BEHAVIOUR BASED SAFETY

GUIDELINES FOR THE SAFE LOADING

& UNLOADING OF ROAD FREIGHT VEHICLES

ISSUE 2 M A RC H 2007
The issue of these Guidelines was realised with the financial support (Reference TREN-SUB-2003-SQAS-S07.30607)
of the European Commission - Directorate General for Energy and Transport.
 TABLE OF CONTENTS

TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Objective and Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1. Responsibilities and roles in loading/unloading operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Parties involved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.1 Management responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.1.1 Management of the loading/unloading site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.1.2 Management of the transport company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 Operational responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. BBS observations of loading/unloading operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Responsibilities for implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.1 Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.2 Operators/drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.3 BBS observers.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Observations . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Record keeping/analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Follow-up / Corrective actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Qualifications of observers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.7 Frequency of observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Appendix 1: Roles and tasks for load securing in Cargo Transport Units (CTUs) . . . . . . . . . . . . . . . . . . . . . . . 14
Appendix 2: Example of checklist for observation of loading/unloading operations . . . . . . . . . . . . . . . 15

Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16

List of other Best Practice Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

CEFIC / ECTA GUIDELINES 3

INTRODUCTION
O / OBJECTIVE
OBJ C AND
D SCOPE

INTRODUCTION
Continuous efforts to improve safety during the transport and the associated handling of chemicals
are part of the overall aim to improve safety performance of both the chemical industry and the
transport industry.

Analysis of accident statistics indicates that a majority of transport-related incidents and accidents
do happen during loading/unloading operations. Further detailed analysis shows that the human
factor is by far the most important cause. It is therefore essential to increase safety during loading
and unloading by influencing human behaviour.

These guidelines aim at offering guidance regarding the safety of loading/unloading operations
by clarifying the roles and responsibilities of the different parties involved and by introducing the
principles of Behaviour Based Safety (BBS).

Separate BBS Guidelines for the Safe Driving of Road Freight Vehicles have already been published
in October 2003.

OBJECTIVE AND SCOPE

BBS is a management programme that aims at increasing the safety of operations by positively
influencing the behaviour of all persons involved, through a process of observation, coaching and
communication.

The objective of these guidelines is to provide assistance in the prevention or elimination of unsafe
conditions and situations during loading/unloading operations, recognising the need for interaction
between the different parties involved.

These guidelines consist of two parts:

- Section 1 defines the responsibilities and roles of the different parties involved in
loading/unloading operations, in particular operators and drivers;
- Section 2 explains how BBS observations should be implemented for loading/unloading
operations.

The scope of the current guidelines includes the safe loading/unloading of chemical products by
operators and drivers at production sites, storage terminals, warehouses and customers, and covers
the loading/unloading of bulk as well as packaged goods.

In all circumstances, the applicable national or international regulations should always be complied
with and take precedence over the recommendations made in the present guidelines.

The guidelines are of a voluntary nature. Individual companies may decide to apply the guidelines
either in full, or partly, according to their own judgement and in light of their specific circumstances.

4 SAFE LOADING & UNLOADING

 RESPONSIBILITIES & ROLES

1 RESPONSIBILITIES & ROLES

IN LOADING / UNLOADING OPERATIONS

1.1 PARTIES INVOLVED

QP RINCIPAL
The party or parties commissioning the transport company and/or the loading/unloading site.

QT RANSPORT COMPANY/CARRIER

The haulier contracted by the principal (including subcontractors, if any).

QD RIVER
The person who is actually carrying out the transport.

QS ITE
The site where the actual loading or unloading takes place, including production sites, storage
terminals, warehouses and customers premises.

QO PERATOR
The site employee who is physically carrying out the loading/unloading operation.

PARTIES INVOLVED IN LOADING / UNLOADING OPERATIONS

CEFIC / ECTA GUIDELINES 5

RESPONSIBILITIES
S & ROLES
O S

1.2 RESPONSIBILITIES

1.2.1 Management responsibilities

The following responsibilities are essential for the management of loading/unloading sites and
transport companies. They should be reflected in operating procedures.

