TLIA107C

Secure Cargo
Learner Guide
Contents
What this Learner’s Guide is about ........................................ 3
Planning your learning ........................................................... 4
How you will be assessed ...................................................... 7

Section 1............................................................................................. 9
Prepare to secure cargo/containers ....................................... 9

Section 2........................................................................................... 48
Loading and unloading cargo............................................... 48

Additional resources ....................................................................... 56

Feedback on activities .................................................................... 60

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What this Learner’s Guide is about

This  learning  guide  is  about  the  skills  and  knowledge  required  to  
secure  cargo  including  preparing  to  secure  cargo/containers,  lashing  
and  unlashing  cargo,  protecting  cargo  from  weather  and  packing  and  
unpacking  cargo.  It  may  apply  in  cargo  securing  contexts  in  the  
stevedoring,  transport,  distribution  and  allied  industries.  

The  Elements  of  Competency  from  the  unit  TLIA107C  Secure  cargo  
covered  in  this  Learner’s  Guide  are  listed  below.  
Prepare  to  secure  cargo/containers  
Lash  and  unlash  cargo    
Protect  cargo  from  the  weather  
Pack  and  unpack  cargo  

This  unit  of  competency  is  from  the  Transport  and  Logistics  Training  
Package  (TLI07).  

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Planning your learning

It  is  important  to  plan  your  learning  before  you  start  because  you  may  
already  have  some  of  the  knowledge  and  skills  that  are  covered  in  this  
Learner’s  Guide.  This  might  be  because:  
• you  have  been  working  in  the  industry  for  some  time,  
and/or  
• you  have  already  completed  training  in  this  area.  

Together  with  your  supervisor  or  trainer  use  the  checklists  on  the  
following  pages  to  help  you  plan  your  study  program.  Your  answers  to  
the  questions  in  the  checklist  will  help  you  work  out  which  sections  of  
this  Learner’s  Guide  you  need  to  complete.  

This  Learner’s  Guide  is  written  with  the  idea  that  learning  is  made  more  
relevant  when  you,  the  learner,  are  actually  working  in  the  industry.  
This  means  that  you  will  have  people  within  the  enterprise  who  can  
show  you  things,  discuss  how  things  are  done  and  answer  any  
questions  you  have.  Also  you  can  practise  what  you  learn  and  see  how  
what  you  learn  is  applied  in  the  enterprise.  

If  you  are  working  through  this  Learner’s  Guide  and  have  not  yet  found  
a  job  in  the  industry,  you  will  need  to  talk  to  your  trainer  about  doing  
work  experience  or  working  and  learning  in  some  sort  of  simulated  
workplace.    

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Section 1: Prepare to secure cargo/containers

Are  you  able  to:   Yes   No  

1. prepare  and  maintain  work  area  
according  to  national  standards,  safety  
codes  and  site  operating  procedures?        
2. report  unsafe  work  practices  and/or  
equipment  to  appropriate  personnel?        
3. select  and  wear  appropriate  protective  
clothing,  equipment  and  fittings        
4. erect  formwork  where  no  lashing  points  
exist?        
5. read  and  interpret  lashing  plan?        

Section 2: Lash and unlash cargo

Are  you  able  to:   Yes   No  

1. conduct  work  in  accordance  with  industry  
standards,  statutory  requirements,  safety  
codes,  site  operating  conditions  and  any  
special  requirements  of  the  cargo?        
2. identify  lashing  points  and  use  appropriate  
lashing  equipment  for  each  lashing  point?        
3. lash  and  secure  cargo  to  lashing  points  and  
ensure  the  correct  spread  of  lashings  and  
that  lashings  are  secured,  attached  and  
tensioned?        
4. fasten  tensioners  securely?        
5. release,  disconnect  and  remove  fittings  
from  cargo  when  unlashing?          
6. place  lashing  equipment  in  designated  
storage  areas  or  clear  from  working  area?          
7. ensure  lashing/unlashing  operations  do  not  
cause  injury  to  personnel  or  damage  to  
machinery  or  cargo?eq          
8. complete  lashing  in  accordance  with  
lashing  plan?          

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Section  3:  Protect  cargo  from  weather  

Are  you  able  to:   Yes   No  

1. safely  cover/uncover  cargo,  ensure  
appropriate  covering  and  lashing  is  used  
and  ensure  that  no  injury  is  caused  to  
personnel  or  damage  to  cargo  or  
equipment?          
2. conduct  work  in  accordance  with  
requirements  of  national  standards,  safety  
codes  and  site  operating  procedures?        

Section 4: Pack and unpack cargo

Are  you  able  to:   Yes   No  

1. identify  and  report  damaged  cargo  
following  enterprise  procedures?          
2. sort  and  stack  cargo  prior  to  packing  and  
unpacking,  and  ensure  the  stack  is  in  the  
correct  location,  in  accordance  with  
national  standards,  safety  codes,  and  site  
operating  procedures?        
3. identify  cargo  through  the  interpretation  of  
marks  or  numbers?        
4. maintain  tight  stow  of  cargo?        
5. handle  cargo  ensuring  no  injury  to  
personnel  or  damage  to  cargo  or  
equipment?          

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How you will be assessed

Assessment  of  this  Unit  of  Competency  will  include  observation  of  real  
or  simulated  work  processes  using  workplace  procedures  and  
questioning  on  underpinning  knowledge  and  skills.  It  must  be  
demonstrated  in  an  actual  or  simulated  work  situation  under  
supervision.  

You  will  be  required  to  demonstrate  that  you  can:  

• load  and  secure  cargo  safely  and  in  line  with  the  ‘Load  
Restraint  Guide’  including  protecting  cargo  from  weather  
• report  damaged  cargo  
• pack  and  unpack  cargo  safely.  

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Section 1

Prepare to secure
cargo/containers

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Section outline

Areas  covered  in  this  section  

Preparing  to  secure  cargo/containers  including:  
 preparing  work  area  
 safe  working  
 balancing  loads  and  load  limits  
 erecting  formwork  if  no  lashing  points  exist    
 locating  and  interpreting  the  lashing  plan  
Loading  and  unloading  cargo  
Lashing  loads  
Protecting  cargo  from  the  weather  

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How do you prepare yourself and your work

area for securing cargo?

