Shipping Container Unloading and Palletization Ergonomics

To define safe and ergonomic techniques for unloading shipping containers and manually building pallets. The purpose is to reduce the risk of back strain, shoulder injuries, and repetitive‑motion disorders while maintaining efficient workflow. This procedure applies to any facility receiving containerised freight.

This SOP covers the unloading of standard 20‑ft and 40‑ft dry shipping containers using manual labor and pallet jacks. It does not cover mechanical forklift unloading, bulk commodity handling, or hazardous material protocols. Personnel must be trained in manual materials handling and familiar with the layout of the receiving dock.

• LOTOLockout/tagout all dock‑leveling equipment before entering container. Ensure container is chocked and landing gear stable.
• PPEWear cut‑resistant gloves, steel‑toe boots, safety glasses, and hearing protection if using powered equipment. Use back brace if individual boxes exceed 20 kg.
• ENVVentilate container for 5 minutes before entry. Use a personal gas monitor if cargo could off‑gas (e.g., chemicals, treated wood).
• TEAMNever unload a container alone. A minimum of two people is required: one inside moving cartons, one outside receiving on pallet.

• Adjustable‑height pallet jack (walkie‑rider preferred) – rated for 1,500 kg
• Ergonomic box cutter with curved blade (self‑retracting)
• Anti‑fatigue mat (1.2 m × 1.8 m) for container floor
• Rated wooden pallet (size matching container floor pattern)
• Load straps or stretch wrap with tension handle
• PPE: cut‑resistant gloves, steel‑toe boots, safety glasses
• Back support belt (optional for heavy cartons)
• Personal gas monitor (if cargo is unknown or sealed for >48 hours)