1.2.1.1 MANAGEMENT OF THE LOADING / UNLOADING SITE

1/ COMPETENCE OF OPERATORS 4/ PRODUCT QUALITY

The management of the site should The preferred option is product acceptance
ensure that operators are fit for duty on the basis of a Certificate of Analysis.
and have passed successfully all the Taking samples from vehicles should
training necessary to fulfil the legislative be avoided. If the taking of samples is
requirements and site requirements, absolutely required, the management of
in particular regarding the handling of the site should ensure that samples are
dangerous goods. taken by qualified site personnel or by
appointed surveyors with adequate safety
Operators dealing with foreign drivers
precautions.
should be able to communicate in the
local language and in at least one of the
5/ CARGO SECURING
following languages (English, French or
The management of the site, in co-
German). As a minimum they should be
operation with the management of the
able to communicate in the terminology of
transport company, should ensure that the
Transperanto (see www.transperanto.org).
respective roles and tasks are carried out as
described in Appendix 1.
2/ SITE INSTRUCTIONS
The management of the site should ensure
6/ EMERGENCY PREPAREDNESS
that the site access requirements are
The management of the site should
communicated to the hauliers and that
ensure that the necessary site safety
safety procedures are communicated to
equipment is made available at the
the drivers upon arrival. Management must
loading and unloading locations, e.g.: fire
promote and maintain safety awareness,
extinguisher(s), eye wash, safety shower,
particularly during product handling. The
first aid equipment, emergency escape
management should ensure that loading /
routes, emergency stop, decontamination
unloading operations are carried out under
equipment, and absorbent materials.
supervision.
7/ NEAR MISS & INCIDENT REPORTING
3/ WORKING AT HEIGHTS
The management of the site should ensure
The management of the site should
that there is a procedure to report all
provide safe conditions for working at
near misses, incidents, loading/discharge
heights (including safe access to top of
problems and unsafe situations or
vehicles) in conformity with the European
conditions, including follow-up. There
Directive 2001/45/EC of 27 June 2001.
should be a system in place to share
information on important near-misses,
incidents or unsafe situations with all
parties involved.

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 RESPONSIBILITIES & ROLES

1.2.1.2 MANAGEMENT OF THE TRANSPORT COMPANY

1/ EQUIPMENT 3/ CARGO SECURING

The management of the transport The management of the transport
company should always supply equipment company, in co-operation with the
that is fit for the operation to be carried management of the site, should ensure
out and meets all applicable legal that the respective roles and tasks are
requirements. carried out as described in Appendix 1.

2/ COMPETENCE OF DRIVERS 4/ NEAR MISS & INCIDENT REPORTING

The management of the transport The management of the transport
company should ensure that drivers are fit company should ensure that there is
for duty and have passed successfully all a procedure to report all near misses,
necessary training to fulfil the legislative incidents, loading/discharge problems and
requirements and site requirements, in unsafe situations or conditions, including
particular regarding the transportation and follow-up. There should be a system in
handling of dangerous goods. place to share information on important
near-misses, incidents or unsafe situations
Drivers who are involved in international
with the principal.
transport operations, should be able to
communicate in the local language of the
loading/unloading site or in at least one of
the following languages (English, French
or German). As a minimum they should be
able to communicate in the terminology of
Transperanto (see www.transperanto.org).

1.2.2 Operational responsibilities

Continuous monitoring of the (un)loading process by operator and driver in close co-operation,
is essential. To this end operator and driver should be well aware of each others responsibilities,
as detailed in the following table.

In certain areas there are joint responsibilities of operators and drivers. In these cases the same
text has been repeated for both operators and drivers in the table.

In all circumstances, the applicable national or international regulations should always be com-
plied with and take precedence over the recommendations made in the present guidelines.

CEFIC / ECTA GUIDELINES 7

RESPONSIBILITIES & ROLES

OPERATOR DRIVER
1/ TRANSPORT EQUIPMENT

Before the (un)loading operation starts, operators should check Before entering the site, drivers should check that the vehicle
that the transport equipment offered meets all the require- and all ancillary equipment are fit for the operation to be car-
ments for the operation to be carried out. ried out and meet all requirements as specified in the driver’s
instructions for the operation.

2/ SITE INSTRUCTIONS

Operators should always adhere to the site instructions and be Unless specifically agreed otherwise, drivers should always re-
an example for drivers. port at the gate or site entrance and ask for instructions. These
Operators should witness the whole (un)loading activity, unless instructions may include emergency procedures, required PPE,
site procedures stipulate otherwise. parking restrictions, route to loading or unloading point and
general info such as the prohibition of smoking, alcohol and
drugs, prohibition of the use of mobile phones, driving speed
limits etc. Drivers should always adhere to the site instructions.
Drivers should witness the whole (un)loading activity, unless
site procedures stipulate otherwise.

