⚠ EXCLUSION ZONE — 12 FEET (3.6 m) AROUND ALL SIDES OF THE CONTAINER DURING UNLOADING ⚠
Anyone not directly involved in the unloading must stay behind the exclusion zone line or behind the designated wall barrier at all times.
1. PURPOSE
This Standard Operating Procedure establishes the minimum requirements for the safe unloading of wooden glass cases from a shipping container mounted on a transport trailer at the Rossen Glass & Mirror Ltd. facility. Glass cases are heavy, top-heavy, and contain fragile product — an uncontrolled case shift or fall can cause severe or fatal injury. The trailer introduces additional hazards: suspension movement during unloading, an elevated working surface, and a load that must be kept balanced from the centre outward to prevent the trailer from becoming unstable. This SOP ensures that all unloading is performed in a controlled, planned, and sequenced manner using the overhead crane with a spread bar and metal lifting cables, with strict exclusion zone enforcement and proper case securing throughout.
2. SCOPE
This SOP applies to all unloading of wooden glass cases from a shipping container on a transport trailer backed into the Rossen Glass & Mirror Ltd. shop bay. It covers the truck driver's role, the overhead crane unloading process, the centre-outward alternating unloading sequence required to maintain trailer balance, the management and securing of remaining cases throughout the operation, and the control of all personnel access to the unloading area.
3. AUTHORISATION — WHO MAY PARTICIPATE
Participation in a container unloading operation is restricted. Only the following personnel may be within the unloading area or directly involved in the operation:
- Trained employees — shop floor employees who have completed unloading training and reviewed this SOP.
- Employees under direct supervision — employees in training, accompanied and directly supervised by a trained supervisor for the entire duration of the operation.
All other employees, visitors, and contractors must remain outside the 12-foot (3.6 m) exclusion zone or behind the designated wall barrier. There are no exceptions. The supervisor leading the unloading is responsible for enforcing this at all times.
4. RESPONSIBILITIES
Supervisor / Lead Unloader
- Plan the unloading sequence before the container is opened — know the order cases will be removed and where each will be placed.
- Establish and communicate the exclusion zone to all shop floor personnel before work begins.
- Ensure all participants are trained or directly supervised throughout the operation.
- Confirm all remaining cases inside the container are secured or strapped before any crane movement begins.
- Call and enforce all stops if an unsafe condition arises.
Truck Driver
- Back the trailer into the shop bay as directed by Rossen Glass & Mirror Ltd. staff.
- Break the container seal and open the doors, then immediately move to the cab or beyond the exclusion zone.
- Remain in the truck cab or behind the 12-foot exclusion zone for the entire duration of unloading — the driver does not participate in or observe the operation from within the exclusion zone.
- Do not re-enter the trailer or unloading area until given the all-clear by the supervisor.
Crane Operator
- Complete the crane, spread bar, and cable pre-use inspection before the operation begins.
- Follow all instructions from the supervisor / lead unloader.
- Never initiate a lift until the supervisor has confirmed cables are correctly attached to the case.
- Stop the crane immediately if the exclusion zone is breached or any unsafe condition is observed.
All Participating Employees
- Wear all required PPE for the duration of the operation.
- Follow the supervisor's instructions and the sequence established before unloading began.
- Never enter the container or move a case without the supervisor's direction.
- Report any unsafe condition, case movement, or strap failure to the supervisor immediately.