What safety issues do you need to consider

when securing cargo?
Cargo  may  be  transported  many  kilometres  and  during  that  
time,  the  load  can  be  subject  to:  
• vibration  or  rocking  back  and  forth  (road  or  sea)  
• heat  and  cold  
• bumping  from  other  objects,  equipment,  vehicles  and  
when  taken  over  rough  roads  or  ground  
• the  whole  load  being  tilted  (cargo  ships  can  roll  a  long  way  
in  heavy  seas,  trucks  going  around  corners  at  speed  can  tilt  
a  long  way)  
• attempts  to  remove  items  from  the  cargo  through  theft  
• inspection  by  customs  officers  and  other  authorities.  
Each  of  these  factors  can  have  an  effect  on  how  secure  the  
cargo  is  and  in  combination  can  lead  to  improperly  secured  
cargo  coming  loose.  
The  most  important  aspect  of  the  tasks  associated  with  
securing  cargo  is  safety.    This  is  usually  referred  to  OHS  or  
Occupational  Health  and  Safety.    Later  in  this  Learner’s  Guide,  
information  will  be  given  on  how  to  allow  for  each  of  these  
factors  outlined  above  so  that  loads  or  cargo  are  safely  
secured.      
A  good  way  to  remember  who  is  affected  by  safety  is  to  think  
about:  

OWN  Health  and  Safety  

OTHERS’  Health  and  Safety  
OCCUPATIONAL  Health  and  Safety  

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The  focus  is  then  on  your  safety,  that  of  others  and  making  
your  occupation  a  safe  occupation  to  work  in.  

When  thinking  about  safety  and  tackling  any  task,  it  is  a  good  idea  to  
take  some  time  to  look  at  the  job  and  identify  any  risks  that  might  be  
involved  in  the  job.    This  is  called  risk  analysis.    Think  about:  
• What  could  go  wrong?  
• How  likely  is  this  to  happen?  
• What  are  the  consequences  if  this  happens?  
• What  can  I  do  to  prevent  anything  like  that  happening?  
• If  I  can’t  (totally)  prevent  this  happening,  what  will  protect  
me  and  others  from  injury  if  it  does  happen?  

To  take  the  last  point,  Personal  Protective  Equipment  (PPE)  is  used  to  
protect  yourself  and  can  include:  
• safety  boots  (you  will  probably  require  these  to  be  worn  
throughout  your  working  day)  
• hard  hat  
• gloves  
• hair  net  
• safety  glasses  
• breathing  apparatus  
• face  shield  
• disposable  coveralls.  

The  PPE  required  will  depend  on  the  cargo  being  handled  and  what  
risks  are  associated  with  spillage  or  leakage  of  the  contents.    The  cargo  
should  be  labelled  with  HAZCHEM  signs  if  the  contents  are  hazardous.    
You  may  be  handling  material  that  is  hazardous  because  it  is:  
• explosive    
• flammable    
• corrosive  
• radio-­‐active  
• an  oxidising  agent  
• poisonous.  

Part  of  your  induction  and  further  training  within  your  workplace  
should  have  included  Occupational  Health  and  Safety  and  you  should  
know  how  to  read  HAZCHEM  signs  and  what  protection  you  are  
required  to  use  when  handling  such  materials.    You  trainer  should  give  

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you  a  copy  of  the  HAZCHEM  Safety  Card  from  Worksafe  Victoria  for  
review.  

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If  you  are  unsure,  seek  advice  from  your  OHS  representative,  training  
staff  or  your  fellow  team  members.    The  time  taken  to  check  what  is  
required  is  time  well  spent  and  may  avoid  injury,  either  immediate  or  
long  term  to  yourself.    Some  chemicals  have  an  effect  over  time  with  
repeated  exposure.    The  safety  of  yourself,  others  and  property  
including  the  load  or  cargo  itself  is  assured  if  cargo  is  secured  
according  to  guidelines  which  will  be  explored  in  this  Learner’s  Guide.  

An  essential  resource  to  complement  this  Learner’s  Guide  is  the  ‘Load  
Restraint  Guide’  produced  by  the  National  Road  Transport  Commission  
(see  under  resources).    This  publication  provides  a  guide  to  securing  
loads  in  line  with  relevant  regulations  and  legislation.  

The  first  activities  focus  on  PPE  that  you  require  in  your  job  role  and  
reporting  unsafe  practices.  

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Activity 1: Personal protective equipment

Respond to the following questions. Talk to your supervisor,

trainer, team members, OHS representative, others in the
workplace if you need help answering the questions.

What equipment are you required to wear at all times?

What other equipment would you be required to wear when

securing cargo that does not include hazardous material?

What types of hazardous material do you handle in your

workplace? Use the table below to list five types of cargo that
require HAZCHEM labels or otherwise require other types of PPE
or specialised PPE to be used or worn during handling.

Description of cargo Specialised PPE required

There is feedback on this activity at the back of this Learner’s

Guide.

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Activity 2: Reporting unsafe equipment and practices

Talk to your trainer about reporting of unsafe equipment and

practices. While it is easy enough to talk to someone and tell them
that equipment is not safe to use, reporting unsafe practices can be
very difficult.

You need to be aware of what is the safe or required way of doing

things and then practice doing it correctly. Once you feel confident
of doing the task yourself, you will get better and quicker at doing
that task. Eventually you may get a reputation for doing it well and
new team members will ask for your help.

In safety studies, it is recognised that people can become unsafe

when they do things without thinking and quickly because they
have done it so many times before.

Ask your trainer what you should do to report:

• unsafe equipment
• unsafe work practices of others.

There is feedback on this activity at the back of this Learner’s

Guide.

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What vehicle will I use?