3/ ON-SITE DRIVING AND PARKING

Where possible operators should ensure that vehicles are driven Drivers should proceed to the (un)loading area and park the ve-
and parked according to site instructions and should report any hicle according to site instructions. It is important to constantly
observed unsafe situations to the site management. assess the safety situation, not only whilst driving on site but
also when arriving at the (un)loading point.
Drivers should always take the necessary precautions to pre-
vent any movement of the vehicle during loading/unloading.

4/ PERSONAL PROTECTIVE EQUIPMENT (PPE)

Operators should wear PPE as required by site instructions and Drivers should wear PPE as required by site instructions.
must ensure that the driver does the same. As a minimum the driver should have the following PPE avail-
able in his vehicle: safety helmet, safety shoes, safety glasses,
suitable working gloves and clothing covering the whole body.

5/ EMERGENCY PREPAREDNESS

Prior to the start of the operation, operators should indicate Prior to the start of the operation, drivers should check the
the location of the site safety equipment to the drivers, e.g.: fire location of the site safety equipment, e.g.: fire extinguisher(s),
extinguisher(s), eyewash, safety shower, first aid equipment, eyewash, safety shower, first aid equipment, emergency escape
emergency escape routes, emergency alarm activation, emergen- routes, emergency alarm activation, emergency stop, decon-
cy stop, decontamination equipment and absorbent materials. tamination equipment and absorbent materials.

6/ DOCUMENTATION, MARKING AND LABELLING

The operator should check that all data on the transport docu- The driver should hand over all relevant documents to the
mentation are in line with the goods to be loaded or unloaded operator. Documents may include: weighing ticket, delivery
and that the hazard marking, labelling and placarding of the note, certificate of analysis, cleaning certificate and transport
goods and the transport equipment is in accordance with the document, if necessary with the required dangerous goods
regulations. information.
Operators should sign all relevant documents to confirm that The driver should ensure that arrival/departure times, number
the operation was satisfactorily completed. If there are any of packages, temperature, pressure, volume and weights, as
remarks, these should be written on these documents. applicable, are noted and that signature(s) are obtained on all
copies of the transport document. Customs and other docu-
mentation should be completed as per job instructions. Any
deviations noted at the (un)loading point should be communi-
cated by the driver to the site and be written on the transport
documents before departure.
The driver should ascertain that the correct hazard markings
and placards have been affixed to the vehicle.

8 SAFE LOADING & UNLOADING

 RESPONSIBILITIES & ROLES

OPERATOR DRIVER
7/ PRODUCT SAMPLES

When required or agreed at order entry stage, the operator Drivers should ensure that the supplier’s sample is stored in
should ensure that the driver hands over the supplier’s sample. a safe way and handed over at the delivery point. Storing of
Storing of samples in the drivers cabin should be avoided at any samples in the driver’s cabin should be avoided at any time.
time. Packaging and labelling of the sample should be in accordance
Product sampling directly from road tankers or tank contain- with legal requirements. Drivers should not take samples
ers should be avoided. If the taking of samples is absolutely directly from the road tanker or tank container.
unavoidable, they should be taken by qualified site personnel
or appointed surveyors, with adequate safety precautions.

8/ WORKING AT HEIGHTS

Operators should follow the site procedures when working at Drivers should follow the site instructions when working at
heights. heights.

9/ TANK CAPACITY

The operator should check if the tank can accommodate the Before loading, the driver should check with the operator if the
quantity to be transferred. transport tank or tank compartment can accommodate the
Before loading, the operator should check the capacity of the quantity to be transferred.
transport tank or tank compartment with the driver.
Before unloading, the operator should check the capacity of the
site storage tank.

10/ EQUIPMENT UNDER PRESSURE

The operator should always check if the transport tank and/or The driver should always check if the transport tank and/or
equipment is under pressure before making or breaking any equipment is under pressure before making or breaking any
connections, and communicate with the driver. connections, and communicate with the operator.
Before leaving the site after loading/unloading, the driver
should seek permission from the operator to depressurise the
tank, unless otherwise required.

11/ LOADING OF LIQUIDS IN MULTI COMPARTMENT TANKS

Operators should ensure that in filling the tanks, the regulations The driver should ensure that the operator is loading according
concerning the separation of dangerous goods in adjoining to the load plan.
compartments are complied with.
Operators should ensure that the correct product and quantity
is loaded into the designated compartment(s) according to the
load plan.

12/ HOSES AND OTHER EQUIPMENT

The operator should check if the equipment owned by the site, The driver should check if the equipment owned by the haulier,
e.g. product hose, vapour return or nitrogen/air pressure line, e.g. product hose, vapour return or nitrogen/air pressure
couplings, gaskets and seals, is in good condition, fit for pur- line, couplings, gaskets and seals, is in good condition, fit for
pose and product and pressure resistant. The operator should purpose and product and pressure resistant. The driver should
carry out a visual check on the internal cleanliness. carry out a visual check on the internal cleanliness.

