Marley New Zealand Limited
Loading and Unloading of Large Bore (>280mm) PE Pipe
Standard Operating Procedure
Scope:
This procedure has been developed to give the forklift operator, the truck driver, and the customer’s site representative a clear understanding of the safe work practices expected of them during the loading and unloading of large bore polyethylene pipe in order to prevent injury.
This procedure applies to the loading and unloading of trucks.
Part 1 - Loading at a Marley Site.
People responsible for ensuring that the loading procedure is understood and followed:
- The designated OSH certified ‘F’ endorsed forklift operator
- The Warehouse Team Leader
Note: It is the responsibility of the Warehouse Manager and Team Leaders to police this procedure in the interests of safe working conditions.
Pre loading checks
1. Prior to the truck being loaded, each person listed above as being responsible for the loading procedure must read the procedure and acknowledge their understanding of it by signing the Loading Procedure Declaration on page 3.
2. An area in the yard will be designated as the large bore PE pipe loading zone and will be marked accordingly.
o The area is to be determined by the Warehouse Manager and shown on the attached site map.
o During loading, the area is to be marked out with road cones to highlight that loading is in operation
o The road cones will hold the following signage: Caution large bore PE pipe loading, Keep Clear. Authorised Personnel Only.
o The area is to be large enough to protect personnel in the event of a pipe falling during the loading process.
3. Prior to loading, the forklift operator and the truck driver are to inspect the area to ensure that it is safe to work within it, with no obstructions that could interfere with the safe operation of the forklift, and that no other personnel are present inside the area.
4. The forklift operator is responsible for the control of the area. In the event of a disagreement between the forklift operator and the truck driver, the warehouse team leader will assume authority.
5. A permit to work at height, which will require the use of a safety cage, is required if the forklift operator or the truck driver need go 2 metres above the ground.
6. All loads that exceed one layer of pipe must be transported on a truck that is fitted with bolsters.
7. Personnel protective equipment must be worn at all times. The minimum requirement is high visibility vests and safety shoes.
8. The forklift operator and the truck driver are to agree on which side the truck will be loaded. The non-loading side of the truck is to have the full bolsters in place at all times. If non-sectioned bolsters are employed, both the loading and non-loading sides are to have the full bolsters in place at all times. Where sectioned bolsters (the preferred design) are employed, the full bolster (all sections) is to be in place on the non loading side at all times. The sectioned bolster on the loading side must be above the height of the load at all times.
Loading
1. Always load only 1 pipe at a time
2. The forklift operator is to keep the truck driver in his line of sight, outside of the designated loading area, while loading. If the forklift operator loses sight of the truck driver, he must immediately stop loading.
3. If the forklift operator or the truck driver needs to leave the area, loading is to cease, and the person remaining is to ensure that no one enters the restricted area.
4. If the forklift operator or truck driver see any personnel entering the restricted area at any time after the placement of the cones, all loading activity is to stop until such time as the area is cleared of personnel
5. The truck driver must communicate to the forklift operator if he intends moving during the loading process, at which time the forklift driver must stop the process immediately. This also applies when the belly strapping is being undertaken.
6. The height of the load, from the trailer to the top of pipe, can be no higher than 2.8 metres, in accordance with Transit requirements
7. Under no circumstances should anyone stand on the load, secured or otherwise.
8. The truck driver is ultimately responsible for security of the load.
9. The pipe is to be separated and secured at each level with 100x100x2400 dunnage with wedges attached.
10. Dunnage is to be placed 1 metre in from each end. In the case of 12 metre lengths, dunnage is also to be placed in the middle of the pipe. Pipe longer than 12 metres is to have dunnage placed 1 metre in from each end with 2 further pieces of dunnage equally spaced in the middle of the pipe.
11. All layers are to be belly strapped to secure the load. Strapping must not distort or damage the pipe.
Important: It is the responsibility of the forklift operator and the truck driver to ensure that no personnel are inside the designated loading area.
LOADING PROCEDURE DECLARATION
By signing below I acknowledge that I have read and understand this document, and I confirm that I will comply with the procedure. Any questions that I had about the procedure were answered satisfactorily.
Signed: _____________________________ Date: _____/_____/______
Name: ___________________________________________________
Position: ____________________________________________________
Company: ___________________________________________________
Note: The signed declaration is to be held in Marley’s dispatch office and matched with the corresponding completed unloading declaration.
Both documents are to be held on file for a minimum period of 2 weeks after the pipe has been delivered and unloaded at the customer’s site.
Part 2 – Unloading at a Customer’s Site
People responsible for ensuring that the unloading procedure is understood and followed:
- The transport operator’s authorised unloader (if other than the truck driver)
- The customer’s site representative
Note: The truck driver is ultimately responsible for ensuring that this procedure is followed. The truck driver is authorised to prohibit unloading of the truck in the event of unsafe conditions.
