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Securing loads on trucks

What is the problem?
Chains and webbing with tensioning devices (tensioners) are commonly used to secure loads on
trucks.
Some types of tensioners have caused severe head, face and shoulder injuries to workers when
used incorrectly and near misses are a common occurrence.

Tensioners include:
webbing hand ratchets
under-vehicle webbing winches
chain dogs
other chain tensioners.

What are the risks?

Using tensioners to tighten and release chains and webbing puts workers at risk of:
musculoskeletal injuries, particularly to the back, shoulders and hands, from the repetitive
force required to tighten chain tensioners, webbing winches and webbing hand ratchets
pinched fingers
falls from overbalancing
fractures, contusions and lacerations from being struck by extension bar handles used with
over-centre lever style tensioners (dogs), which can rebound and fly off the dog.

What is a solution to the problem?

Depending on the type of load being carried, the National Transport Commissions Load Restraint
Guide 2004 (LRG) performance standards must be met to prevent loads from coming away from
the truck during transit, or shift, causing vehicle instability.
Manufacturers instructions should be followed while using tensioners. To eliminate or reduce the
risk of injuries while using chains and webbing with tensioners, the following solutions can be used
in order of priority 1 being the preferred option.
1. Minimise the use of chains and webbing by using:
systems to reduce or eliminate the need for chains and
webbing, e.g. use a coil containment system, pin, pegs,
posts, headboards or goose-neck on a drop-deck trailer to
help block the load (see Figure 1)
a truck that is custom-designed for loads, e.g. some pallet
loads may suit a truck with combination internal side and
middle expanding walls, combined with an inward-sloping
floor and load-rated curtain.

Figure 1. Removable posts in a truck help

block the load

2. Use webbing straps instead of chains

Webbing straps, if suitable for restraining a load, are lighter than chain. Webbing tensioners are
also lighter to handle and, if fixed to the trailer, will not need handling. If webbing is used, two
2500 kg lashing capacity straps can often replace one regular (8 mm) chain with a 4000 kg
lashing capacity. The load will need to be assessed, and webbing and chain should not be
used together.
As webbing is slightly elastic, it may stretch in transit and can also be damaged by sharp edges
on loads.
If using a hand ratchet with webbing:
- a pull-down webbing ratchet will reduce the risk of shoulder injuries because it will not need
to be repeatedly pushed up.
- it is easier to pull the ratchet handle (see Figures 2 and 3) when the strap length allows the
ratchet to be between waist and shoulder height.

Figure 2. A pull-down hand ratchet reduces the risk of shoulder

injury (note the extended top plate).

Figure 3. A ratchet cap/hat winch does not require the handle to

be reinserted with every turn (note the black casing or cap).

If using a winch with webbing:

- use a geared winch or one that does not require the removable handle to be reinserted with
every turn. This reduces the risk of the handle coming off and unbalancing the worker. The
handle should fit snugly on the socket or in the winch cap holes
- a geared winch requires less force and encourages better posture because workers do not
need to repeatedly bend low when positioning or tensioning the handle. The more teeth a
geared winch has, the less force is needed to gain high tension (see Figures 4 and 5).

Workplace Health and Safety Queensland, Department of Justice and Attorney-General

Health and safety solution Securing loads on trucks
PN10951 Version 2 Last updated 10 March 2011
 Figure 5. This is another type of geared winch on the market.
Figure 4. This is a type of geared winch on the market. Geared
winches generally do not require the handle to be repeatedly
reinserted.

3. Use chains with non-rebounding tensioners

If using chain lashings, an alternative to an over-centre lever
style load binder (a dog), should be used. An extension bar
should not be used to increase chain tension (see Figure 6).
Many workers find they cannot get satisfactory chain tension
when using a dog so they often use an extension bar to
increase the tension. This practice is dangerous because the
extension bar can rebound quickly during tightening and
releasing and may even fly into the air. This applies to Figure 6. An over-centre lever style load
generic, manufactured extension bars, pipe handles and any binder (a dog) with an extension (cheater
other makeshift extension bar. bar). An extension bar should not be used to
tension chains.

A turnbuckle tensioner (see Figure 7), or another type of non-rebounding tensioner (see Figures
8, 9, 10 and 11) can be used instead of a dog. Turnbuckles have no kickback and can gain very
high tensions without using extension bars. Ratchet and sliding lever turnbuckles are available.

Figure 7. Two types of ratchet turnbuckle chain tensioners.

Figure 8. A type of chain tensioner.

Figure 9. A type of chain tensioner

Workplace Health and Safety Queensland, Department of Justice and Attorney-General

Health and safety solution Securing loads on trucks
PN10951 Version 2 Last updated 10 March 2011
Figure 10. A type of chain tensioner Figure 11. A type of chain tensioner

To tighten a dog without an extension bar, a recoil-less (pivoting) dog can be used. These dogs
do not store energy in the handle when under tension reducing the risk of the handle hitting
workers when released.
An extension bar should not be used to tighten or release a dog unless all other chain tensioners
are assessed by the operator as unsuitable for each load and adequate tension cannot be gained
by the dog alone.
When using tensioners, workers should:
wear gloves with all chain tensioners to reduce the risk of pinched hands
position chain tensioners below shoulder height, or use a stable-standing aid when applying or
releasing tensioners
inspect and maintain tensioners regularly to ensure effectiveness and safety. A record, such as
a defective vehicle report, and history of maintenance will help identify how often they need to
be inspected.

Further information
This information has been taken from the Worksafe Victoria Guidance Note Safe handling when
securing loads on trucks.

Further information is available from www.worksafe.qld.gov.au or by calling the WHS Infoline on

1300 369 915.

The State of Queensland (Department of Justice and Attorney-General) 2011

Copyright protects this document. The State of Queensland has no objection to this material being reproduced, but asserts its right to be recognised as
author of the original material and the right to have the material unaltered.
The material presented in this publication is distributed by the Queensland Government as an information source only. The State of Queensland makes no
statements, representations, or warranties about the accuracy or completeness of the information contained in this publication, and the reader should not
rely on it. The Queensland Government disclaims all responsibility and all liability (including, without limitation, liability in negligence) for all expenses,
losses, damages and costs you might incur as a result of the information being inaccurate or incomplete in any way, and for any reason.

Workplace Health and Safety Queensland, Department of Justice and Attorney-General

Health and safety solution Securing loads on trucks
PN10951 Version 2 Last updated 10 March 2011