CEFIC / ECTA GUIDELINES 9

RESPONSIBILITIES & ROLES

OPERATOR DRIVER
13/ CONNECTIONS

All site connections should be properly marked/labelled. The The driver should be familiar with the equipment of the vehicle,
operator is responsible for correctly connecting/fitting product e.g. (un)loading valves, pressure/vapour return connections,
hoses and vapour return or nitrogen/air pressure lines to the number and capacity of compartments, hoses, couplings and
storage tank, whilst the driver is responsible for making the gauges. The driver is responsible for making the connections
connections to the vehicle, unless site procedures stipulate to the vehicle, whilst the operator is responsible for making
otherwise. When making or breaking connections, co-ordina- the connections to the storage tank, unless site procedures
tion and co-operation between operator and driver is of vital stipulate otherwise. When making or breaking connections, co-
importance to avoid incidents. ordination and co-operation between the driver and operator is
of vital importance to avoid incidents.

14/ PERMISSION TO (UN)LOAD

The operator should give explicit approval to the driver to operate The driver is only allowed to operate equipment on the vehicle
equipment on the vehicle such as valves, compressor and pump. such as valves, compressor and pump after explicit approval of
Operators should operate the storage tank valves, pressure the operator.
valves and the pump, as applicable. The driver should not operate site equipment.

15/ VEHICLE RESTRICTIONS

The operator, in co-operation with the driver, should ensure The driver, in co-operation with the operator, should ensure
that the maximum permissible vehicle gross weight is not that the maximum permissible vehicle gross weight is not
exceeded. exceeded.
Operators should ensure that the minimum and maximum During loading of the vehicle, the driver should take all possible
permissible degree of filling of the tanks is observed. precautions not to exceed the maximum permissible axle weight.

16/ DISCONNECTION

Operators should ensure that before disconnecting hoses, all Before departure the driver should ensure that all hoses are
valves are closed and all hoses are free of pressure and product. disconnected, drained, blanked off (if necessary) and properly
stored. All manlids and valves should be closed and properly
tightened. The earthing cable as well as any loose equipment
should be cleared away. The driver should ensure that it is safe
to leave the (un)loading point by walking around the vehicle.

17/ REPORTING OF UNSAFE SITUATIONS, NEAR MISSES AND INCIDENTS

Operators should report all loading/discharge problems, unsafe Drivers should report all loading/discharge problems, unsafe
situations or conditions, near misses and incidents, as per com- situations or conditions, near misses and incidents, as per com-
pany procedure. pany procedure.

18/ STOWAGE, SECURING AND SEGREGATION OF PACKAGED GOODS

Before starting loading, operators should ensure that packages The driver should prepare the vehicle for (un)loading (i.e. opening
that are already loaded on the vehicle when it arrives at the load- doors and canvas, removing blocking and bracing material, undo-
ing site, are stowed and secured in an adequate way so that they ing the strapping etc.). When opening the doors of the vehicle,
cannot damage the goods to be loaded. the driver should always be aware of the possibility of packages
falling out.
Operators should ensure that packages are stowed and secured
in such a way that they cannot move in any direction. Free space Before loading commences, the driver should ensure that pack-
between packages should be avoided and sufficient lashings ages that are already loaded on the vehicle when it arrives at the
should be applied. Special precautions should be taken when loading site, are stowed and secured in an adequate way so that
packages of different types are stowed on the same vehicle. they cannot damage the goods to be loaded.
Operators should ensure that the regulations on prohibition of Drivers should ensure that packages are stowed and secured in
mixed loading and the regulations concerning separation of food such a way that they cannot move in any direction. Free space
stuffs, animal feedstuffs etc, are followed, taking into account the between packages should be avoided and sufficient lashings
goods that are already loaded in the vehicle. must be applied.
Operators should not allow the vehicle to leave the loading/ Drivers should not leave the (un)loading site without checking
unloading site in an unsafe condition. stowage and securing.
More detailed guidance concerning the roles and tasks for load More detailed guidance concerning the roles and tasks for load
securing are included in Appendix 1. securing are included in Appendix 1.