5. HAZARDS & RISK SUMMARY
| Hazard | Potential Harm | Controls |
|---|
| Glass case tipping or falling | Crush injury, fatality, severe laceration | Exclusion zone; secure remaining cases at all times; planned sequence |
| Cases shifting inside container during lift | Domino effect — multiple cases falling | Secure all adjacent cases with straps before any lift begins |
| Crane load swinging inside container | Collision with cases or personnel, destabilisation | Slow crane speed; guide with tag line; no sudden movements |
| Cable not properly attached to case before lift | Case slipping free — dropped load, crush injury or fatality | Two-person cable check mandatory before every lift; no lift without supervisor confirmation |
| Spread bar or cable failure mid-lift | Case dropped — crush injury or fatality | Pre-use inspection of spread bar, cables, and hooks before every operation |
| Cables removed before case is secured on rack | Unsecured case tipping off rack | Case must be fully placed, stable, and strapped to rack before cables are detached |
| Personnel inside exclusion zone | Struck by falling case or swinging load | 12-foot exclusion zone enforced before and throughout unloading |
| Trailer suspension movement during unloading | Unexpected case shift or loss of balance | Trailer chocked; unload centre-outward, alternating sides; monitor trailer stability |
| Trailer becoming imbalanced | Trailer tipping, cases falling | Strict centre-outward alternating sequence maintained at all times |
| Opening container doors — unsecured load | Cases falling out when doors opened | Inspect before opening; open one door cautiously from the side, never from the front |
| Poor lighting inside container | Failure to see case condition or cable attachment points | Use portable lighting; do not enter a poorly lit container |
| Cuts from protruding fasteners, banding, or cable ends | Laceration to hands | Gloves highly recommended whenever handling cases, cables, or banding |
| Struck by falling overhead debris or swinging spread bar | Head injury | Hard hat highly recommended; keep clear of spread bar swing radius |
| Truck driver in unloading area | Struck by case or crane load | Driver stays in cab or behind exclusion zone for the entire operation |
6. PERSONAL PROTECTIVE EQUIPMENT (PPE)
| PPE Item | When Required | Status |
|---|
| Steel-toed safety footwear (CSA Grade 1) | At all times during the operation | MANDATORY |
| Hard hat | Throughout the entire unloading operation | Highly Recommended |
| Safety glasses / goggles | Throughout the entire unloading operation | Highly Recommended |
| Cut-resistant gloves (ANSI A4 minimum) | Whenever handling cases, straps, or banding | Highly Recommended |
| High-visibility vest | When other shop floor operations are running concurrently | Highly Recommended |
7. EXCLUSION ZONE
⚠ 12-FOOT (3.6 m) EXCLUSION ZONE — ENFORCED BEFORE CONTAINER DOORS OPEN ⚠
The exclusion zone is the single most important safety control in this operation. A falling glass case can travel, bounce, or slide well beyond the footprint of the container. The exclusion zone must be established and communicated before the container doors are opened — not after.
- A minimum 12-foot (3.6 m) clear zone must be maintained around all accessible sides of the container throughout the entire unloading operation.
- The exclusion zone boundary must be marked with cones, tape, or barriers before work begins.
- Anyone not directly involved in the unloading must remain beyond the zone boundary or behind the designated wall barrier at all times — no exceptions, regardless of how brief their intended presence is.
- The crane operator and any employee guiding a case are inside the exclusion zone by necessity — all other personnel are not.
- If the exclusion zone is breached at any time during the operation, the supervisor must call a stop immediately. The crane must halt and no cases may move until the zone is clear again.
- The exclusion zone remains in effect until the last case has been removed, placed safely, and the container is secured.
⚠ WARNING: Do NOT allow anyone to enter the exclusion zone to "quickly grab something" or to watch the operation from close range. A case that begins to fall gives no warning and no time to move. The zone boundary is the safety line — it is never negotiable.
8. PRE-UNLOADING PREPARATION
1
Supervisor inspects the load and accepts or rejects itBefore the exclusion zone is established or any unloading begins, the supervisor inspects the exterior of the container and the visible condition of the cases. The supervisor checks for signs of damage to the container walls, doors, or cases — including crushed or broken boards, water damage, evidence of shifting, or cases that are leaning. Based on this inspection, the supervisor either accepts the load and proceeds with unloading, or rejects it and contacts the appropriate party to address the damage claim before any cases are moved. Unloading does not begin until the supervisor has made and communicated this decision.
2
Brief all participantsBefore any equipment is moved, the supervisor briefs all participating employees on the unloading plan: the centre-outward alternating sequence, each person's role, the exclusion zone boundaries, the cable attachment confirmation protocol, and the stop signal. Confirm everyone understands before proceeding.
