A truck arrives for a scheduled delivery, but the conditions are not what the driver expected. The unloading area is occupied, the ground is uneven, pedestrians are passing through and the forklift nominated for the job is unavailable.
The freight may have left the depot safely restrained, but that does not mean it can be unloaded safely under the conditions now in front of the driver.
Effective truck loading and unloading safety involves checks at five stages:
- Before dispatch
- Arriving at the site
- Setting up the work area
- Loading or unloading
- Securing, checking and leaving
The transport operator, driver and receiving site all have a role. The process must also allow work to stop when the load, equipment or site conditions differ from the original plan.
SafeWork NSW identifies loading and unloading as an activity that commonly involves interaction between people, vehicles and mobile plant. Its guidance focuses on planning, site induction, vehicle immobilisation, exclusion zones, suitable equipment and clear communication.
Truck Loading and Unloading Safety in Five Stages
A practical loading and unloading procedure should cover the whole task rather than beginning when a forklift or crane starts moving.
1. Before dispatch
Confirm that the truck, trailer, load configuration, restraints and planned handling equipment are suitable for the freight and destination.
2. Arriving at the site
Complete the required induction, locate the site contact and compare the actual work area with the information provided before dispatch.
3. Setting up the work area
Position and immobilise the vehicle, establish the loading exclusion zone and confirm how the driver and plant operators will communicate.
4. Loading or unloading
Check load stability before releasing restraints. Keep people outside crush and fall zones and use equipment suited to the load.
5. Securing, checking and leaving
Complete the final load restraint inspection, clear the area and record defects or site changes that could affect future deliveries.
Who Controls the Loading or Unloading Task?
Responsibility should not be passed entirely to the driver or assumed to belong only to the receiving site.
Each business must manage the risks that fall within its influence or control and coordinate with the other businesses and workers involved. The person who controls the receiving workplace may determine where the truck parks, how traffic is separated and what site equipment is available. The transport operator controls matters such as vehicle suitability, driver instructions, restraints and dispatch planning.
The driver and plant operators must then follow the agreed system and raise concerns when it cannot be applied safely.
| Stage | Primary lead | Coordination needed |
| Before dispatch | Transport operator or dispatch team | Driver, loader and customer |
| Site arrival | Receiving-site contact | Driver and transport operator |
| Work-area setup | Person directing the onsite task | Driver and plant operators |
| Loading or unloading | Agreed supervisor or operator | Everyone working near the exclusion zone |
| Final checks | Driver and loader | Dispatch and receiving site |
Before work starts, everyone involved should know:
- Who is directing the task?
- Who is permitted inside the work area?
- Where must the driver wait?
- What communication method will be used?
- Who can stop the task?
A scheduled delivery time does not override an unsafe condition. If the agreed controls cannot be established, the task should be changed, delayed or stopped.
WHS Safety at the Site and Load Restraint on the Road
Loading and unloading involves two connected but distinct areas of responsibility.
Work health and safety requirements apply to how the task is performed at the workplace. This includes vehicle movement, mobile plant, falling loads, crush zones, access to truck trays, site conditions and interaction between workers.
Heavy-vehicle loading requirements apply to how freight is positioned and restrained for transport on the road. Under the Heavy Vehicle National Law framework, a heavy vehicle must be loaded so its placement does not make the vehicle unsafe or unstable, the load is not likely to fall or become dislodged and an appropriate restraint system is used.
The current NHVR Load Restraint Guide is the 2025 edition. It provides best-practice information, diagrams and worked examples, but NHVR clearly states that the guide is an information resource rather than a legal document.
Both areas need attention. A load may have been adequately restrained during transport but still be unstable when a curtain, gate, chain or strap is released.
A useful rule is:
Do not release a restraint until you understand what it may be holding in place.
Stage 1: Before Dispatch
Good unloading starts before the vehicle leaves the depot.
