HMT_Bulk_Loading_and_Unloading__1702633572

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HMT
Bulk
Loading/Unloading
www.safetyontheweb.com
Introduction
If you load or unload hazardous materials in

bulk containers, it is your responsibility to
follow the correct procedures. Incidents
involving hazardous materials can lead to
serious injury, property and environmental
damage, and even death.
Introduction
Department of Transportation statistics show

that 97 percent of all hazardous material
incidents involve tank cars and tank trucks.
And surveys show that up to 50 percent of all
vehicles are placarded incorrectly.
Identifications & Markings
Bulk Packaging is packaging other

than a vessel or barge that hazardous
materials are loaded onto which has a
maximum capacity greater than 119
gallons, has a maximum net mass
greater than 882 pounds, or has a water
capacity greater than 1,000 pounds.
This includes railroad tank cars, tank

trucks, and portable tanks that meet the
criteria just mentioned. All bulk
containers must have the correct
placards and markings according to the
requirements in Title 49 of the Code of
Federal Regulations.
Railroad Tank Cars

Proper Shipping Name
Reporting Marks
Tank Car Classification
Safety Valve & Tank Test Information
DOT Hazard Warning Placarding
Tank Trucks
Shipper’s Name and Location
DOT Hazard Warning Placarding
UN or NA Identification Number
Railroad tank cars can be divided into

two groups:
Pressurized Tank Cars
General Purpose Tank Cars
A general purpose or non-pressurized

tank car is cylindrical in shape with
convex (curves or bulges outward)
heads.
Loading devices and equipment are

found in the platform area on the top of
the tank car.
In addition, bottom outlet valves for

unloading are at the center of the car,
and heater coil outlets sometimes
protrude from underneath the tank.
Pressure tank cars are also

cylindrically shaped with convex
heads. Pressurized tank cars are
always loaded from the top. The
loading devices and fittings are
located in one housing on the top
center of the tank cars.
Loading & Unloading
As a person who loads and unloads bulk

shipments of hazardous material, there are
two reasons why it is important that you
follow the proper procedures and
safeguards:
Loading & Unloading
1. To ensure your safety and health.

2. To reduce the odds of a release
occurring during transport.
Loading & Unloading
It is also important that you are familiar

with the material you work with.
Loading & Unloading
Though Material Safety Data Sheets do not

necessarily provide specific DOT
information, they are a valuable source for
finding out the physical characteristics and
hazards of a material, the recommended
Personal Protective Equipment to be worn,
and other safety precautions.
Loading & Unloading
There are specific requirements that must

be followed when loading and unloading
tank trucks or portable tanks into or onto
trucks.
Loading & Unloading
When loading or unloading a bulk package

on a truck, whether the tank is portable or
cargo, the vehicle’s engine must be shut
off, the parking brake set, and the wheels
chocked.
Loading & Unloading
Because of the possible buildup of static

electricity, the vehicle must also be
grounded.
Loading & Unloading
The responsible person must verify that the

driver understands the potential hazards of
the material, is wearing the proper Personal
Protective Equipment, and knows the
proper procedures to follow in case of an
emergency.
Loading & Unloading
The driver must have a clear view of the

vehicle and remain within 25 feet of the
truck during the loading or unloading
process.
Loading & Unloading
Before loading or unloading, the person

performing the function must inspect the
tank to make sure all fittings, valves, and
safety relief devices are in proper condition
for safe transportation.
Loading & Unloading
Loading and unloading both pressure and

general purpose tank cars requires the
same thorough checklist as tank trucks.
Before the process begins, blue flags are
positioned with one of the two following
warnings:
Loading & Unloading
STOP, TANK CAR CONNECTED

or
STOP, MEN AT WORK
Loading & Unloading
The wheels are then chocked, and the hand

brake is set.
Loading & Unloading
Because of the potential for static

electricity buildup, the tank car is
grounded.
Loading & Unloading
On general purpose tank cars equipped

with secondary outlet valves, the plugs
must be removed, and the top and bottom
valves opened during loading. Internal
heating coil caps must also be removed
during loading.
Loading & Unloading
If loading, check the tank car’s interior for

cleanliness, and to verify that the previous
contents are compatible with the material
being loaded.
Loading & Unloading
Make sure all valves and fittings are in

their proper setting, and all loading or
unloading connections are properly
attached. If corrective actions are needed
to the tank car before loading or
unloading, notify the switching office or
terminal manager.
Loading & Unloading
After loading and before shipment or