It  is  said  that  ‘planning  is  9/10ths  of  a  job’  or  task.    This  applies  across  
all  work  areas  including  when  you  are  securing  cargo  ready  for  
transportation.    This  planning  will  include  risk  analysis  (see  above).  

Your  first  piece  of  planning  should  be  to  look  at  the  securing  job  that  
you  are  about  to  do  and  to:  
• determine  the  load  that  will  be  carried    
• determine  the  type  of  vehicle  that  you  will  use  to  transport  
the  cargo  or  load.  

The  question  to  now  ask  is:  

“Does this vehicle suit

the load that needs to be
transported?”

For  example,  if  you  need  to  transport  logs,  you  would  use  a  ‘pole-­‐type  
trailer’  that  instead  of  a  tray  has  a  pole  type  structure  with  cross  bars  
to  which  the  logs  are  attached.    A  line  drawing  of  this  type  of  structure  
viewed  from  above  looks  like:  

(This  type  of  structure  is  used  for  pipes,  telegraph  poles,  girders  and  
other  rigid  long  cargo).  

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As a further example, if you had to transport a load of rocks for a

landscaping project, you would probably select a tip-truck or vehicle
with sides (on the tray) so that the rocks cannot fall off the truck.
You should contain the load by putting a cover or net over the rocks
in case the road is rough and rocks fly out of the truck when a
pothole is encountered.

Would a utility carry the load? Space and weight are the things to
consider. Vehicles are labelled with a GVM (Gross Vehicle Mass)
representing the laden mass (weight of the vehicle and the
maximum load allowed) as specified by the manufacturer.

The space occupied by the rocks needs to be considered. For

rocks, if the rocks don’t fit into the vehicle’s tray, they are probably
also too heavy for that vehicle!!

The load length and width is an important consideration.

For most states/territories, a load on a vehicle must not project

more than 1.2 metres in front of the vehicle, or more than 150
millimetres from the outermost part of either side of it. This is
shown in the diagram below:

1.2 metres

Vehicle as seen
150 150
millimetres from above millimetres

1.2 metres

Under  the  same  regulations,  the  total  height  of  vehicle  and  load  must  
not  exceed  4.3  m.    (Always  check  your  own  state/territory  regulations).  

The  next  activities  ask  you  to  look  at  selection  of  vehicles  for  
transporting  loads  and  cargo.  

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Activity 3: Selecting the right vehicle

Consider each of the following loads and the available vehicles.

Choose the vehicle you think is most appropriate to carry the load.

Add any additional precautions you would take such as putting a

net over the load.

Available vehicles:

6 cylinder station wagon

4 cylinder utility with tray and sides

Flat bed 4 tonne truck with 3 axles

Articulated vehicle with flat bed and 4 axles and a carrying capacity
of 15 tonnes.

Load or cargo Vehicle chosen Comments

Fork lift

Shipping container

Refrigerator

Cubic metre of sand

Tiles for a bathroom

There is feedback on this activity at the back of this Learner’s

Guide.

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Activity 4: GMV of vehicles

Find out the GMV of the vehicles that are used at your workplace (if
this is a large number, do this exercise for five different vehicles).
Provide examples of types of loads suited for this vehicle. An
example has been provided for you. Ask for help from your trainer
or supervisor if you cannot easily locate this information.

Vehicle description GMV Examples of types

of loads suited for
this vehicle

3 tonne twin axle flat 3 tonne Plaster board,

bed tray truck building lumber

There is feedback on this activity at the back of this Learner’s

Guide.

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How do prepare my work areas and the vehicle

for loading?

Having  selected  the  type  of  vehicle  appropriate  to  carry  the  load,  the  
next  consideration  is  getting  the  area  ready  for  loading  operations.    
This  will  involve:  
• selecting  an  area  for  loading  that  allows  for  fork  lifts  or  
other  equipment  used  for  loading  cargo  
• clearing  the  area  of  obstructions  
• removing  rubbish  that  may  cause  a  slip  to  occur  
• avoiding  areas  of  oil  spill  that  may  increase  the  chance  of  
an  accident  
• installing  any  formwork  or  other  equipment  required  for  
lashing  on  the  truck  or  trailer.  

The  first  four  points  relate  to  a  common  sense  approach  to  safety.    
Trying  to  work  in  cramped  conditions  or  conditions  that  might  
contribute  to  an  accident,  is  foolish.    A  few  minutes  taken  to  survey  
the  work  area  are  time  well  spent.  

The  last  point  relates  to  moveable  fixtures  on  trucks  or  trailers  that  
assist  in  lashing  down  the  load.    For  example,  if  pipes  or  rolls  of  paper  
are  being  transported,  there  is  a  danger  that  the  round  (cylindrical  
objects)  can  roll  off  the  truck  or  trailer.    Special  triangular  blocks  will  
be  required  to  be  fixed  into  place.    Vehicles  used  for  transporting  this  
type  of  material  may  have  these  permanently  attached.    Other  vehicles  
may  need  such  an  attachment  added.    These  blocks  or  formwork  
cannot  just  be  placed  on  the  truck  or  trailer  tray,  but  must  be  secured  
to  ensure  that  they  do  not  come  loose  when  the  cargo  is  being  
transported.    They  can  be  temporary  or  removable  structures.  

The  diagram  below  illustrated  this  point  (the  view  is  looking  at  the  rear  
of  the  tray):  

Blocks
LOAD (pipe, etc.)

Tray of truck

(NOTE  :  Lashings  not  shown  for  simplicity  of  drawing)  

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Smaller  pipes  may  be  ‘cradled’  –  a  piece  of  formwork  is  added  
to  house  the  pipes  as  shown  below  (note  that  dimensions  are  
exaggerated  and  that  pipes  would  be  closer  together  with  
more  across  width  of  tray!).    The  cradle  should  also  be  secured  
so  that  it  will  not  move  around.  

CRADLE
LOAD (pipes)

Tray of truck

(NOTE  :  Lashings  not  shown  for  simplicity  of  drawing)  

 
Further  examples  can  be  found  in  the  ‘Load  Restraint  Guide’.  
The  next  activity  looks  at  formwork  required  for  loads.    

