KNZ, and Kamlok are discussed, describing characteristics, advantages, disadvantages, and conditions for safe use.
Contact List
Please refer to the document for detailed contact information of workgroup members and contributors involved in drafting these guidelines.
Part C: Annexes
Annex 1: Example Risk Assessment for Bulk Solids Unloading Sites
A table detailing various risks, their probability, exposure, severity, and recommendations for risk mitigation measures.
Annex 2: Pictorial Examples of Access/Egress to the (Un)Loading Area
Illustrations showcasing necessary considerations to avoid collisions or hazards upon truck access to (un)loading sites.
Annex 3: Examples Behaviour Based Safety Observation Reports
A practical checklist designed for observing and documenting typical activities during a (un)loading process.
Annex 4: Roles and Tasks for Load Securing in Cargo Transport Units
A matrix listing management responsibilities, operational procedures, tasks, and roles at different stages of loading and unloading.
Annex 5: Hierarchy and Lists of Applicable Legislation
Detailed overview of legislative and regulatory requirements relevant to safe (un)loading of chemicals, categorized by health, safety, environment, and transport regulations.
Annex 6: Best Practice Guidelines
A list of best practice guidelines available online for various aspects of chemical logistics and transport safety.
Annex 7: Examples of Risks and Risk Mitigation for (Un)Loading Operations
Tables outlining potential risks and appropriate technical measures for different types of chemical products during (un)loading operations.
Annex 8: (Un)Loading Expressions / List in English
A set of 142 expressions in English, covering general and emergency scenarios, communication with drivers, and product-specific instructions.
Annex 9: Examples of Pictographic Loading Instructions
Pictograms and cartoons to ensure clarity in instructions provided to drivers during the loading/unloading process.
For further details and appendices, refer to the complete document in the PDF format provided online.