10 SAFE LOADING & UNLOADING

 BBS OBSERVATIONS

2 BBS OBSERVATIONS
OF LOADING/UNLOADING OPERATIONS

2.1 PROCESS
The process for implementing BBS should reside at the loading/unloading site (for the opera-
within the company responsible for the loading/ tors) and at the transport company (for the
unloading site in close co-operation with the drivers). The operators and drivers should
transport companies, as an important element receive a copy of the report.
of their continuous improvement programmes.
It should include the following steps:
› The results of the BBS observations should
be used by the management of the loading/
unloading site and the transport company
— The management of the company respon-
as input for continuous improvement pro-
sible for loading/unloading develops a BBS
grammes.
implementation plan based on the prin-
ciples described in these Guidelines. œ The management of the site and of the
transport company should ensure that there
˜ The management selects BBS observers
is a system in place to report all near misses,
and ensures that they obtain training in ac-
incidents, loading/discharge problems and
cordance with the principles set out in these
unsafe situations or conditions, including
Guidelines.
follow-up. Operators and drivers should
™ BBS observers carry out observations of report all near misses, incidents, loading/dis-
loading/unloading operations using a charge problems and unsafe situations or
checklist (see example in Appendix 2) and conditions, as per company procedure.
communicate findings to operators and
drivers.
Note. In the case of unsafe situations observed
š BBS observers report their findings to the during unloading operations at customer sites, the
management of the site and the transport BBS observation should be initiated by the supplier
company. The reports should be kept on file in co-operation with the customer and the haulier.

PROCESS FOR BBS OBSERVATIONS

— œ
˜

› ™

CEFIC / ECTA GUIDELINES 11

BBS OBSERVATIONS
O S

2.2 RESPONSIBILITIES FOR

IMPLEMENTATION
Successful implementation of BBS for loading/unloading operations requires a top-down manage-
ment approach. BBS must be fully integrated in the organisation and management systems of the
parties involved. It needs to be one of the key drivers for continuous performance improvement.

2.2.1 Management
MANAGEMENT SHOULD:
• Prepare a document describing the company's approach towards BBS and the implementation
plan for all components of the loading/unloading operations.
• Communicate this plan to all personnel involved and review it at least annually.
• Initiate, implement and provide ongoing support for the BBS programme.
• Define roles, provide resources, resolve issues and remove barriers for a successful
implementation.
• Set targets, monitor status and results.
• Keep records.
• Manage and continuously review the improvement process based on BBS data analysis.

2.2.2 Operators/drivers
OPERATORS AND DRIVERS SHOULD:
• Understand the purpose of the BBS programme and be committed to participate.
• Report unsafe conditions to the observer.
• Discuss performance weaknesses with the observer and help in finding solutions.
• Implement improvement actions as a result of the BBS analysis.

2.2.3 BBS observers

BBS OBSERVERS SHOULD:
• Execute the BBS observations.
• Observe and interactively communicate the findings with the operators/drivers.
• Collect data and report results to management.
• Identify and report any issues that need to be followed up by operators/drivers or management.

12 SAFE LOADING & UNLOADING

 BBS OBSERVATIONS

2.3 OBSERVATIONS
The observation should be interactive, without interfering with the actual loading or unloading
process except to stop an unsafe situation. The interactive part consists of the coaching the ob-
server may deem necessary to increase safety awareness and behaviour of the operator and/or the
driver. Coaching must always take place in a positive way in order to obtain full acceptance and thus
maximum results.
A checklist (adapted to the type of loading or unloading operation) should be fully completed for
both the operator and driver involved (see example of a checklist in Appendix 2). For any significant
finding, either positive or negative, a brief explanation of the remark made and the subsequent
coaching that was provided should be specified.
After the observation is finished, irrespective of the fact that remarks were made or not, the ob-
server should take time to communicate the results of the observation to both operator and driver
involved. Preferably a copy of the completed observation form should be handed over to both.
The loading/unloading site should register all observations and ensure that the transport company
involved receives a copy of the observation report.

2.4 RECORD KEEPING / ANALYSIS

Records of the observations, together with the completed checklists, should be kept on file by the
loading/unloading site and the transport company. Operators/drivers should have the possibility of
obtaining a copy of their personal record as a reminder/learning tool for continuous improvement.
Management should use the collected data to identify structural trends and issues.

2.5 FOLLOW UP / CORRECTIVE ACTIONS

Results of analyses should trigger corrective actions to equipment, processes, safety programmes
and employees in the loading/unloading site and the transport company. The effectiveness of
implemented corrective actions should be monitored through key performance indicators.