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Activity 5: Formwork

Talk to your supervisor, trainer and other team members involved

in loading cargo. Ask them to show you examples of formwork
used to secure loads. Use the table below to record your findings.
One example has been completed for you as a guide.

Cargo being Description of formwork Fixed or

loaded used (or draw line drawing added?
below)

Cement Pipe cradle Fixed

pipes

There is feedback on this activity at the back of this Learner’s

Guide.

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How do I load the vehicle?

Having  selected  the  type  of  vehicle  appropriate  to  carry  the  load  and  
having  prepared  the  work  area,  the  next  consideration  is  how  to  place  
the  load  so  that  the  load  is  placed  correctly  (safely)  on  the  vehicle:  

Placing  the  load  considers  making  sure  that:  

• steering  is  not  adversely  affected  
• the  load  distribution  is  balanced  along  the  length  of  the  
truck    
• the  load  is  as  close  as  possible  to  the  centre  line  of  the  
truck  
• centre  of  mass  of  the  load  is  as  low  as  possible.  
Steering  will  be  affected  if  when  loaded  the  truck  appears  to  
be  at  an  angle  to  the  horizontal  and  is  due  to  the  load  not  
being  balanced  along  the  length  of  the  truck:  
Load is too far forward
on truck

FRONT OF
TRUCK
Load is positioned too
far back on truck

If  the  load  is  not  placed  along  the  centre  line  of  the  truck,  the  
load  could  cause  problems  when  cornering,  particularly  at  
high  speed  or  on  roads  that  are  cambered  steeply  (view  is  
looking  at  rear  of  truck):  

Load may tip Load

over in this
direction on Tray of
badly truck
cambered,
rough roads.

(NOTE  :  Lashings  not  shown  for  simplicity  of  drawing)  

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Load  is  better  placed  as  follows:  

Load

Tray of
truck

(NOTE  :  Lashings  not  shown  for  simplicity  of  drawing)  

 
To  keep  the  centre  of  gravity  of  the  load  as  low  as  possible:  
• multiple  containers  should  be  spread  across  the  tray  of  the  
truck  (see  1  below)  
• tall  containers  should  be  laid  over  on  their  side  if  possible  
(see  2  below).  
1.  Loading  multiple  containers:  

Correct
method

Incorrect
method

2.  Loading  tall  containers  or  objects  

Incorrect
method

Correct
method

The  regulations  allow  for  an  absolute  maximum  height  on  

trucks  and  trailers  of  4.3    to  4.6  metres  (depending  on  
state/territory).    Another  consideration  is  the  height  of  bridges  
and  structures  across  roads.    The  required  route  may  limit  the  
height  of  a  load  (including  the  height  of  the  tray  or  trailer)  
unless  alternative  routes  can  be  found  that  allow  passage  of  
the  high  load.

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The  load  should  be  placed  so  that  the  centre  of  gravity  is  in  
front  of  the  centre  of  the  rear  axle  group  of  the  truck  or  
trailer.      

The centre of gravity is the point where the weight of the load is
half way in both the horizontal and vertical axes. For example,
for a brick which is solid and uniform it will be the point at which
the lines marking the point half way up the brick and the centre
point of its face meet:

Centre of gravity

For a load, the centre of gravity may be different as the cargo

loaded will not be of uniform consistency like a brick. Loads are
marked with ‘centre of gravity’ using an international cargo
symbol (see later in Learner’s Guide)

Vehicles  may  be  supplied  with  a  load  distribution  graph  that  

shows  the  loads  allowable  over  the  tray  or  trailer.    To  
understand  these  graphs  you  may  need  some  assistance  from  
your  trainer  or  supervisor.      
The  point  where  the  greatest  weight  can  be  loaded  will  be  just  
in  front  of  the  rear  axle(s).    Regulations  relating  to  the  legal  
axle  limits  should  be  followed.    These  can  be  obtained  from  
the  following  web  site  that  is  linked  to  the  web  site  for  the  
National  Road  Traffic  Commission:  
http://scaletext.law.gov.au/html/pastereg/1/617/0/PR000170.ht
m  
A  copy  of  this  document  is  also  provided  to  learners  as  
Handout  1:  Legal  Axle  Limits.  An  example  of  calculations  of  
legal  axle  limits  is  contained  in  the  ‘Load  Restraint  Guide’.  
While  it  may  seem  more  logical  just  to  secure  the  load  (for  
loads  that  do  not  completely  fill  the  tray  of  the  truck  or  trailer)  
by  moving  the  load  up  to  the  headboard,  this  may  result  in  an  
unbalanced  or  unsafe  load.      
The  space  between  the  load  and  the  headboard  can  be  filled  
with  ‘dunnage’  or  packing  as  your  aim  is  to  also  prevent  
movement  of  the  load  during  transit.    These  sorts  of  
techniques  will  be  detailed  further,  later  in  this  Learner’s  
Guide.  
The  next  activity  looks  at  balancing  loads  and  axle  load  limits.  

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Activity 6: Balancing loads

Arrange with your trainer to assist with loading some trucks and
trailers. Watch how others load the truck, paying careful attention
to how:

• the load distribution is balanced along the length of the truck

• the load is as close as possible to the centre line of the truck

• centre of mass of the load is as low as possible.

Also try to locate the centre of gravity of different cargo being

loaded. Summarise what you have learnt in the space below:
________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

There is feedback on this activity at the back of this Learner’s

Guide.

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Activity 7: Axle load limits

Work with your supervisor and trainer to practice calculating legal

axle load limits for vehicles used in your workplace. Practice these
calculations for a number of vehicles. The manufacturer makes
load distribution graphs available at sale of the vehicle.

There is feedback on this activity at the back of this Learner’s

Guide.

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How is the load actually distributed over the tray

or trailer?