3
Direct the driver to the cabOnce the driver has broken the seal and opened the container doors, direct the driver to return to the truck cab. Confirm the driver is in the cab or beyond the exclusion zone before any further steps are taken. The driver does not re-enter the area until given the all-clear by the supervisor at the end of unloading.
4
Establish and mark the exclusion zonePlace cones, tape, or barriers to mark the 12-foot exclusion zone around the trailer and container opening. Communicate the zone to all shop floor employees not participating in the operation — they must remain outside it or behind the wall barrier for the entire operation.
5
Inspect the spread bar and cablesBefore every unloading operation, inspect the spread bar for cracks, bends, or deformation. Inspect every metal cable for kinks, fraying, broken strands, or worn ends. Inspect all hooks and shackles for cracks, distortion, and functioning safety latches. Any defect is an immediate out-of-service condition — do not use until repaired or replaced.
6
Complete the crane pre-use inspectionThe crane operator must complete a full crane pre-use inspection per SOP EQ-CRANE-001. Confirm the crane hoist, hook, and controls are all in good working order. Do not begin unloading if any crane fault is found.
7
Position the crane above the container openingPosition the overhead crane so it is aligned directly above the container entrance and ready to lower the spread bar into the container without obstruction. Confirm the travel path to the landing zone (rack) is clear of people and obstacles.
8
Inspect the container interior before entryWith the doors open, visually inspect the interior from outside the container. Confirm lighting is adequate — use a portable light if needed. Note the arrangement and condition of all cases, identify any that appear damaged or leaning, and plan the centre-outward alternating sequence based on what you see. Do not enter the container until the supervisor confirms it is safe.
9
Secure all cases not immediately being movedBefore the first lift, inspect the securing condition of every case in the container. Any case not already secured by internal bracing or original packing straps must be strapped before the adjacent case is moved. This check is repeated before every subsequent lift.
10
Confirm the rack and landing zone are readyConfirm the receiving rack is in position, clear, and ready to accept the first case before any lifting begins. Never lift a case without a prepared, confirmed landing zone.
9. UNLOADING PROCEDURE
Cases are unloaded one at a time using the overhead crane with a spread bar and metal lifting cables. The unloading sequence is centre-outward, alternating ends — one case from the far end of centre, then one from the near end of centre, working outward toward the container doors. This sequence is mandatory to maintain trailer balance throughout the operation. Deviation from this sequence requires supervisor approval.
9.1 Unloading Sequence — Centre-Outward, Alternating Sides
1
Identify the centre of the loadBefore the first lift, the supervisor identifies the centre case or centre pair of cases and establishes the unloading sequence from that point outward toward the container doors. This sequence is communicated to all participants before work begins.
2
Alternate ends with every liftRemove one case from the far end of centre, then one from the near end of centre, then the next far, then the next near — working outward toward the container doors with each pair. Never remove two consecutive cases from the same end without first removing the equivalent case from the opposite end.
3
Monitor trailer balance throughoutAfter each lift, observe the trailer for any sign of lean, settling, or instability before proceeding to the next case. If the trailer appears to be leaning or the suspension seems uneven, stop and consult the supervisor before continuing.
9.2 For Each Case — Before the Lift
1
Confirm the exclusion zone is clearBefore each and every lift, confirm no unauthorised person is within the 12-foot exclusion zone. Do not proceed until the zone is clear and the truck driver is confirmed in the cab.
2
Verify remaining cases are securedConfirm all cases adjacent to the one being lifted are secured by original bracing or strap. If any adjacent case is unsecured, stop and strap it before proceeding. This check is mandatory before every single lift.
3
Assess the case conditionInspect the wooden case for broken boards, bowing sides, damaged lifting points, or visible glass breakage. A structurally compromised case may not hold the cable attachment under load or may break apart mid-lift. Do not lift a damaged case without supervisor approval and a safe plan.
4
Lower the spread bar into positionLower the spread bar into the container above the case, positioning it so cables will attach squarely and symmetrically to the case's designated lifting points on both sides. The spread bar must be centred over the case so the load will hang level.
