Serious incident involving the unloading of materials

Possible control measures to prevent similar incidents

A Person Conducting a Business or Undertaking (PCBU) has a duty to ensure workers and other people are not exposed to health and safety risks, including the risks associated with loading and unloading trucks and trailers.

The most effective control measure is to eliminate the hazard or hazardous work practice associated with loading and unloading operations. Where elimination can’t be achieved, other controls can be implemented to minimise the risk.

This can include designing or modifying the trailer so the worker does not need to be near the trailer during the loading and unloading process (this could also be considered an engineering control). For example, trailers fitted with stanchions and cradles to support loads and prevent unexpected movement.

In situations like the incident, where materials are being unloaded from a truck, a safe system of work (along with a traffic management plan) should be implemented and maintained. This could include, but is not limited to:

• where practicable, arranging the load so workers do not need to climb onto the trailer.
• inspecting and preparing the area. Confirm that the worksite is free of debris, holes and objects that could obstruct the loading process, or cause slips, trips and falls. Ideally the lay down area should be located on firm, level ground.
• separating people from loading areas using barriers, fences or other similar options.
• ensuring the forklift is equipped with lifting attachments that are suitable for the load being unloaded.
• providing workers with instruction, training and supervision on safe work procedures. Training and instruction should be provided to workers by a competent person in an easy-to-understand manner.
• confirming workers involved in the activities are aware of the weight of the stock to be unloaded.
• consultation regarding the work and the related risks must occur between the PCBU and workers and others whose health and safety is likely to be affected.
• when choosing the right plant for loading and unloading operations, ensure the plant is used only in accordance with manufacturer’s specifications and its intended purpose.

Traffic management plan

Whenever mobile plant such as a forklift is used in a workplace, a traffic management plan must be implemented to ensure the safety of drivers and pedestrians. It should be developed by those in charge of the business in consultation with workers and others in the workplace. Everyone affected by the plan must understand it and follow it.

The plan should consider:

• the physical environment, such as lighting, road surfaces, ventilation, and weather
• traffic destination, flow, volume, and priorities
• forklift stopping distances, turning (tail swing), and operator blind spots
• forklift characteristics, such as stability and attachments
• load characteristics, such as height, width and type - reorganising the layout of the workplace to minimise areas shared by pedestrians and forklifts
• ensuring workers are not placed at risk by walking with a load on the forklift to stabilise the load
• blind spots and corners
• a combination of audio (e.g., reversing alarms and horns) and visual (e.g., flashing lights) warning devices
• signs to indicate who must give way
• implementing and enforcing procedures that describe how pedestrians and forklifts must interact in different situations.

Further information and advice on traffic management can be found at Traffic management guidance plan and example template (PDF, 2.01 MB)

Any remaining risk must be minimised with suitable personal protective equipment. For example, the use of hard hats, steel cap boots, eye protection, hearing protection and high visibility vests where necessary. Administrative control measures and PPE rely on human behaviour and supervision. If used on their own, they are least effective in minimising risks.

The control measures you put in place should be reviewed regularly to make sure they work as planned.