Introduction
This guidance provides information for employers about risk controls that can be used to eliminate or reduce the risk of MSD associated with hazardous manual handling of items in shipping containers and enclosed trailers.
MSD is an injury, illness or disease that arises in whole or in part from hazardous manual handling, whether occurring suddenly or over a prolonged period. It does not include an injury caused by crushing, entrapment or cutting resulting primarily from the mechanical operation of plant.
This guidance emphasises the importance of taking a thorough look at current work practices to identify potentially hazardous manual handling.
Consult with employees and work with your supply chain to identify and deal with manual handling hazards in the workplace.
Many workplaces invest in a range of mechanical aids to assist in controlling MSD risk, some of which appear below.
A way of controlling hazards is to ensure that the most appropriate type of shipping container and packing methods for the relevant type of load have been used.
Correct packing practices at the start of the supply chain will assist in safe unpacking at the end of the chain. For example, many companies arrange for their suppliers to provide items on stillages, pallets or slipsheets. This allows items to be packed and unpacked into shipping containers using powered mechanical aids which could provide a cost benefit as well as reducing the risk of injury from manually packing or unpacking items within the container.
Where loose packing is used, ensure the supplier provides information about the packing order so that unpacking can occur without double handling.
This guidance should be read in conjunction with other WorkSafe Victoria guidance which details other health and safety risks, such as traffic management, that need to be controlled when unpacking shipping containers to ensure that any new practices do not introduce further risks in the workplace. See Further information for related guidance
Employer obligations
As an employer, you have a general duty to make sure your workplace is safe and without risks to health, including specific duties in relation to hazards such as manual handling.
Identify and eliminate manual handling in tasks
You must identify any tasks that involve hazardous manual handling.
If these tasks pose a risk of MSD, you must eliminate the risk so far as is reasonably practicable.
If the risk cannot be eliminated you must, so far as is reasonably practicable, reduce the risk.
Reduce manual handling risks
If it’s not reasonably practicable to eliminate the risk, you must reduce the risk by:
- changing the workplace layout, the workplace environment or the systems of work
- changing the objects used in the task, or
- using mechanical aids, or
- a combination of the above risk control measures
If it is still not reasonably practicable to reduce the risk using a higher level control, you may control that risk by providing information, training or instruction to your employees. The employer may only rely solely or primarily on the use of information, instruction or training to control a risk of a MSD associated with hazardous manual handling if none of the measures set out above is reasonably practicable.
The employer, when determining any measure to control a risk of a MSD associated with hazardous manual handling, must take into account the following:
- postures
- movements
- forces
- duration and frequency of the hazardous manual handling
- environmental conditions including heat, cold and vibration that act directly on a person undertaking hazardous manual handling
Review and revise measures
You must review and, if necessary, revise any measures implemented to control risks:
- before any alteration is made to any thing, process or system of work involving hazardous manual handling, including, for example, a change in the place where that work is undertaken
- if new or additional information about hazardous manual handling becomes available to you
- if an occurrence of a musculoskeletal disorder at your workplace is reported by or on behalf of an employee
- if, for any other reason, the risk control measures do not adequately control the risks
- after a notifiable incident occurs that involves hazardous manual handling
- after receiving a request from a health and safety representative
Consult with employees
Consult with employees to develop safe systems of work, which will eliminate or reduce unsafe or unnecessary manual handling.
You must consult with employees, including health and safety representative (if any) when identifying hazards and risks, and deciding how to control those risks.
Risks
Manually packing and unpacking shipping containers involves actions or forces likely to cause a MSD.
Manual handling injuries can result from a single incident or from doing the same movements repeatedly over a period of time.