A  load  that  has  a  dangerous  projection  should  be  placed  with  the  
projection  away  from  the  driver,  in  case  of  accident.    For  example,  a  
low  loader  carrying  a  grader  would  face  the  grader  blade  towards  the  
back  of  the  tray  or  trailer.    Similarly,  the  load  shown  below  has  a  
projection  and  is  placed  away  from  the  driver.  

(NOTE  :  Lashings  not  shown  for  simplicity  of  drawing)  

Previously  a  part  load  was  referred  to  and  ‘dunnage’  was  

recommended  to  pack  out  space.    Consider  the  line  drawing  of  the  
truck  below.  

(NOTE  :  Lashings  not  shown  for  simplicity  of  drawing)  

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The  load  is  placed  so  the  centre  of  gravity  is  in  front  of  the  rear  axles.    
The  tray  is  level  or  horizontal  indicating  that  the  placement  of  the  load  
is  suited  to  the  truck  and  its  load  distribution  graph.    There  is  a  space  
left  between  the  headboard  behind  the  driver  and  the  load.    This  
should  be  BLOCKED  or  DUNNAGE  inserted  to  fill  this  space  so  that  
forward  movement  of  the  load  is  prevented  during  braking.    The  load,  
after  blocking,  is  shown  below.  

Blocks of hardwood
inserted in space
behind headboard

(NOTE  :  Lashings  not  shown  for  simplicity  of  drawing)  

Gates  are  also  used  to  help  secure  a  load,  especially  for  curtain  sided  
vehicles.    These  are  especially  useful  for  regular  shaped  loads  such  as  
pallets.      

In  general  for  pallets  should  be  stacked  on  layer  high  on  a  trailer  unless  
there  is  sufficient  rigidity  and  strength,  in  which  case  they  can  be  
stacked  two  high.    For  a  full  load,  pallets  can  be  restrained  by  the  
headboard  and  tie-­‐down  lashings  and  gates  used.    The  lashings  should  
be  over  every  separate  pallet  or  row  of  pallets  and  lashing  added  in  
transverse  direction  as  in  the  diagram  below.  

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SIDE  VIEW  OF  TRAILER  

Pallets  

Trailer  tray   NOTE - Lashings shown

as dotted line as below:
END  VIEW  OF  TRAILER  

Pallets  

Trailer  tray  

Further  detail  is  available  in  the  ‘Load  restraint  Guide’.  

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What is used for actually lashing the load

down?

A  variety  of  materials  can  be  used  to  actually  tie  down  the  load.    These  
can  include:  
• chain  
• rope  
• webbing  
• steel  wire  
• nets  
• twist  locks  for  containers.  

These  materials  are  governed  by  standards  that  give  allowable  size,  
composition,  etc.    You  should  talk  to  your  trainer  or  supervisor  for  
more  advice  on  these  materials  and  their  use.    Fasteners  are  used  with  
these  materials  and  can  include:  
• load  binders  (also  known  as  a  ‘dog’)  or  turn-­‐buckles  (for  
chain)  
• hand  (or  motorised)  ratchet  tensioning  devices  or  winches  
(for  webbing)  
• shackles  (for  connecting  chains  to  the  trailer  deck  at  
special  anchor  points)  
• slings  (  rope,  webbing  or  steel-­‐wire  rope  with  eyes  formed  
at  either  end).  

Where  lashings  are  taken  over  the  load,  protectors  are  often  used  to  
prevent  the  rope  or  webbing  from  fraying  and  to  prevent  damage  to  
the  load.      

The  trailer  of  the  truck  may  have  anchor  points  constructed  to  take  
fasteners  or  use  a  tie  rail  to  tie  the  end  of  the  rope.    Lashings  should  be  
tied  close  to  the  tie  rail  supports  rather  than  the  unsupported  section  
of  the  rail  (see  also  in  ‘Load  restraint  Guide’).  

Having  followed  the  information  in  this  Learner’s  Guide  and  the  ‘Load  
Restraint  Guide’  together  with  advice  and  support  from  team  
members  in  your  workplace,  you  can  load  trucks  or  trailers  safely  and  
according  to  regulations.    The  information  given  above  is  a  starting  
point.    More  detailed  information  is  available  in  the  references  given  
and  these  should  be  used  and  the  techniques  practised.    The  next  
activity  applies  these  principles  to  loading  trucks.  

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Activity 8: Distributing loads

Arrange with your trainer to assist with loading some trucks and
trailers. Watch how others load the truck, paying careful attention
to how:

• loads having projections are faced away from the driver

• dunnage or blocking is used where space is left between the

headboard and the load

• GMV of vehicle is appropriate for load and any required

formwork is erected.

Summarise what you have learnt in the space below:

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

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Also ask your trainer or supervisor to help you name the devices
used to restrain loads and to help you with any requirements
related to these such as size, breaking strain, allowable materials,
etc. Record what you have learnt in the table below:

Item Use of item Requirements for

item

There is feedback on this activity at the back of this Learner’s

Guide.

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How is the load actually tied down and how

much lashing is required?

Lashing  plans  provide  a  guide  to  how  particular  sorts  of  loads  are  
restrained.    Your  company  might  produce  these  plans  or  you  may  use  
plans  produced  by  State/Territory  authorities  such  as  the  VicRoads  
materials  in  the  reference  section.    The  ‘Load  Restraint  Guide’  also  
provides  valuable  information  about  how  to  secure  particular  loads.  

The  plan  is  based  on  eliminating  or  minimising  the  chance  of  the  load:  
• moving  forward  into  the  driver’s  cabin  
• falling  off  the  sides,  back  of  the  truck  or  trailer    
• flying  off  as  truck  goes  over  rough  surfaces  or  goes  over  a  
pot  hole  
• overturning  and  dislodging  load.  

Advice  on  how  much  restraint  to  use  may  be  provided  within  the  
lashing  plan.    Where  advice  is  not  available,  the  following  principles  
should  be  applied.  