Match the vehicle and trailer to the freight
Confirm that the proposed vehicle and trailer are suitable for:
- The dimensions and weight of the freight
- The expected load distribution
- The load’s centre of gravity
- The required gates, posts, headboards or containment
- The planned restraint method
- The equipment that will load or unload the freight
- The access and conditions at the destination
There is no single restraint or handling method that suits every load. The correct system depends on the freight, packaging, vehicle, restraint equipment and how the freight will be handled at each end of the journey.
For repeat work, a documented loading plan can help loaders apply the same approved configuration consistently. NHVR recommends that loading plans account for the load, vehicle, restraint equipment and selected restraint method.
Inspect the vehicle, restraints and equipment
The pre-start and load restraint inspection should cover items such as:
- Straps, chains, tensioners and anchor points
- Gates, doors, curtains, posts and fasteners
- Headboards, side structures and containment systems
- Hydraulic hoses and controls
- Stabilisers and outriggers
- Trailer connections
- Lifting equipment and attachments
- Access steps and fall-control equipment
- Defects reported during earlier work
Restraint equipment should be correctly rated, compatible with the task and free from damage or excessive wear. Even relatively minor damage can reduce its ability to restrain a load.
SafeWork NSW advises drivers to inspect their vehicles before work, complete required pre-start checks, verify that load restraints are available and serviceable, inspect hydraulic systems and confirm that previously reported maintenance issues have been addressed.
A defect should not simply be recorded and left for the next person. The procedure should explain when equipment must be removed from service and who can authorise its return.
Obtain site information before the truck leaves
Dispatch should obtain enough information to plan the delivery or collection, including:
- The correct delivery point
- Site access and vehicle restrictions
- Turning and reversing arrangements
- Loading-dock requirements
- Ground conditions and gradients
- Overhead powerlines or structures
- Pedestrian and vehicle routes
- The lifting or handling equipment available
- Induction and personal protective equipment requirements
- The site contact
- Expected lighting or weather conditions
- Any booking or arrival restrictions
Record this information on the run sheet, delivery booking or driver instructions. Do not rely on the driver discovering critical conditions after arrival.
Stage 2: Arriving at the Site
Arrival should be treated as a verification point rather than an administrative formality.
Complete the induction and find the site contact
The driver should locate the nominated site coordinator and complete any required induction before entering the operational area.
The induction or task briefing should confirm:
- Where the truck must park
- Who will load or unload the freight
- What equipment will be used
- Which traffic routes apply
- Where the driver must stand
- Who may enter the loading area
- How communication will occur
- Who is directing the activity
SafeWork NSW advises drivers to locate the site contact, complete required inductions, confirm the site’s loading or unloading process and understand the roles of the people involved.
A generic visitor induction may not be enough. The driver also needs information specific to the delivery, load and work area.
Compare actual conditions with the plan
Before releasing restraints or positioning handling equipment, check whether anything has changed.
Look for:
- An occupied or obstructed unloading area
- Soft, uneven or sloping ground
- Poor lighting or visibility
- Passing vehicles or pedestrians
- Insufficient clearance for the truck or plant
- Overhead services
- Unavailable or unsuitable equipment
- Rain, wind or slippery surfaces
- Damage or movement within the load
- People working inside the proposed exclusion zone
For a temporary, mobile or uncontrolled site, SafeWork NSW recommends obtaining site information before arrival and completing a risk assessment before loading or unloading. Environmental conditions, terrain, lighting, traffic and pedestrians should all be considered.
An unloading risk assessment does not need to become a lengthy exercise for every routine delivery. It must, however, be meaningful enough to identify when the planned method no longer works.
Decide whether the task can proceed
When conditions differ from the plan, possible actions include:
- Moving the truck to a more suitable area
- Arranging different lifting equipment
- Temporarily closing a pedestrian route
- Changing the unloading sequence
- Establishing additional barriers
- Contacting dispatch for instructions
- Rescheduling the delivery
“Making do” is not an adequate control when the ground, equipment or work area is unsuitable.
Stage 3: Setting Up the Work Area
Once the site has been assessed, the vehicle and surrounding area must be prepared before freight moves.