Activities
Several activities increase the risk of injury associated with packing or unpacking shipping containers including the following:
- repeated lifting of items, particularly those that are above shoulder height or below mid-thigh height
- lifting and carrying heavy items
- pushing trolleys or hand pallet jacks on a slope
- carrying items over long distances or uneven surfaces
- adopting awkward postures repeatedly or sustaining them for long periods
- high or sudden forces
Common load types
Common load types that are often packed or unpacked from shipping containers include:
- stone slabs
- palletised loads
- large bulky awkward loads (items more than 25 kg and with one dimension more than 500 mm)
- similar loose packed loads
- boxes, bags and bales
- mixed loads types
Risk controls
Risk controls for packing and unpacking of shipping containers are:
- Recommended risk control measures which are preferred
- Suggested measures which may be used when it is not reasonably practicable to implement recommended risk control measures
While the control measures may reduce the risk of MSD, other risks may be present and need to be considered, for example crushing, and risks associated with the use of powered mobile plant.
The following common load types and practical solutions can enable safe packing and unpacking of shipping containers.
Stone slabs
Hazards include:
- high force
- awkward postures
- sustained movement from lifting and lowering
- handling large stone slabs
- being crushed by slabs or mobile plant
Recommended risk control measures
Open top containers
Use crane or forklift with an appropriate attachment to pack and unpack stone slabs into open top shipping containers. Restraints that prevent slabs from falling should be applied and removed by a person from each slab from outside the shipping container. Restraints should be in place before shipping container is moved.
Using a crane
Apply and remove load restraints from each slab from outside the shipping container.
This allows individual slabs to be accessed for mechanical lifting using a gantry or bridge type crane. The crane is fitted with a vacuum lifter or lifting clamp to unpack stone slabs into L- or A- frames into closed top containers.
Closed top containers
Deliver stone slabs in stillages in closed top shipping containers.
Release load restraints from outside the shipping container.
Unpack the stone slabs using a forklift or crane fitted with an attachment such as a jib with clamp or one that has a footplate and side grabs. This allows the entire stillage to be secured and removed from the container.
Hazards to avoid
Employees should not enter the fall shadow of the slab within the shipping container to release or attach the load restraints.
Employees should not pack or unpack by hand, stone slabs within the shipping container.
Palletised loads
Hazards include:
- high force
- awkward postures
- repetitive movement from lifting and lowering
- handling palletised loads
- being hit by mobile plant
Recommended risk control measures
Secure products onto pallets, slip-sheets or stillages and pack into shipping containers using powered mobile plant. This eliminates the need for manual handling of loads.
Powered mobile plant including forklift, ride on pallet jack, electric tug and walkie stacker fitted with fork arms (tynes), with slipsheet or grab attachments are used to unpack the palletised load from the shipping container.
Review the design of the pallet being used and consider whether it is a barrier to mechanical unpacking and storage.
Some companies have designed racking so that palletised loads can be put directly into racking.
Suggested measures
Securely load products on pallets or stillages. Use a hand pallet jack to pack or unpack lightweight palletised loads from the shipping container on level ground only. For heavier loads a powered pallet jack should be used.
Hazards to avoid
Employees should avoid moving unstable loads on pallets using hand or powered pallet jack.
Employers should consider the starting force the employee needs to manually apply to get the load moving and whether there is a different model of hand pallet jack that could better suit your employee.
The lifting capacity of a hand pallet jack refers to the weight of goods that can be lifted — not to the starting force to get it moving manually.
One model of hand pallet jack loaded with 2300 kg reported a starting pushing force of 45 kg whereas a different model only required 15 kg for the same load.
An ergonomically designed pallet jack loaded to its rated load will have:
- a starting force not exceeding 21 kg (f)
- a rolling force not exceeding 12 kg (f)
- an emergency stopping force not exceeding 36 kg (f) on a flat level surface
Note: Kg (f) 'kilogram-force' is a metric unit of force and attempts to quantify the force required to overcome the gravity of an object.
Large bulky awkward loads
This may include loads such as whitegoods, electrical goods and furniture.
The packages may be individual items or multiple packages loaded onto a pallet, skid pallet or slip-sheeted.
Hazards include:
- high force
- awkward postures
- repetitive movement from lifting and lowering
- handling large bulky awkward loads
- being hit by falling loads or mobile plant
Recommended risk control measures
Secure large bulky awkward products and loads onto pallets, skids, slipsheets or other equivalents. This allows for the packing of shipping containers by powered mobile plant and removes the need for manual handling of loads.