2.6 QUALIFICATIONS OF OBSERVERS

A successful programme depends heavily on the skills of the observers. The selection of the observ-
ers is therefore critical. It is advisable that observers have an independent position in relation to the
operators/drivers. Training of direct colleagues should be avoided.
The observer may be a representative of either the company involved in the loading/unloading
operation or of the transport company. He/she should have knowledge of these Guidelines and be
fully aware of all details of the loading or unloading operation to be observed. He/she should be
capable of communicating comments on safety issues from a position of knowledge to the operator
and driver involved.
Observers should obtain extensive training on the content, objectives and requirements of the BBS
implementation plan, based on the principles set out in these Guidelines.

2.7 FREQUENCY OF OBSERVATIONS

Observations should be carried out on a representative number of all the loading/unloading opera-
tions taking place at a site. Each observation should cover all the activities of the loading/unloading
operation.

CEFIC / ECTA GUIDELINES 13

APPENDICES

APPENDIX 1: ROLES AND TASKS FOR LOAD SECURING IN CARGO TRANSPORT UNITS (CTUs)

PROCESS / STAGE TASK / ACTIVITY PRINCIPAL CARRIER

Management Carry out risk assessment • •
responsibilities Document packaging specifications (including stacking rules) •
Define CTU requirements (type, specifications, LTL cargo rules) •
Determine and document CTU weight/axles limits •
Agree load distribution plans (number of packages/gross weight limits/axle weight limits) • •
Agree on supply of cargo securing material • •
Develop good securing and stowage practices for the agreed load plans • •
Define and agree working instructions (who will do what) • •
Document operational procedures/instructions • •
Train and instruct employees involved • •
Offering CTU Select CTU in line with principal’s requirements •
“Fit for Load” Ensure good condition of CTU (load floor, side walls, curtains, lashing points, headboard) •
Fulfill LTL cargo rules (including segregation rules) •
Ensure that LTL cargo is secured and stowed adequately •
Provide re-usable securing material (e.g. lashings, friction material,
rigid protection edges,…) •

PROCESS / STAGE TASK / ACTIVITY LOADER DRIVER

Pre-loading Instruct driver on specific safety instructions (e.g. interaction during loading operation) •
checks/tasks Check weight of CTU with respect of routing/model/legislation/truck type • •
Adjust quantity to be loaded taking into account the weight of the CTU •
Select one of previously agreed load plans •
Immobilize CTU • •
Open CTU •
Check if CTU meets requirements and is safe to load •
Check availability and condition of the cargo securing material •
Confirm agreement on loading / securing operational procedure • •
Loading/ Load according to selected load plan •
securing Ensure correct segregation of cargoes •
operation
Supply additional cargo securing material (e.g. air bags, sheets, one way straps,..) •
Application of blocking and bracing •
Application of lashing as agreed by the management in the working instructions •
Post-loading Check the applied cargo securing (blocking, bracing and lashing) • •
checks/tasks Close CTU •
Apply seal if applicable and note on the transport documentation •
Sign off loading document (confirming loading and cargo securing is correctly carried out) • •
Check and correct cargo securing during transport (e.g. partial loading /unloading) •
• Under all circumstances applicable national and international (e.g. ADR) regulations take precedence on these general guidelines and should be
implemented.
• It is not the purpose of this guideline to define liabilities in case of damage to the transported goods.
• For FCA (Free Carriage/see Incoterms) consignments the above matrix may not apply. In this case the respective roles and tasks need to be agreed
between the principal (customer), the management of the loading site and the carrier prior to the transport operation.
• In case the driver is not present during loading, the loader must fulfill the roles initially assigned to the driver (e.g. containers, swapbodies, drop
and swap,…).

14 SAFE LOADING & UNLOADING

 APPENDICES

APPENDIX 2: EXAMPLE OF CHECKLIST FOR OBSERVATION OF LOADING/UNLOADING OPERATIONS

ACTIVITY REFERENCE BBS GUIDELINE OPERATOR DRIVER

SITE ACCESS
Availability of standard PPE 1.2.2.4
Safe parking of vehicle 1.2.2.3
Check of documents 1.2.2.6
Adherence to site instructions 1.2.2.2
Location of site safety equipment 1.2.2.5

BEFORE LOADING / UNLOADING

Process for declaring vehicle fit for loading 1.2.2.1 / 6
Proper use of standard PPE 1.2.2.4
Proper use of special PPE 1.2.2.4
Check of load securing and stowage material** 1.2.2.18
Check if there is pre-loaded cargo** 1.2.2.18
Co-operation between driver and operator 1.2.2.13 / 14 / 15
Checking of tank capacity* 1.2.2.9
Safe working at heights 1.2.2.8
Checking if bottom valve, blind cap etc. are properly closed before loading* 1.2.2.13
Awareness of risk of opening manholes* 1.2.2.10
Control of gaskets* 1.2.2.12
Checking of pressure / vacuum / nitrogen status* 1.2.2.10
Sampling* 1.2.2.7
Checking of hoses* 1.2.2.12
Making connections* 1.2.2.13
Stowage plan** 1.2.2.18

