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A Guide To
Handling Breakbulk Cargo

Since its inception in 1958, Ceres has gone beyond the usual
expectations from the customary perspective of how a
stevedoring and terminal operator should perform. For over
fifty years, Ceres has developed and implemented successful
stevedoring and terminal operating principles and systems to
meet the growing requirements of our customers.

The Ceres Corporate Quality Control Policy drives each of our

actions and activities in all of our operations. Ceres’ team of
senior managers and skilled longshore workforce implement
these quality processes and procedures at every port location
to keep productivity high, expedite vessel turnaround and ensure
that cargo handling is safe and secure.

The Ceres Guide to Handling Breakbulk Cargo clearly presents

our procedural guidelines to employees, labor and customers.
Breakbulk cargo requires special handling
and we want everyone involved to under-
stand the importance of the necessary steps
that are needed to correctly handle these
cargoes. From accountability, planning and
operations set-up to labor, discharging/load-
ing cargo and troubleshooting, processes
must be strictly followed and safety must al-
ways be our first priority.

Ceres is at your service to accommodate

every customer’s breakbulk cargo handling
requirement. Be assured that through the Ceres Quality Assurance
Processes, breakbulk cargo is safe and secure. Ceres treats it with
the utmost care and in the most efficient manner.

Ceres has a policy of continuous improvement of its services and reserves the right to make changes
to procedures and policies without notice.
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Table Of Contents

4 Quality Policy

5 Introduction-Accountability

7 Proper Berthing Procedures

8 Dock Receipt/Terminal Tally

9 Breakbulk Vessels

10 Determining Labor Requirements

11 Safety First: Handling Breakbulk/Slings

13 Breakbulk Equipment

15 Operational Safety: PPE

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Quality Policy

Quality Policy
Quality is an integral part of our total strategy to serve our
customers. Our service objectives are reached through the
implementation of a well-defined quality program, continuous
improvement of our procedures and processes, and prevention
of nonconformities that conflict with the customers’ requirements
and the ISO 9001 International Standard.

Our Mission
To provide reliable, independent and responsible stevedoring
and terminal services, that is dependable, of high quality and
consistent with the customer’s requirements and expectations.

We shall be successful in this mission by:

n Keeping focused on the customer’s needs
n Providing leadership to our employees in their efforts to satisfy
the customer
n Providing employees with adequate resources to accomplish goals
n Providing employees with a corrective & preventative action process
for continuous improvement
n Defining & controlling business processes with accurate &
useful procedures
n Regularly measuring the results of our efforts
n Changing our services to match our customers’ changing demands
n Dealing professionally with our suppliers.

It is our goal to provide all of the above in a safe and secure

environment that complies with Federal, State and Local laws and
practices.

Thomas Simmers, President & CEO

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Introduction-Accountability

The Ceres Breakbulk Guide has been compiled to assist you with a com-
prehensive understanding of both the loading and discharging of breakbulk
cargoes while incorporating the ultimate goal of providing our customers
with efficient and reliable Quality Service.

Breakbulk was once the dominant method of transporting goods over land
and sea. Since the advent of containerization, breakbulk shipping appears to
be slowly but steadily sliding towards extinction worldwide. Most commodities
can be unitized to fit standard shipping containers, e.g., pallets of canned
goods, perishables or almost any consumer purchase. Yet, there still is an
economical need to move oversized, hard-to-handle breakbulk cargo that
would be impossible to fit into a container.
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We define breakbulk cargo as noncontainerized general cargo. It is stored in

boxes, bales, pallets or other units that are loaded onto or discharged from
ships or other forms of transportation. Examples include iron, steel, machinery,
liner board and wood pulp or cargo that does not fit into a container. Because
many of these cargoes are associated with projects such as energy plants or
heavy industry, specialized ships are employed to handle the heavy, hard-to-
handle or loose cargo. It also takes Ceres’ expertise and organized planning
system to handle these vessels and their cargo and execute a successful
breakbulk operation.

Throughout the years, Ceres has been very active in the breakbulk community.
Ceres is an active participant in breakbulk trade discussions and conferences
where we keep up-to-date with current transport practices. Ceres also inter-
acts with breakbulk carriers to define their requirements and relate how we
can better serve the customers that utilize Ceres’ breakbulk capabilities.