unloading and release, disconnect the
appropriate lines or hoses. If loading,
check to make sure the required outage has
been left to allow for expansion, or that the
tank is empty if you have been unloading.
Loading & Unloading
Make sure you properly seal the dome

cover and uniformly cross-tighten all
securing nuts. All valves must also be
securely closed.
Loading & Unloading
Check to be sure that all valve caps and

plugs are in place and have been tightened
with a wrench. All protective housings and
covers must also be in place, closed, and
wrench tight.
Loading & Unloading
On general purpose tank cars, make sure

the bottom outlet valve gasket is in good
condition. Tighten the bottom outlet
valve cap with a wrench that has a
minimum 36-inch handle.
Loading & Unloading
The plug in the bottom outlet valve should

be wrench tight. Make sure all secondary
outlet valves and plugs are tight.
Loading & Unloading
Check the tank car for any signs of leakage

or spills, and make sure the correct
placards are in place.
Loading & Unloading
If loading, check the marks to see that the

load limit has not been exceeded and the
OSHA hazard warning is in place.
Loading & Unloading
The person loading or unloading must be

able to rapidly halt cargo transfer during
the process if the material is hazardous.
Placarding
After all final checks, once the tank cars,

portable tanks, and tank trucks have been
loaded or unloaded, but before their
shipment, they must be placarded according
to 49 CFR Part 172.504.
Placarding
Placards inform emergency response

personnel of the hazard class and associated
dangers of the material being transported.
Placarding
The regulations require specific placards for

each of the nine hazard classes, as well as
specific placards for those hazard classes
that are further separated into divisions.
Placarding
Most bulk transport containers require four

placards, one on each side and each end.
Placarding
As a general rule of thumb, placards must

be visible on all four sides of a bulk
packaging and at least three inches away
from any other markings.
Placarding
If a portable container holds more than 119

gallons, but less than 1,000 gallons, the tank
may be placarded on two opposite ends.
Placarding
Sometimes a material will have a primary

and a secondary, or subsidiary, hazard. In
these cases, placards showing both hazards
must be displayed, but the secondary hazard
class placard must have the hazard class
number removed or obliterated.
Summary
Loading and unloading hazardous materials

is a serious responsibility. Be familiar with
and respect the hazards associated with the
material you load or unload.
Summary
Follow all procedures and safe work practices,

including proper selection of tools and
Personal Protective Equipment.
Summary
Make sure you double check that all valves,

fittings, caps, seals, and closures are properly
secured, whether you used them or not.
Summary
Check the placards before releasing the bulk

container.
Summary
Knowing and following the proper procedures

can ensure safe transportation of bulk
shipments.
Summit Training Source,
Inc.
Contact us at:
1-800-842-0466
or at
info@safetyontheweb.com

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www.safetyontheweb.

If you load or unload hazardous materials in

Department of Transportation statistics show

Bulk Packaging is packaging other

This includes railroad tank cars, tank

Railroad Tank Cars

Railroad tank cars can be divided into

A general purpose or non-pressurized

Loading devices and equipment are

In addition, bottom outlet valves for

Pressure tank cars are also

As a person who loads and unloads bulk

1. To ensure your safety and health.

It is also important that you are familiar

Though Material Safety Data Sheets do not

There are specific requirements that must

When loading or unloading a bulk package

Because of the possible buildup of static

The responsible person must verify that the

The driver must have a clear view of the

Before loading or unloading, the person

Loading and unloading both pressure and

STOP, TANK CAR CONNECTED

The wheels are then chocked, and the hand

Because of the potential for static

On general purpose tank cars equipped

If loading, check the tank car’s interior for

Make sure all valves and fittings are in

After loading and before shipment or

Make sure you properly seal the dome

Check to be sure that all valve caps and

On general purpose tank cars, make sure

The plug in the bottom outlet valve should

Check the tank car for any signs of leakage

If loading, check the marks to see that the

The person loading or unloading must be

After all final checks, once the tank cars,

Placards inform emergency response

The regulations require specific placards for

Most bulk transport containers require four

As a general rule of thumb, placards must

If a portable container holds more than 119

Sometimes a material will have a primary

Loading and unloading hazardous materials

Follow all procedures and safe work practices,

Make sure you double check that all valves,

Check the placards before releasing the bulk

Knowing and following the proper procedures

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