The  restraining  forces  to  be  used  should  be:  

 

Direction  of   Situation   Restraining   Example  for  5  

movement   where   force  required   tonne  load  
restraint  is  
required  

FORWARD   Braking  in   80%  of  weight   5  x  .8  =  4  

(towards  driver)   forward   of  load   tonnes  
direction  

BACWARDS   Braking  in   50%  of  weight   5  x  .5  =  2.5  

(away  from   reverse   of  load   tonnes  
driver)   direction  

SIDEWAYS   During   50%  of  weight   5  x  .5  =  2.5  

cornering     of  load   tonnes  

VERTICALLY   Over  rough   20%  of  weight   5  x  .2  =  1  tonne  

(load  flying  off)   surfaces)   of  load  

These  possible  movements  are  shown  in  the  diagram  below:  

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The  forces  on  the  load  are  as  follows:  

The  load  can  be  restrained  by  friction  alone.    This  is  referred  to  an  
INDIRECT  RESTRAINT.  
Friction is the force
Friction  combined  with  tie  down  
between two surfaces.
lashings  may  be  enough  to  secure  
The higher the friction,
the  load.   the less likely they are to
slip.
DIRECT  RESTRAINT  can  be  
Rougher surfaces have
provided  by:   more friction that smooth
• Containing  the  load  (e.g.  cargo   surfaces. Dry surfaces
carried  within  the  tray  of  a  tip   have more friction than
truck).   wet surfaces. Oily or
greasy surfaces have low
• Blocking  the  load  (e.g.  using  the   friction.
headboard,  gates  to  stop   A measurement called
movement  in  one  or  more   the coefficient of friction
direction  with  the  addition  of   is given for particular
blocks  or  dunnage).   surfaces. The lower the
number, the more
• Attaching  the  load  to  the  vehicle  
‘slippery’ the surface.
(e.g.  using  twist  locks,  direct  
The range is from 0 to 1.
lashing).  

 
“It seems that
  banana skins have a
low coefficient of
  friction!”

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Tie  down  lashings  are  lashings  that  secure  the  load  by  applying  force  
to  increase  the  friction.    A  comparison  can  be  made  to  sitting  outside  
and  reading  the  paper  and  putting  an  object  on  the  bit  of  the  paper  
you  are  not  reading  so  that  the  wind  does  not  blow  it  away.    

A  number  of  factors  affect  the  amount  of  lashing  required.    These  
include:  
• friction  between  the  surface  of  load  and  tray  -­‐  note  that  special  
mats  can  be  inserted  between  the  load  and  the  tray  of  the  truck  or  
trailer  to  increase  friction.  
• lashing  materials  chosen  -­‐  these  are  rated  by  the  manufacturer  with  
a  figure  given.  
• angle  of  lashing  –  lashing  should  be  at  30  degrees  or  more  to  the  
horizontal  (see  below);  dunnage  or  hardwood  blocks  can  be  used  
to  lift  the  load  to  change  the  angle  as  required.  

DUNNAGE  ADDED  TO  INCREASE  TIE  DOWN  ANGLE:  

  These
angles
  should be
greater
  than 30
degrees. Tray of
  truck
 
 
(Lashings  shown  as  double  line)  

 
Dunnage
  added to
increase
  angle as
required.
 
Tray of
  truck
 
(Lashing  shown  as  double  line)  

The  ‘Load  Restraint  Guide’  provides  tables  of  recommended  numbers  

of  lashings  for  various  weights  of  loads.    This  guide  should  be  used  and  
the  application  of  the  information  practised  for  various  loads,  as  in  the  
next  activity.  

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Note  that  tie  down  lashings  should  be  as  near  to  vertical  as  possible.  

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Activity 9: Lashing plans

Ask your supervisor or trainer to supply you with lashing plans for
loads typical of what you will be securing at your workplace. Read
through the lashing plan and ask questions if you have any areas of
the plan that you cannot understand.

Summarise the main features of the plan in the space below.

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

There is feedback on this activity at the back of this Learner’s

Guide.

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Activity 10: Calculating lashing required

Using the ‘Load Restraint Guide’, practice calculating lashing

required for loads. Complete the following table (the first example
has been done for you):

Load and co- Angel of Rating of No of lashings

efficient of lashing lashing used required
friction

20 tonnes 60 to 90 2 tonne 6
degrees
0.4

3 tonnes 60 to 90 3 tonne
degrees
0.4

17 tonnes 30 to 60 2 tonne
degrees
0.4

9 tonnes 30 to 60 2 tonne
degrees with
0.2 front of load
blocked

2 tonnes 60 to 90 0.3 tonne

degrees
0.4

There is feedback on this activity at the back of this Learner’s

Guide.

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What materials and equipment are used for

lashing?

A  variety  of  equipment  and  materials  are  used  for  lashing.      

The  uninformed  probably  

think  first  of  natural  fibre  
rope  but  these  should  not  
be  used,  as  they  are  not  
strong  enough.    Synthetic  
ropes  should  be  used  only  
for  light  loads  to  0.5  tonne  
for  12mm  rope.      

Recommend  knots  are  

illustrated  in  the  ‘Load  
Restraint  Guide’.    These  
should  be  practiced  so  
that  they  are  ‘second-­‐
nature’.    

Other  restraints  include:  

• webbing  assemblies  comprising  webbing  made  of  woven  
synthetic  material,  end  fittings  and  winches  with  either  
attached  or  portable  tensioners.    Tensioners  can  be  
mechanical  or  hand  operated.    
• chains  with  hooks  and  lever-­‐type  load  tensioners  
(commonly  called  ‘dogs’)  or  turnbuckle  tensioners  
• other  devices  such  as  twist  locks  for  locking  down  
containers.  

The  ‘Load  Restraint  Guide’  provides  illustrations  of  these  types  of  
lashings.      

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Equipment  used  for  lashing  should  be  checked  before  use  for  
serviceability.    The  actual  load  should  be  protected  from  damage  from  
lashing  materials  by  the  use  of  corner  protectors,  sleeves  or  other  
packaging  material.  

Lashing  material  and  equipment  is  the  focus  of  the  next  activity.    