When a breakbulk carrier expresses interest in a port where Ceres operates,

we are requested to submit a proposal of our rates to perform the loading or
discharging. Our rates take into consideration, labor cost, equipment usage,
knowledge of the cargo, risk factor and the vessel or line involved. Over the
years, we have established good working relationships with many of the break-
bulk carriers. The Ceres reputation for competitive rates, reliability, expertise
and quality assurance has built a strong trust level and confidence within the
breakbulk community. Ceres gets the job done correctly, safely and in a timely
manner.
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Proper Berthing Procedures

Ceres can provide detailed information on the best berth to

accommodate a particular breakbulk cargo. Some cargoes go to
or are delivered directly to rail cars while others may require large
open pier space.

Knowledge of a terminal’s capabilities in each respective port is a

necessity to provide good information to an ocean carrier. It is
important that the ship be provided with the breakbulk terminal’s
facilities so that loading or unloading can be planned. Similarly,
the terminal will need the vessel’s information to start preparation
and planning for the ship’s arrival and loading/discharging of cargo.

It is important that the Ceres superintendent board the vessel and

introduce him/herself to the vessel command. The Ceres super-
intendent should request at least three copies of the stowage &
rotation plan, stowage factor, available cubic space and all special
instructions. He/she must advise the vessel command of all local
union regulations as well as Ceres Safety Guidelines. Before
loading/unloading commences, there should be an agreement
made between the master and the terminal representative to
achieve the final loading plan. This would include the rate of load-
ing and order in which the cargo is to be distributed. Discuss every
detail of the breakbulk loading or discharge so that the operation
can be carried out safely and in a timely manner.
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Dock Receipt/Terminal Tally

The dock receipt and terminal tally varies from port to port and
terminal to terminal but the basics are the same. Ceres receives
the cargo for a particular carrier or vessel. Prior to the loading
start, Ceres receives a list of cargoes so that exact weights and
measurements can be determined and forwarded to the vessel
command.

These weights and measurements are critical for the ship because
the information is used to calculate the vessels stability (tipping
point) and sailing condition (draft). They are also used in the layout
and planning of working the vessel.
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Breakbulk Vessels

Most general cargo or breakbulk vessels account for a

respectable portion of the world merchant fleet. The majority of
multi-purpose, general cargo ships have squared hatches, box
shaped holds and the ability to adjust the tween decks to different
heights to provide easier access for cargoes. They are designed
to handle a multitude of breakbulk cargo, e.g., pallet loads, bags,
drums, cartons, cases and crates. Additionally, containers can be
accommodated on deck and sometimes under deck. In some
instances, deep tanks for cargo oils may be fitted in holds. Geared
breakbulk vessels have their own cargo cranes capable of lifting
over 400 metric tons each. Cargo is generally loaded aboard using
vessel's gear and forklift machines.

All ships with cranes must be class-certified and approved. Prior

to any operation where the ship’s gear is used, the cargo gear
certificate must be current and checked for validity. The Ceres
superintendent must make a visual inspection of the gear to
guarantee that it is in proper working condition.

There are, however, some gearless carriers that transport mostly

bulk cargoes (grain, ore) but occasionally will also carry breakbulk
or heavy cargoes. Gearless vessels require shore cranes or float-
ing cranes. The Ceres superintendent uses the same inspection
procedures for these vessels. The cranes’ published lifting
capacities are required to be tested and certified for accuracy.
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Determining Labor Requirements

After receiving the terminal tallies or cargo list, Ceres has to

determine the size of the labor gang required. Ceres is a union
employer and is obligated by contract to employ a union gang.
These are minimum-sized work groups. Larger, more difficult
cargoes frequently require adding people to the work gang so that
we can complete the job safely and expeditiously.