5
Attach the cables to the case — confirmation from both endsOne employee attaches the cable hook at each end of the case. Each person is responsible for their own end: confirm the hook is fully seated on the lifting point, the safety latch is closed, the cable is not twisted or crossed, and the attachment point on the case is sound. Each employee then calls out their confirmation directly to the crane operator — "Far end good" / "Near end good" or pre-agreed equivalent signals. The crane operator does not raise the case until a clear verbal confirmation has been received from both ends. If either person is not satisfied with their attachment, they say so and the issue is resolved before any lift attempt.
9.3 Performing the Lift and Move
1
All personnel clear before liftingOnce the cables are confirmed, all employees must step back and clear of the case before it is raised. No one stands beside, behind, or over a case that is about to be lifted. The crane operator calls "Case going up" and waits for a clear acknowledgement before raising.
2
Take up the slack slowlyRaise the crane hoist slowly until the cables are taut but the case has not yet left the trailer floor. Pause and confirm the spread bar is level and all cables are equally loaded. If one end appears to be taking more load than the other, lower, reposition the spread bar, and recheck the cable attachments.
3
Test lift — raise only a few centimetresRaise the case just 5–10 cm off the trailer floor and pause. Confirm the case is hanging level and stable, the spread bar is not tilting, and no adjacent cases have shifted. If anything looks wrong, lower immediately and investigate before proceeding.
4
Raise to minimum clearance heightRaise the case only as high as needed to clear the container door frame and any obstacles in the travel path. Keep the load as low as safely possible throughout the move.
5
Move slowly — no sudden starts or stopsTravel the crane at the lowest safe speed. Sudden movements cause the case and spread bar to swing, risking collision with remaining cases or personnel. Smooth, deliberate movement at all times.
6
Guide with a gloved hand or tag line onlyIf the case needs to be steered into final position, use a gloved hand on the case body or a tag line. Never use your body to stop a swinging case. No one stands in the path of a moving or swinging load.
7
No one under the case at any timeNo employee may stand under a suspended case at any point — not to check the landing zone, not to guide it, not for any reason. Maintain the 12-foot exclusion zone for the full duration of every lift.
9.4 Setting Down and Securing the Case
1
Confirm the rack is readyBefore lowering, confirm the receiving rack is correctly positioned, clear, and ready to accept the case. Do not lower a case onto an unprepared or obstructed rack.
2
Lower slowly — keep hands and feet clearLower the case slowly and steadily onto the rack. All hands and feet must be clear of the pinch zone between the case base and the rack. Use a tag line or guide stick for final alignment rather than bare hands under the case.
3
Confirm the case is fully and stably seated on the rackThe case must be resting fully and squarely on the rack — not balanced on an edge or corner, not leaning. If it is not fully stable, raise slightly, reposition, and lower again.
4
Place both securing bars before removing cablesBefore the cables are detached, both securing bars must be slid into position across the rack to hold the case. Confirm both bars are fully seated and engaged. Do not remove the lifting cables until both bars are in place — the bars are the only thing preventing the case from tipping once the cables are released.
5
Remove the cables only after both bars are confirmed in placeOnce both securing bars are in position and confirmed, detach each cable hook from the case. Confirm all hooks are fully clear, then raise the spread bar clear of the case and rack before moving the crane back to the container.
⚠ WARNING: Cables must NEVER be removed from a case before both securing bars are in position on the rack. An unsecured case can tip without warning the moment the cables are released. Bars in place first — cables off second, every single time.
10. SECURING CASES INSIDE THE CONTAINER
As cases are removed, the remaining cases become progressively less supported by their neighbours. Active securing of remaining cases is one of the most critical controls in this operation.
- Before the first lift, assess the securing status of every case in the container. Note which cases rely on adjacent cases for lateral support.
- Any case that will lose lateral support when its neighbour is removed must be strapped to the container wall, floor anchor point, or a secure adjacent case before the neighbouring case is lifted.
- Use ratchet straps or cam-buckle straps of adequate rated capacity for the estimated case weight. Do not use bungee cords or rope as a substitute.