Pre unloading checks
1. Prior to the truck being unloaded, each person listed above as being responsible for the unloading procedure must read the procedure and acknowledge their understanding of it by signing the declaration on the last page.
2. The truck driver is to ensure the load has not shifted in transit before attempting to unload
3. The use of an unloading/lifting device such as a Hiab or crane is recommended. However, if these are not available; the authorised unloader is to employ an alternative safe unloading/lifting device, e.g. a suitably rated forklift.
4. Equipment not specifically designed for the purpose of unloading is not to be used, e.g. a tractor with a front end loader. Any unloading method that involves rolling the pipe from the truck is totally unacceptable.
5. A designated large bore PE pipe unloading area is to be determined before unloading commences
o This area is to be determined by the customer site representative in consultation with the authorised unloader
o The unloading area is to be marked out with road cones and caution tape to highlight that unloading is in operation.
o The area is to be large enough to protect personnel in the event of a pipe falling during the unloading process.
6. Unloading can only be undertaken during the hours between 30 minutes after sunrise and 30 minutes before sunset.
7. Prior to unloading the customer site representative and the authorised unloader are to inspect the area to ensure the following:
o It is safe to work within, with no obstructions that could interfere with the safe operation of unloading.
o Power lines do not interfere with the operation (a minimum distance of 4 metres clearance is required).
o The ground is suitable.
o The ground can withstand the load.
o The location is level.
o No other personnel are present within the designated area.
8. Personnel protective equipment must be worn at all times. The minimum requirement is high visibility vests and safety shoes.
9. The customer site representative and the authorised unloader are to agree from which side the truck will be unloaded. The non-unloading side of the truck is to have the full bolsters in place at all times. If non-sectioned bolsters are employed, both the unloading and non-unloading sides are to have the full bolsters in place at all times. Where sectioned bolsters (the preferred design) are employed, the full bolster (all sections) is to be in place on the non unloading side at all times. The sectioned bolster on the unloading side must be above the height of the load at all times.
Unloading
1. Always unload only 1 pipe at a time.
2. The authorised unloader is to keep the customer site representative (and truck driver if he is not the authorised unloader) in his line of sight, outside of the designated unloading area, while unloading. If the authorised unloader loses sight of either person, he must immediately stop unloading.
3. If the customer’s site representative or the authorised unloader needs to leave the area, loading is to cease, and the person remaining is to ensure that no one enters the restricted area.
4. If the customer site representative or the authorised unloader see any personnel entering the restricted area at any time after the placement of the cones, all unloading activity is to stop until such time as the area is cleared of personnel.
5. Both the truck driver (if he is not the authorised unloader) and the customer site representative must communicate to the authorised unloader if they intend moving during the unloading process, at which time the authorised unloader must stop the process immediately. This also applies when the belly strapping is being released, even though the bolsters remain in place.
6. Under no circumstances should anyone stand on the load, secured or otherwise.
7. The belly strapping is to be released 1 layer at a time. The bolsters must remain in place during the process of releasing each layer of belly strapping and the unloading of the pipe. If sectioned bolsters are used, sections can be removed from the unloading side, but at no stage can the height of the bolster be less than the height of the load.
8. Storage of the pipe at the customer’s site is the responsibility of the customer. It is recommended that pipe is stored in a single layer on level ground.
Important: It is the responsibility of the customer site representative and the authorised unloader to ensure that no personnel are inside the designated unloading area.
Unloading by Customer
1. If unloading of the product is to be carried out by the customer on site, instead of by the carrier, the customer’s site representative must read and sign firstly the Unloading Procedure Declaration, and secondly the Customer Unloading Declaration on the next page.
2. The truck driver retains the authority to prohibit unloading of the truck in the event of unsafe conditions or practises.
Issue Date: 15/05/08 Issue No: 01 Authorised:
UNLOADING PROCEDURE DECLARATION
By signing below I acknowledge that I have read and understand this document, and I confirm that I will comply with the procedure. Any questions that I had about the procedure were answered satisfactorily.
Signed: _____________________________ Date: _____/_____/______
Name: ___________________________________________________
Position: ____________________________________________________
Company: ___________________________________________________
CUSTOMER UNLOADING DECLARATION
By signing below I confirm that I have the necessary equipment and procedures in place to safely unload the product on site:
Signed: _____________________________ Date: _____/_____/______
Name: ___________________________________________________
Position: ____________________________________________________
Company: ___________________________________________________
Important: The truck driver retains the authority to prohibit unloading of the truck in the event of unsafe conditions or practices.
Note: The signed declaration(s) are to be sent to Marley’s dispatch office no later than 48 hours after completion of the unloading.