DURING LOADING / UNLOADING

Co-operation between driver and operator 1.2.2.13 / 14 / 15
Presence during loading / unloading 1.2.2.2
Operation of storage tank valves and pump* 1.2.2.14
Awareness of potentially unsafe conditions 1.2.2.17

AFTER LOADING / UNLOADING

Checks after completion of loading / unloading* 1.2.2.16
Disconnection of hoses, proper closure of valves and manlids* 1.2.2.16
Proper securing and stowage (including packages from pre-loaded cargo)** 1.2.2.18
Proper marking and placarding of the tank/transport unit 1.2.2.6
Check of max. permissible vehicle gross weight/axle weight 1.2.2.15
Check of max. and min. permissible degree of filling* 1.2.2.15
Document check 1.2.2.6
* bulk only
** packed only

CEFIC / ECTA GUIDELINES 15

CONTACTS

Bernard Lemaire Eric van Beek

Arkema Den Hartogh Logistics
4 – 8, cours Michelet, La Défense 10 P.O. Box 1159
92091 Paris La Défense Cedex 3180 AD Rozenburg
France The Netherlands
T +33 149008696 T +31 181 247817
F +33 149005236 F +31 181 233317
[email protected] [email protected]

Jörg Reinbold Luc Renier

BASF Aktiengesellschaft Dow Benelux BV
GUS/DT - J 660 Herbert H Dowweg 5
67056 Ludwigshafen 4530 AA Terneuzen
Germany The Netherlands
T +49 621 6071397 T +31 1 115674182
F +49 621 6072211 F +31 1 115674248
[email protected] [email protected]

Peter Kupferschmied Bert Zuidema

Bertschi AG DSM Industrial Services
5724 Dürrenäsch Physical Distribution
Switzerland 6160 BD Geleen
T +41 564640734 The Netherlands
F +41 797226200 T +31 464 773883
[email protected] F +31 464 770003
[email protected]

Paul Lancaster
BP European Acetyls Peter Saey
CMO DSV Road NV
Saltend Schoonmansveld 40
Hull 2870 Puurs
HU12 8DS Belgium
United Kingdom T +32 (0)3 897 27 82
T +44 (0) 7810071393 F +32 (0)3 897 27 89
F +44 (0) 1482 892219 [email protected]
[email protected]

Chris Boland
Jos Verlinden DuPont (UK) Ltd
European Chemical Industry Council Wegwood Way Stevenage
Avenue E. van Nieuwenhuyselaan 4 SG1 4QN Hertfordshire
1160 Brussels United Kingdom
Belgium T + 44 1438 734370
T +32 2 676 73 95 F + 44 1438 734371
F +32 2 676 74 32 [email protected]
[email protected]

Rose-Marie Pype
Wolfgang Neumann European Chemical Transport Association
Degussa AG Avenue de Tervuerenlaan 270
Weißfrauenstraße, 9 1150 Brussels
60287 Frankfurt am Main Belgium
Germany T +32 2 741 86 67
T + 49 692 182743 F +32 2 741 86 82
F + 49 692 183508 [email protected]
[email protected]

Bart van Rens

Evert de Jong Ewals Cargo Care BV
De Rijke Group Ariënsstraat 61 - 63
Malledijk 7 5931HM Tegelen
3208 LA Spijkenisse The Netherlands
The Netherlands T +31 77 3202521
T +31 181 654 292 F +31 77 3202539
F +31 181 654 317 [email protected]
[email protected]

16 SAFE LOADING & UNLOADING

 CONTACTS

Luc Dillen Johan Bakker

ExxonMobil Lyondell
Admin 2 - Polderdijkweg 3 Weenapoint D, Weena 762
2030 Antwerpen 3014 DA Rotterdam
Belgium The Netherlands
T +32 3 543 3331 T +31 10 2755886
F +32 3 543 3325 F +31 10 2755559
[email protected] [email protected]

Elenia Cristiani Pierre-Alain Saclier

Federchimica Norbert Dentressangle Chimie
Via G. da Procida, 11 B.P. 79 - Les fouillouses Ouest
20149 Milano 26140 Saint-Rambert d’Albon
Italy France
T +39 02 34565378 T +33 (0)4 75 03 71 13
F +39 02 34565329 F +33 (0)4 75 03 72 04
[email protected] [email protected]