The need for additional workforce must be communicated to

the line or their representative as soon as the requirement is
discovered. The manning is part of the determination of the
original bid and must be authorized by the appropriate parties.
Many of the breakbulk vessels have tween deck lids and weather
deck hatch covers that must be handled as individual lifts. It is
critical that a proposed schedule is discussed and coordinated
with a port captain to keep costs within budget.
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Safety First:
Handling Breakbulk/Slings

Breakbulk cargo is comprised of various weights and sizes – from

very small crates of parts to huge transformers and locomotives.
Ceres understands the special transport requirements of break-
bulk cargo. Assignments and processes are carefully planned by
Ceres to ensure the seamless transition between ocean, terminal
and land transportation.

Ceres offers tailored handling solutions and combines a unique

blend of on-site knowledge and skill that is necessary to match
modern equipment with each piece of breakbulk cargo. Whatever
the size, weight or quantity, Ceres handles breakbulk cargo safely,
securely and expeditiously.

Synthetic Slings

Ceres has switched from wire rope slings to the modern, synthetic type
of sling. The benefits of synthetic slings:

s Much lighter in weight and more pliable

s Greatly reduce the risk of strained muscles while hooking up
s Soft and conform to lifting lugs in tight places
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Safety First:
Handling Breakbulk

Synthetic Slings

Important points to remember about synthetic slings:

s Synthetic slings are easily damaged and must be constantly watched
and checked. Ceres regularly returns the slings back to the supplier
to have them inspected and certified as safe to use.
s Check all slings after moving heavy lift. Where possible, use chaffing
pads to prevent slings from contacting and rubbing on sharp edges.

Additional facts to remember:

• Chocking and bracing are very important and play a key role in the
safe handling of breakbulk cargo.
• Experienced equipment operators should only operate
breakbulk cargo.
• All cargo markings and instructions should always be reviewed
before discharge or loading and closely followed when handling.
• If cargo is not properly marked, serious thought and planning must
be implemented before handling.
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Breakbulk Equipment:
Size & Type

Ceres has an extensive fleet of modern forklifts, top loaders and

yard tractors available to accommodate every type of breakbulk
cargo. All machines are regularly inspected and maintained for
high performance. Ceres’ wide range of forklifts are capable of
handling from 5,000 lbs. to 62,000 lbs. of cargo.

An integral part of planning a job is determining what equipment

is required to safely and effectively complete the operation. The
use of the proper forklift blade, coil probe, clamps and sack
hooks, as well as matching the right machine with a particular
cargo, is critical for a successful breakbulk operation.
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Breakbulk Equipment:
Size & Type

The correct size forklift blades are equally important as the

machine’s lifting capacity. If blades are too long, they damage the
cargo in back of what is intended to be lifted. If the blades are too
short, the machine may be off balance and not capable of lifting
the cargo.

Once the cargo is delivered shipside and ready to load, longshore-

men must always be aware of what they are slinging and where
to place the lifting gear. Many times, heavy lifts are marked as to
where to place slings. Always review and closely follow cargo
markings and instructions when handling the breakbulk cargo.
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Operational Safety:
Personal Protective Equipment

Safety is the most important part of your job. It is critical to follow

the rules and regulations set forth by the Port, Ceres’ Safety
Program as well as OSHA. A part of the safety procedure is to
protect yourself with Personal Protective Equipment (PPE).

Breakbulk cargo can be very difficult and dangerous to handle

even with the proper equipment and gear. Careless handling and
nonconformance to safety procedures can easily lead to cargo
damage, serious bodily injury and death. Since accidents can
“happen,” do not be careless and underestimate the power of
equipment or oversized cargo. You are not immune to injury. Be
a leader and a Safety example. PPE first starts with you.

PPE REQUIREMENTS
• Safety, high-visibility vest worn at all times. No dirty or ripped vests.
• Hard hat at all times
• Heavy duty gloves
• Steel toe boots – no sneakers
• Clean, sturdy work pants and shirts – no tears or holes in clothing
• No shorts
• No headphones or electronic devices being worn
• No cell phones

Please note that Ceres carefully follows OSHA (Occupational

Safety & Health Administration) Standards.
Safety is a serious responsibility.

Make it yours!
 Corporate Headquarters

Ceres Terminals Incorporated

Two Tower Center Boulevard, 14th Floor
East Brunswick, NJ 08816
Telephone: 201-974-3800

www.ceresglobal.com
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