Loads that aren’t properly secured can injure or kill people and cause significant property damage. This can happen on the road or during loading and unloading work.

The Load Restraint Guide 2018 provides users with the basic safety principles that should be followed when designing an appropriate load restraint system. The guide includes technical information, detailed diagrams and worked examples to assist users in determining the suitable restraints method.

What are the risks during loading/unloading?

Injuries are caused when:

• handling side-gates on trucks
• opening and closing side-curtains on trucks
• placing load restraints and corner protectors over loads
• using tensioning devices with chains and webbing.

Handling side gates on trucks

To eliminate the risks associated with handling gates, consider whether you need them. There may be more suitable alternatives, such as:

• vehicles with folding sides or sliding panels
• vehicles custom-designed for loads – e.g. some pallet loads may suit a vehicle with an internal side and middle expanding wall, an inward sloping floor, and load-rated curtain
• load-rated curtains – follow the manufacturer’s instructions about weight, placement and type of load
• chains or webbing.

^{Truck with folding sides.}

If it’s not reasonably practicable to eliminate the use of gates, consider gates that don’t need to be removed during loading/unloading (and can be retrofitted to the vehicle), such as:

• swinging gates
• sliding gates
• hanging gates – use a hanging system that prevents the gates from falling completely if any part fails.

Clean the tracks and rollers regularly.

^{Left: Sliding gate. Right: Hanging gate.}

^{Sliding panel.}

The use of gates that can be removed from the vehicle involves a greater degree of manual handling and therefore should be avoided where possible. If used, these gates should be removed and installed from a solid platform that is a similar height to the truck tray, to ensure the gates are handled between shoulder and knee height. If the gates are tall and heavy, a minimum of two people should remove and install them.

A minimum of two people should be used if the gates are removed or installed from ground level unless the gates are short and light. Advise the delivery site in advance should the driver need help to remove the gates. Team handling should only be used until a more effective control can be implemented or for tasks that are undertaken rarely.

Opening and closing side-curtains

When opening and closing side-curtains:

• check if the load is resting against the curtains before opening them; look up and check for deformity or pressure marks in the curtain, particularly at the top; stand clear at the rear when releasing the curtain tensioner
• use automatic curtains that are self-opening and closing
• follow the manufacturer’s instructions for load characteristics and placement in transit if side curtains are load-rated
• use curtains with a securing system that does not involve buckles – it reduces the risk of pinched fingers and repetitive strain to the hands and fingers
• use load tensioners that operate outside the curtains so they don’t need to be opened as often to check restraint tensions – e.g. winches attached to the coaming rail or under-floor track can be re-tensioned without opening the curtains
• use safe procedures when manually handling curtains:
  • check for trip hazards before opening/closing curtains
  • grab two buckle straps, one in each hand, keep hands close to the body and below shoulder height, and walk back slowly so the curtain moves smoothly
  • be aware of the buckle locations to reduce the risk of buckles becoming tangled.

Ensure the curtain track and rollers are regularly maintained and follow manufacturer instructions for lubrication; keep the track clean by using air, water or vacuum to remove dust; be aware of increased curtain resistance, as it means the track or rollers need maintenance.

^{Curtain track roller on plate with double bearings.}

If the curtains or tracks need repairing, but the truck needs to be used in the short-term:

• clean the track and use dry lube to help rollers move along the roof track
• pull the curtains in sections – when opening, pull back a section of the curtain near the rear of the truck, move forward, pull another section, then repeat until the curtains are fully open.

In windy conditions:

• open the curtain by undoing most, but not all, curtain buckles before releasing the curtain ratchet (it will reduce the chance of the curtains billowing as the ratchet is released); keep two or three buckles attached along the length of the curtain and only unbuckle these as the curtain is pulled back slowly
• when the open curtain is bunched at the rear of the trailer, secure it to the trailer to prevent the wind from catching it – e.g. clip a section of the curtain with a buckle to the rear of the trailer, or pass a rope through the buckle.

Placing load restraints and corner protectors over loads

When placing load restraints and corner protectors over loads:

• don’t throw over loads anywhere near overhead powerlines
• keep pedestrians away from vehicles when restraining loads – e.g. use barriers
• use a system to apply and remove load restraints and corner protectors while standing on the ground, such as:
  • a purpose-built lightweight extension pole, especially one that grips the lashing or corner protector
  • a system designed for a curtain-sider that retracts the webbing straps to the roof of the trailer when not in use - this will eliminate the need for drivers to climb onto the truck to position and pull straps over the load
• reach tools
  • work from a platform ladder or elevating work platform
  • when using chains, use a lead rope to throw and drag the chain over the load – this will reduce the risk of shoulder strain from throwing the chain, and will cause less damage than a chain if it hits someone.

^{Retractable webbing-strap system.}

^{Removable posts that help restrict the movement of the load.}

Using tensioning devices with chains and webbing

The incorrect use of tensioners has resulted in severe injuries to workers and near misses.

Ensure your workers have received training and instruction on the safe use of tensioners and always follow the manufacturer’s instructions. Refer also to the requirements outlined in the National Transport Commission load restraint guide.

Tensioners include:

• webbing hand ratchets
• under-vehicle webbing winches
• chain dogs
• other chain tensioners.

Always consider the safety of your workers when choosing the type of tensioner. For example, a pull down webbing ratchet does not require repeated pushing up and can reduce the risk of shoulder injuries. If using a winch, ensure it doesn’t require the removable handle to be reinserted with every turn; use a geared winch.

Minimise the use of chains and webbing by:

• using an alternative system, such as a containment system, pins, pegs, posts, headboards, or a gooseneck on a drop-deck trailer to help block the load
• using a custom-built truck with expanding walls, sloping floor and load-rated curtains
• ensuring heavy vehicle loading performance standards are still met if any equipment is substituted.

If webbing is being used, consider webbing straps as an alternative to chains. This has the advantage of being lighter and can reduce the risk of injury.

Cheater bars on dogs are dangerous

When binders are used for securing loads, the risks must be eliminated or controlled.

It is strongly recommended that cheater bars (extension bars) are not used on over-centre load binders or ‘dogs’ as they are commonly known. The use of cheater bars on dogs is a dangerous practice and has resulted in many serious injuries.

^{Worker using dog and cheater bar.}

The risks include:

• using a cheater bar to tension a dog creates a risk of the bar flicking up and hitting the worker when the tension is released
• others in proximity are in danger of being hit if the worker loses control of the bar
• the tension on the dog varies according to the length of the bar.

Possible solutions include:

• using something other than an over-centre load binder, such as ratchet or turnbuckle binders
• don’t use cheater bars on dogs
• providing information, training and instruction about using load binders safely.

See Cheater bar on dogs safety alert.