Position and immobilise the truck
Park on a firm, level and hard surface where reasonably practicable, or within a designated loading area suited to the vehicle and task.
The truck immobilisation procedure may include:
- Properly applying the park brake
- Switching off the engine when required
- Removing or controlling the keys
- Deploying stabilisers or outriggers
- Using wheel chocks where appropriate
- Preventing the truck from being driven away
- Checking that trailers and connections remain stable
The controls should reflect the vehicle, surface and work being performed. Wheel chocks may be appropriate in some circumstances, but they should not be treated as a substitute for a functioning braking system or suitable parking location.
SafeWork NSW identifies loading and unloading as a situation in which uncontrolled vehicle movement may occur. Its immobilisation guidance refers to level ground, proper application of the handbrake, wheel chocks, training and supervision.
Establish and enforce the exclusion zone
A loading exclusion zone separates people from mobile plant, vehicle movement, suspended loads and falling freight.
The boundary should account for:
- The movement of forklifts, cranes or pallet equipment
- Truck and plant blind spots
- The area into which freight could fall or roll
- Opening gates, doors and curtains
- The swing radius of cranes or suspended loads
- Reversing movements
- Crush points between the truck, load and equipment
- Nearby pedestrian routes
Permanent loading areas may use marked lines, bollards, rails or fixed barriers. Temporary sites may require cones, mobile barriers and signs.
Marking the area is only the beginning. Someone must control entry, and work must stop when an unauthorised person enters.
SafeWork NSW recommends establishing exclusion zones during loading and unloading and maintaining separation between plant, machinery and people.
High-visibility clothing may help operators see a worker, but it does not physically prevent that worker from entering the path of plant or a falling load. Separation, immobilisation and controlled access are stronger controls.
Confirm communication before movement starts
The communication method should be agreed before a load or item of plant moves.
Depending on the site, this may involve:
- Direct verbal communication
- Agreed hand signals
- Two-way radios
- One nominated spotter
- Continuous visual contact
- A clear stop signal understood by everyone
Avoid having several people direct the same operator. Conflicting signals can create hesitation or unexpected movement.
Before anyone starts, confirm:
- Is the truck immobilised?
- Is the exclusion zone clear?
- Is the plant operator ready?
- Is the driver in the nominated safe location?
- Is the communication method working?
- Has the condition of the load been checked?
Stage 4: Loading or Unloading
This is when workers are most likely to be exposed to moving plant, unstable freight, crush points and falls.
Check whether the load has moved
Loads can shift during braking, cornering or travel over uneven roads. Before opening gates or curtains or releasing chains and straps, look for:
- A curtain bulging outward
- Freight pressing against a gate or door
- Leaning pallets or machinery
- Loose pipes or cylindrical items
- Broken packaging
- Moved dunnage
- Damaged or loose restraints
- An unexpected change in load distribution
If freight could fall, roll or slide when a restraint is removed, establish another method first. This may involve supporting or slinging the load with suitable lifting equipment before the transport restraint is released.
SafeWork NSW specifically advises checking whether a load has shifted during transport before releasing restraints. Its incident guidance also recommends supporting or slinging an unstable load before restraints are removed where necessary.
Keep people out of crush and fall zones
No one should position themselves:
- Between the load and the truck
- Between the truck and mobile plant
- Beneath a suspended load
- Inside the potential fall path of freight
- Behind an operating tailgate
- Between lifting equipment and a fixed object
- Within a plant operating zone without a controlled reason
SafeWork NSW advises that workers should not stand between the load and the truck, trailer, lifting equipment or another pinch point.
The driver should wait in the nominated safe position unless they have an active, agreed role in the task.
Use equipment suited to the load
The selected equipment may include a forklift, crane, vehicle-loading crane, pallet jack, conveyor or another purpose-designed handling system.