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Activity 11: Lashing material and equipment

Talk to your supervisor, trainer and team members about lashing

materials and equipment. Make a list of what is available and how
it is used in the table below. An example is provided for you as a
guide.

Equipment or Use Comments

material

12 mm synthetic rope Light loads Up to 0.5 tonne

There is feedback on this activity at the back of this Learner’s

Guide.

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Activity 11: Securing loads

Practice securing loads including using knots for ropes. Get

feedback from your supervisor, trainer and other team members to
assist you to ‘get it right’. Space is provided for notes you make
while practicing securing loads (handy hints, dos and don’ts, etc)

There is feedback on this activity at the back of this Learner’s

Guide.

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How is cargo protected from the weather?

Curtain  sided  vehicles  are  protected  from  the  weather  without  

requiring  tarpaulins,  etc.      

Other  trucks  and  trailers  that  are  not  enclosed  or  curtain  sided  will  
require  covering  with  a  tarpaulin.    Where  rectangular  tarpaulins  are  
used,  an  overlap  may  be  required.    In  this  case,  the  join  or  overlap  
should  be  facing  the  rear  of  the  truck  or  trailer  so  that  the  wind  cannot  
get  under  the  material  or  rain  be  driven  in.    The  illustration  below  
shows  this:  

  Leading or front edge

of tarpaulin 2 tucked
  under tarpaulin 1.
Direction of air
flow
TARPAULIN TARPAULIN
1 2

Ensure  that  the  tarpaulin  is  secured  tightly  and  will  not  flap  open  or  let  
in  water.  

Similarly,  when  cargo  is  unloaded,  it  should  be  protected  from  the  
weather.    A  tarpaulin  can  be  used  for  storing  cargo  outside.    In  this  
case,  pallets  or  other  material  should  be  used  to  raise  the  cargo  off  the  
ground  where  water  might  get  in  and  cause  damage.  

Tarpaulins  should  be  dried  before  being  folded  and  put  away.    When  
folding,  check  for  tears  and  general  condition.    Specialist  repairers  are  
available  for  re-­‐waterproofing  and  repairs.    Storage  may  be  in  a  special  
locker  provided  within  the  workplace  or  on  the  truck  in  a  convenient  
location  away  from  water,  battery  acid,  oil,  fuel  and  other  materials  
that  will  damage  or  soil  the  tarpaulin.  

When  installing  tarpaulins,  ensure  that  lights,  number  plate,  reflectors,  

etc  are  not  covered  up.  

Safety  should  be  considered  in  removing  the  covers  on  cargo.    If  
stretchable  fastenings  are  used  to  secure  the  tarpaulin,  care  should  be  
taken  when  releasing  the  tension  applied.    The  next  activity  practices  
these  techniques.

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Activity 13: Care for tarpaulins

Ask to be shown how to fold tarpaulins and practise folding them

yourself. The job is usually performed alone, so you need practice
to be able to do this.

Check the condition of any tarpaulins you fold.

Find out where your company sends tarpaulins for repair and re-
waterproofing. Record this in a handy place (diary, etc).

There is feedback on this activity at the back of this Learner’s

Guide.

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Section 2

Loading and unloading cargo

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Section outline

Areas  covered  in  this  section  

Loading  and  unloading  cargo  including:  
 safe  working    
 reporting  damaged  goods  
 working  to  plan  

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How do you pack and unpack cargo safely and

according to plan?

What are the safety requirements of loading and

unloading?

The  section  provided  earlier  on  safe  working  applies  also  to  packing  
and  unpacking  of  cargo.  

The  chance  of  coming  into  contact  with  the  contents  of  the  cargo  is  
higher  than  when  the  cargo  is  packaged  and  loaded  into  containers.    
The  identification  of  hazardous  and  dangerous  goods  within  the  load  is  
of  extreme  importance.    Again,  if  you  are  unsure  of  the  contents  of  the  
cargo  and  whether  you  need  specialised  PPE,  ask!    

A  number  of  international  symbols  provide  further  advice  about  how  

to  handle  cargo  –  when  either  packing  or  unpacking  it.  

These  symbols  are  shown  below:  

The  weight  given  

indicates  
maximum  weight  
that  can  be  
stacked  on  top  of  
this  container  

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These  symbols  are  between  100  mm  and  200  mm  high  and  are  black  in  
colour.    A  combination  of  symbols  may  be  on  the  cargo,  together  with  
HAZCHEM  signs.    The  symbols  are  normally  placed  in  the  upper  left  
and  right-­‐hand  corners  of  the  main  vertical  face  of  the  load  and,  if  
possible,  repeated  on  the  other  vertical  faces.  

‘Sling  here’  and  ‘Keep  away  from  heat’  are  usually  placed  on  the  lower  
vertical  face.  

Practice  your  techniques  in  this  area  by  completing  the  next  activity.  

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Activity 14: Safe working

Talk to your supervisor, trainer, team members and OHS

representatives at your workplace. Discuss the types of cargo that
you handle and any potential hazards that you will meet in packing
and unpacking cargo. These could include hazards due to
exposure to the contents of the cargo or the actual job of packing
and unpacking cargo. Use the table below to record the hazards
most frequently identified and how you would avoid or prevent
these hazards. One example has been done for you as a guide.

Potential hazard How you would avoid or

prevent

Pedestrian accidentally being hit Keep to designated walkways

by forklift and keep eyes open!

There is feedback on this activity at the back of this Learner’s

Guide.

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Activity 15: International cargo symbols

Take a tour around the cargo area of your workplace and make a
list of the international cargo symbols you come across. Make a
sketch drawing of each of these. Ask for assistance if you cannot
understand any of these symbols.

Fragile – handle with Use no hooks Sling here

care

This way up Keep away from Keep dry

heat

Heavy weight this … kgs max Centre of mass

end

There is feedback on this activity at the back of this Learner’s

Guide.

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What do I do if I find damaged goods?