Use mobile plant including forklift, crane, powered pallet jack or walkie stacker fitted with fork arms (tynes), slipsheet or grab attachments to unpack the load from the shipping container.
Suggested measures
Option 1
Use a hand pallet jack of suitable capacity to move the large bulky awkward load on pallets or skids on level ground. Only move loads that are well below the safe working load of the hand pallet jack.
Single items on their own skid may be handled on level ground using a suitable hand truck.
Option 2
A team of people handle the large bulky awkward load onto a suitable trolley and wheel it on level ground. Use a platform ladder to reach products near the top of the container.
Option 3
Team handling of large bulky awkward load onto height adjustable extendable conveyor from the shipping container.
Raise the conveyor to allow operators working in teams to reach products near the top of the container.
Hazards to avoid
Employees should avoid manually handling large bulky awkward products inside the container. ‘Manually handled’ is taken to mean that items are lifted, carried, pushed, pulled or held by one or more people and carried to a pallet or into or out of the container.
Employees should not climb onto products within the container to reach those at the top of the container without being advised by the supplier or customer that the products can take the weight of a person without collapsing or shifting.
Avoid handling products that are heavier than the physical capability of the employee using the pallet jack.
Note: An ergonomically designed hand pallet jack loaded to its rated load will have:
- a starting force not exceeding 21 kg (f)
- a rolling force not exceeding 12 kg (f)
- an emergency stopping force not exceeding 36 kg (f) on a flat level surface
Loosely packed loads
These loads include products packaged in small cartons, crates or boxes.
Hazards include:
- high force
- awkward postures
- repetitive movement from lifting and lowering
- handling loose packed loads
- being hit by falling loads
Recommended risk control measures
Place products on pallets, slip sheets or stillages and pack into shipping containers using powered mobile plant. This removes the need for manual handling of loads.
Use powered mobile plant including forklift, powered pallet jack and walkie stacker fitted with unloading tynes, slipsheet or grab attachments to unpack the load from the shipping container.
Multi-product types
Manually handle each product type within the shipping container using a height adjustable extendable conveyor.
Handle heavy products within the container using a vacuum lifter or other device associated with a height adjustable extendable conveyor.
Load products outside the container or remove them from the conveyor using a vacuum lift or other similar device onto pallets or directly into storage.
Use mechanical handling aids such as a pallet lifter and turntable, vacuum lifter and attachments to assist with handling products onto and off the conveyor.
Suggested measures
Manually load or unload products until mechanical handling aids can be brought into the shipping container.
Option 1: Multi-product types
Use an appropriate hand pallet jack, or trolley to move the load in the shipping container on level ground only.
Option 2: Multi-product types
Manually unload products from the shipping container onto a gravity conveyor.
Heavy products are team lifted onto an extendable conveyor within the shipping container. Products are then removed from the conveyor using a team lift or by sliding them onto pallets raised by a height adjustable pallet lifter / turntable.
Ensure products have been sequentially packed into the container so that the same product type can be placed onto the conveyor and unloaded onto pallets outside the container.
Option 3: Multi product types
Manually load and unload compact products onto a height adjustable pallet lifter or turntable — for example, a scissor lift table or spring loaded pallet positioner — inside the shipping container.
Manually wrap products before removing with powered mobile plant or a hand pallet jack.
Ensure products have been sequentially stacked into the container so that the same product type can be placed onto a pallet within the container.
Use a platform ladder to reach top layers in the container.
Hazards to avoid
Products are loose packed into a shipping container (un-palletised) or are unpacked from the shipping container by hand repetitively and for long duration.
Shipping containers with different loose packed products are unpacked by hand regularly. ‘Unpacked by hand’ means that items are lifted and carried out of the container, then placed onto a pallet for storage or transport by an employee or contractor.
Once carried out of the shipping container, products are placed onto a pallet on the ground, below thigh level, for storage or transport.
Bags and bales
Bags and bales are potentially unstable loads. For example grain, due to their being fluid-like if bags are not tightly packed.