Check:
- Equipment capacity
- Attachment compatibility
- Inspection and maintenance status
- Operator competency
- High-risk work licensing where required
- The load’s weight and centre of gravity
- Suitable lifting or slinging points
- Stability of the operating surface
- Clearance from workers and structures
Do not assume a forklift is suitable merely because one is available. A crane, vehicle-loading crane or different attachment may be needed for freight that is long, unstable, unusually shaped or difficult to access.
Work from ground level where possible
Climbing onto tyres, freight, side rails or an unprotected truck tray should not become the accepted way to reach restraints or guide loads.
Where possible, use:
- Ground-operated restraint systems
- Correctly positioned load-release equipment
- Purpose-designed access steps
- Loading platforms
- Guardrails or edge protection
- Mobile work platforms
Where the work cannot be completed from the ground, assess the fall risk and provide a suitable access and fall-control system.
SafeWork NSW recommends performing loading and unloading tasks from ground level where possible. Where tray access is necessary, a safe access system should be developed, with platforms, guardrails or other suitable fall controls used according to the risk.
Apply clear stop-work triggers
Stop loading or unloading when:
- A person enters the exclusion zone
- The vehicle moves or is not properly immobilised
- The load appears unstable
- The ground is soft, uneven or unsuitable
- The available plant or attachment is inappropriate
- Communication is lost
- The operator cannot see the spotter
- The load weight or centre of gravity is unknown
- Overhead services cannot be avoided
- Lighting or visibility becomes inadequate
- Weather makes the task unsafe
- The planned sequence changes without reassessment
Stopping work is part of the procedure. It is not a failure of the procedure.
Stage 5: Securing, Checking and Leaving
The task is not complete when the final pallet or item is placed on the truck.
Complete the final load restraint inspection
Before departure, check that:
- The freight is stable
- The load distribution remains suitable
- The correct restraint method has been applied
- Straps, chains and tensioners are correctly positioned
- Anchor points and vehicle structures are suitable
- Gates, curtains and doors are secured
- Loose equipment and dunnage are contained
- Stabiliser legs and lifting equipment are in travel position
- No part of the load can fall or become dislodged
NHVR explains that an effective load restraint system should prevent freight from becoming dislodged or moving excessively during transport. The system must suit the load and vehicle and withstand the forces experienced during travel.
When only part of a load has been delivered, check the remaining freight again. Removing one item can change weight distribution, restraint effectiveness or access to other parts of the load.
Clear the area before moving
Before the truck leaves:
- Confirm that workers and plant are clear
- Remove temporary tools and equipment
- Secure access systems and doors
- Retrieve barriers only when the task is complete
- Check the exit route
- Use reversing assistance where required
- Obtain permission to leave where the site system requires it
The driver should not move simply because loading appears finished. There should be a clear handover confirming that the area is safe.
Record defects and changed conditions
Report and record:
- Damaged restraints or vehicle components
- Equipment that was unavailable or unsuitable
- Ground or access problems
- Exclusion-zone breaches
- Unstable freight
- Communication failures
- Changes to the planned method
- Incidents and near misses
- Corrective actions and responsible persons
Where a condition is likely to recur, update the delivery instructions, loading plan or customer information. The same problem should not have to be rediscovered by every driver.
A Checklist Must Match the Actual Work
A generic form is useful only when it reflects the vehicle, freight, equipment and sites involved.
Test this checklist during a live delivery or collection. Compare:
- What the procedure says
- What dispatch tells the driver
- What the driver expects
- What the receiving site provides
- What plant operators actually do
- Where workers improvise
- Whether stop-work authority is understood
- Whether identified actions are closed
The purpose is not to produce another completed form. It is to confirm that the safety controls can be seen and applied during the real task.
Truck loading and unloading safety depends on planning before dispatch and checking that the plan still works when the truck arrives. The vehicle must be suitable and immobilised, the load checked before restraints are released, people separated from plant and the task stopped when conditions cannot be safely controlled.
Use the checklist during one live delivery or collection. Compare the planned process with what the driver, loader and receiving site actually do, then assign any gaps for correction.
The Safety Dept. can help your business keep transport procedures, corrective actions and critical controls current as your vehicles, customers and delivery sites change.