When  checking  cargo,  it  should  checked  to  see  that  quantities  match  
that  listed  on  the  consignment  note,  packaging  slip  or  the  
documentation  that  comes  with  the  cargo.    At  the  same  time,  the  
cargo  should  be  checked  for:  
• damage  that  means  item  cannot  be  used  
• fitness  to  use  (spoiled,  soiled,  dinted,  cracked,  etc.)  
• use  by  date  (freshness,  viability,  etc.)  
• correct  match  to  description  (items  may  be  of  the  correct  
number  but  wrong  size,  colour,  etc.).  

Where  any  variations  or  problems  are  identified,  check  workplace  

procedures  that  apply  to  this  situation.    You  may  be  required  to:  
• fill  out  a  report  of  damaged  goods    
• arrange  for  replacement,  a  credit,  disposal  and  credit  if  
externally  supplied  
• repair  and  charging  to  supplier  if  externally  supplied  
• return  to  supplier  if  externally  supplied.  

The  next  activity  focuses  on  reporting  damaged  goods.  

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Activity 14: Damage reports

Talk to your trainer or other team members involved in handling

cargo. Find out what you are supposed to do with damaged cargo
or cargo that is no longer fit for its intended purpose. Summarise
what you have learnt in the space below.
________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

There is feedback on this activity at the back of this Learner’s

Guide.

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Additional
resources

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Web  sites:  
• National  Road  Transport  Commission      
www.ntc.gov.au  
• Australian  Transport  Safety  Board      
http://www.atsb.gov.au  
• Road  Transport  Authority  (NSW)      
www.rta.nsw.gov.au  
• VicRoads  (Vic)            
www.vicroads.vic.gov.au  
• Transport  SA  
http://www.transport.sa.gov.au  
• Queensland  Department  of  Main  Roads  
http://www.mainroads.qld.gov.au  
• Main  Roads  WA  
http://www.mainroads.wa.gov.au  
• Transport  Tasmania  
http://www.transport.tas.gov.au  
• Northern  Territory  Transport  and  Infrastructure  
http://www.nt.gov.au/ipe/dtw  
• Department  of  Transport  &  Regional  Services    
www.dotars.gov.au  
• Attorney  General’s  Department  (relevant  legislation)  
http://scaletext.law.gov.au/html/pastereg/1/617/0/PR000170.htm    

Organisations:  
• National  Road  Transport  Commission    
Level  15,  628  Bourke  Street,  Melbourne,  Victoria,  Australia  3000    
Telephone:  03  9236  5000  Facsimile:  03  9642  8922  

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Paper-­‐based  resources:  
• Load  Restraint  Guide,  National  Transport  Commission,  
Commonwealth  of  Australia,  2004  
• Publications  from  state/territory  road  transport  authorities  –  for  
example,  VicRoads  has  a  number  of  publications  on  specialised  
load  restraint  situations  such  as:  
• A  Guide  to  Restraining  Steel,  VicRoads,  December  1988  (booklet)  
• 45  Tonne  Truck  &  3  Axle  Dog  Trailer,  VicRoads,  December  1988  
(Information  Bulletin)  
• 3  Axle  and  4  Axle  Dog  Trailer,  VicRoads,  January  1997  (Information  
Bulletin)  
• Other  guides  include:    
 Carrying  Steel  
 Carrying  Rolls  and  Reels  
 Carrying  Concrete  Panels  
 Carrying  Concrete  Pipes  
 Carrying  Bales  
 Carrying  Loads  on  Light  Vehicles  

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Feedback on
activities
The responses provided in this section are suggested responses.
Because every workplace is different, your responses may vary
according to your specific workplace procedures, the equipment
available and the nature of the business.

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Activity 1: Personal protective equipment

Ask your trainer and supervisor to give you feedback on your

responses.

You will probably have to wear safety boots at all times, eyewear
and earwear. At other times you may be handling materials that
require gloves, face masks, respirators and other specialised PPE.
MSDS (Materials Safety Data Sheets) provide information on
handling of hazardous materials. The types of materials your
workplace handles is unlimited and responses will vary across
workplaces.

Activity 2: Reporting unsafe equipment and practices

Procedures will vary across workplaces.

Activity 3: Selecting the right vehicle

Suggested responses are:

Load or Vehicle chosen Comments
cargo

Fork lift Flat bed 4 tonne
truck with 3 axles
Lashing should be via tie down
lashings rated according to weight
of forklift. Loading of forklift will be
via ramp or platform using own
forklift’s power.

Shipping Articulated vehicle Tray may have twist locks or

container with flat bed and 4 require lashing of high rating.
axles and a carrying
capacity of 15 tonnes

Refrigerator 4 cylinder utility with Tie down restraints will be

tray and sides required. Dunnage may be
required to fill space around
refrigerator for lashing down.

Cubic metre 4 cylinder utility with Cover is advised over load to

of sand tray and sides prevent spillage

Tiles for a 6 cylinder station Ensure that load does not move
bathroom wagon around. Tiles are fragile.

Activity 5: Formwork

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Required formwork will vary across workplaces depending on

vehicles and loads.

Activity 6: Balancing loads

Ask for feedback on how you balance loads from your trainer,
supervisor or other team members.

Activity 7: Axle load limits

Your calculations should show that the maximum load can be

placed just forward of rear axles.

Activity 9: Lashing plans

Lashing plans provide an easy to read guide to how to secure

different types of loads. Information will include load distribution,
lashing points, precautions and advice.

Activity 10: Calculating lashing required

Suggested answers are:

Load and co- Angel of lashing Rating of No of
efficient of lashing used lashings
friction required

3 tonnes 60 to 90 degrees 3 tonne 1

0.4

17 tonnes 30 to 60 degrees 2 tonne Must use

alternative
0.4 load restraint
methods

9 tonnes 30 to 60 degrees with 2 tonne 7

front of load blocked
0.2

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2 tonnes 60 to 90 degrees 0.3 tonne 4

0.4

Activity 11: Lashing material and equipment

The ‘Load restraint Guide’ provides useful information to help you

check your responses.

Activity 15: International cargo symbols

The ‘Load restraint Guide’ has a list of these symbols.

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