Hazards include:
- high force
- awkward postures
- being hit by falling loads
- repetitive movement from handling large bulky awkward loads including
- lifting
- lowering
Recommended risk control measures
Place bags and bales on pallets, slip sheets or stillages and pack into and out of shipping containers using powered mechanical aids. This removes the need for manual handling of loads.
Pack large bulk bags with lifting points or bales into open containers using cranes or powered mobile plant. Use attachments to sling and pack these products into and out of closed containers.
Use powered mobile plant including forklift, crane powered pallet jack and walkie stacker fitted with fork arms (tynes), slipsheet, bale clamp, jib or grab attachments to pack and unpack bags and bales on pallets, slipsheets or stillages from the shipping container.
Pack and unpack loose bags and bales using a vacuum lifter or other device onto a height adjustable extendable conveyor within the shipping container.
Handle bales using a plate fork attachment.
Handle products from the conveyor using a vacuum lift or other mechanical device to place them onto pallets raised by height adjustable lifters with turntables.
Suggested measures
Option 1: Single product loads
Wrap bags and bales onto pallets, slipsheets, stillages or skids inside the container.
Use an appropriate hand pallet jack on level ground only and with loads that are well below the safe working load of the hand pallet jack and within the physical capability of the employee.
Option 2: Multi product loads
Manually handle products in the shipping container using an extendable gravity conveyor.
Use a platform ladder to reach top layers in the container.
Use mechanical handling aids such as a pallet lifter and turntable, vacuum lifter and attachment to assist with handling products from the conveyor.
Option 3: Single product type
Manually unpack bags weighing no more than 25 kg directly onto height adjustable pallet lifter with turntable inside the shipping container. Remove from the container by powered pallet jack.
Ensure bags are packed in order into the container so that the same product type can be placed onto a pallet within the container.
Use a platform ladder to reach top layers in the container.
Hazards to avoid
Employees should not regularly manually lift bags or bales that exceed 25 kg in weight.
Employees should avoid regularly unpacking shipping containers with different loosely packed bags by hand.
Employees should not climb onto loose packed bags or bales within the container to reach the loads at the top of the container, which may lead to a risk of falling.
Mixed loads
A mixed load may include:
- products packaged in small cartons, crates or boxes
- larger items, for example:
- white goods
- flat packs
- sacks
- bags
- irregularly shaped items
Hazards include:
- high force
- awkward postures
- being hit by falling loads
- repetitive movement from handling large bulky awkward loads including
- lifting
- lowering
Recommended risk control measures
Stack small cartons of mixed loads on pallets, slipsheets, skids or stillages. Pack and unpack larger products using powered mobile plant.
Mechanical packing and unpacking of products removes the need for manual handling of loads.
Work with suppliers to consolidate loads from multiple vendors and load shipping containers to enable mechanical removal of mixed load items.
Manually unpack loose conveyable products from the shipping container using a height adjustable extendable conveyor.
Use mechanical handling aids such as a pallet lifter and turntable, vacuum lifter and attachments to load products on and off the conveyor.
Suggested measures
Manually unload loose products until mechanical handling aids can be brought into the shipping container to unpack them.
Option 1: Palletised loads
Deliver small cartons of mixed loads on pallets and large items on skids.
Use a powered pallet jack to remove the pallets or skids.
Use an appropriate hand pallet jack only on level ground. Work with loads that are well below the safe working load of the hand pallet jack and within the physical capability of the employee.
Option 2: Multi-product loads
Manually unload small loose products from the shipping container using an extendable conveyor onto raised pallets outside the container.
Use a platform ladder to reach top layers in the container.
After smaller items are removed from the mixed load, use mobile plant including forklift, crane, powered pallet jack and walkie stacker fitted with unloading fork arms (tynes), slipsheet or grab attachments to unpack the larger items.
Hazards to avoid
Employees should avoid lifting and carrying by hand: cartons, crates, bags and other larger items.
Employees should avoid packing or unpacking by hand, repetitively and for long duration, shipping containers with different loose packed products.
Employees should not climb onto loose packed cartons or products within the container to reach the loads at the top of the container – this can present a risk of falling where the cartons or products cannot take the weight of a person without collapsing or shifting.