- Route straps so they bear against the case body — not across the top or over the designated cable attachment points, as these must remain accessible for the next lift.
- After each case is removed, re-assess the securing status of all remaining cases before the next lift. As the container empties, the dynamics change — do not assume that what was sufficient before is still sufficient now.
- If a case is found to be leaning or has shifted since the last check, stop immediately. Do not attempt to lift an adjacent case until the leaning case is safely stabilised.
NOTE: A strap on a case costs 60 seconds. A fallen case costs far more. When in doubt about whether a case needs strapping — strap it.
11. POST-UNLOADING PROCEDURE
1
Confirm all cases are safely placed and securedOnce the last case is removed, do a walk-around to confirm every placed case is stable and secured in its new location. No case should be free-standing without lateral support or a strap.
2
Inspect the container interiorEnter the empty container and inspect for remaining product, dunnage, broken glass, or debris. Remove any glass fragments carefully — wear gloves and safety glasses. Do not leave debris in the container.
3
Close and secure the container doorsClose and latch the container doors, then give the all-clear to the driver to pull out of the bay.
4
Remove exclusion zone markingsRemove cones, tape, or barriers used to mark the exclusion zone once the operation is fully complete and all cases are secured.
5
Park and shut down the craneReturn the crane to its parked position. Lower the spread bar to a safe resting position and stow the cables neatly. Power down the crane per SOP EQ-CRANE-001.
6
Clean up the areaSweep and clear any dunnage, packing material, banding, or debris from the unloading area. Glass fragments or dust on the floor are a slip and laceration hazard — clean thoroughly.
12. EMERGENCY PROCEDURES
If a case begins to tip or fall:
- Call out "Case falling" loudly and immediately. All personnel must move away — do not attempt to catch or brace a falling glass case.
- Once the case has come to rest and the area is safe, assess for injuries and call 911 if anyone is hurt.
- Do not move any other cases until the supervisor has assessed and stabilised the situation.
- Preserve the scene for incident investigation before cleanup begins.
If a cable, hook, or spread bar appears to be failing during a lift:
- Stop the crane immediately. Call out "Case coming down."
- Lower the case to the nearest safe surface as smoothly and quickly as possible — do not travel to the landing zone.
- Once the case is down and all personnel are clear, assess the equipment. Do not use the spread bar or cables again until the fault is identified and corrected.
- Investigate the cause and inspect all cables and the spread bar before any further lifts.
If an injury occurs:
- Call 911 immediately for any serious injury. Administer first aid if trained.
- Do not move the injured person unless they are in immediate further danger.
- Stop all unloading operations and secure the area until emergency services arrive.
- Report the incident to the supervisor and complete an incident report as soon as possible.
13. TRAINING & AUTHORISATION
Only the following employees may participate in a container unloading operation:
- Trained employees — must have reviewed and signed acknowledgement of this SOP and SOP EQ-CRANE-001, and completed at least one supervised unloading before participating independently.
- Employees under training — must be under the direct, continuous supervision of a trained supervisor for the entirety of the operation. They may not perform any task independently during the training period.
- Renewal training is required after any incident or annually, whichever comes first.
- The supervisor leading the operation is responsible for confirming the authorisation status of all participants before the container doors are opened.
14. REFERENCES & RELATED DOCUMENTS
- SOP EQ-CRANE-001 — Overhead Crane & Vacuum Lifter
- SOP SHP-GLS-001 — Glass & Mirror Handling
- Ontario Occupational Health and Safety Act (OHSA), R.S.O. 1990
- Ontario Regulation 851 — Industrial Establishments
- CSA Z142 — Code for Power-Operated Lifting Devices
- Rossen Glass & Mirror Ltd. Incident Reporting Procedure
15. ACKNOWLEDGEMENT & SIGN-OFF
By signing below, all parties confirm they have read, understood, and agree to comply with this Standard Operating Procedure.
| Role | Printed Name | Signature | Date |
|---|
| Employee | | | |
| Supervisor | | | |
| H&S Representative | | | |