Luc Haesaerts Jean-Michel Lemaitre

Haesaerts Intermodal Nova Innovene
Koningin Astridlaan 29 Avenue de la Gare 12
2870 Breendonk 1700 Fribourg. Switzerland
Belgium Mobile +33 685 304077
T +32 3 860 64 64 T +41 26 426 56 56
F +32 3 886 71 68 F +41 26 426 56 57
[email protected] [email protected]

Horst Metze Nicolaas Meijboom

Hoyer GmbH Internationale Fachspedition Shell Chemicals Europe B.V.
Wendenstrasse 414-424 Hoofdweg 256
20537 Hamburg 3067 GJ Rotterdam
Germany The Netherlands
T +49 40 210 44 435 T +31 10 231 7007
F +49 40 210 44 427 F +31 10 231 7076
[email protected] [email protected]

Huig van Wijnen Colin V. Humphrey

Huntsman Holland United Transport Tankcontainers
P.O. Box 1020 Victoria House Pearson Court
3180 AA Rozenburg Pearson Way Teesdale Stockton on Tees
The Netherlands Cleveland TS176PT. United Kingdom
T +31 181292299 T +44 1789842917
F +31 181293989 F +44 1789470128
[email protected] [email protected]

Martin Schefzick Jörg Roth

INEOS Köln GmbH VCI (Verband der Chemischen Industrie e. V.)
Alte Straße 201 Liaison Office Brussels
50769 Köln Rue du Commerce 31
Germany 1000 Brussels
T +49 2133 556751 Belgium
F +49 2133 556199 T +32 2 5480692
[email protected] F +32 2 5480699
[email protected]

Andreas Zink
LKW Walter Peter Räuchle
I.Z. Süd Objekt 14 Wincanton Chemical Logistics (WCL)
2355 Wiener Neudorf Antwerpener Strasse 24
Austria 68219 Mannheim. Germany
T +43 57777 2344 T +49 621 8048-306
F +43 57777 52344 F +49 621 8048-527
[email protected] [email protected]

CEFIC / ECTA GUIDELINES 17

OTHER
LIST OFBEST
OTHER
PRACTICES
BEST PRACTICE
GUIDELINES
GUIDELINES

LIST OF OTHER BEST PRACTICE GUIDELINES ISSUED BY CEFIC AND ECTA

• Recommendations on Safety, Health and Environmental (SHE) Management Practices for Logistics
Services (April 2002)

• Guidelines for Safety Awareness and Behaviour in the Supply Chain (April 2002)

• Guidelines for Standardised Delivery Performance Measurement (April 2002)

• Guidelines for 16 hour operation (April 2002)

• Standard Rail Tank Cars for the Carriage of Liquid Chemicals in Bulk: Requirements for Design,
Construction and Testing (August 2003)

• Behaviour Based Safety – Guidelines for safe driving of road freight vehicles (October 2003)

• Guidelines for Transportation Security (December 2003)

• Industry Guidelines for the Security of the Transport of Dangerous Goods by Road (April 2005)

• Guidelines on Subcontracting of Chemical Road Transport (October 2005)

• Guidelines for Transport Equipment used for Chemical Packed Cargo (March 2007)

These guidelines can be downloaded from the Cefic website (www.cefic.org)

and the ECTA website (www.ecta.be).

Special thanks to L. van der Lee en Zonen BV for the photo

18 SAFE LOADING & UNLOADING

DISCLAIMER This document is intended for information only and sets out guidelines for the safe loading/unloading of road freight vehicles. The information contained in
these guidelines is provided in good faith and, while it is accurate as far as the authors are aware, no representations or warranties are made about its completeness. It is not
intended to be a comprehensive guide to all detailed aspects of the safe loading and unloading of road freight vehicles. No responsibility will be assumed by the participat-
ing associations, Cefic and ECTA, in relation to the information contained in these guidelines.
CEFIC AISBL - EUROPEAN CHEMICAL INDUSTRY COUNCIL EUROPEAN CHEMICAL TRANSPORT ASSOCIATION*
Avenue E. van Nieuwenhuyselaan 4 Avenue de Tervuerenlaan 270
1160 Brussels - Belgium 1150 Brussels - Belgium
T +32 2 676 72 11 T +32 2 741 86 67
F +32 2 676 73 00 F +32 2 741 86 82
www.cefic.org www.ecta.be

*ECTA is supported by EPCA (European Petrochemical Association)