SAFE TO

LOAD
GUIDE
By : Road Transport
Safe to load Guide
• This practical training guide with many illustrations is developed to help
inspectors to realize the safe to load inspection.
• Each topic is based on five questions namely:
◦ What is it ?
◦ Where to find them ?
◦ Why is it important to safety ?
◦ What to expect ?
◦ Which decision to take ?

• The training guide explains clearly what decision to take in case of non-
compliance of the vehicle:
◦ Give the hauler a warning in writing (the deficiency must be repaired before the next loading)
◦ The truck must be rejected and not loaded till it complies.

2
Safe to Load Guide
Common controls
•Technical vetting of truck
•Driver’s accreditations
•Visibility
•Safety belts
•Lighting
•Battery cut off switch
•Fire extinguishers
•Driver’s PPE
•Wheels and rims
•Tires
The safe to load inspection must be done
•Fifth wheel and king pin
•Parking brake test with seriousness and rigor. It helps to
•Marking and stick up improve the quality, reliability and safety
•Emergency phone number of the fleet.
•Condition of welds and absence of cracks
•General condition of electrical wiring
•Earthing studs
•Ladder, handrail, upper walkway
•Leaks
•Bottom valves
•Composite hoses
•Flame arrestor
•Equipment
•General outlook

3
 Technical Vetting of truck (1/2)
• What is it ?
▪ Document issued by a accredited service Provider certifying that the
truck is fit to be on the road.
▪ Document must have a registration number and a validity date (stamp
on registration document).

• Where to find it ?
▪ In the driver’s documentation (cabin).

• Why is it important to safety ?

▪ A set of normalized tests (checklist) are carried out in specific and
dedicated Workshops proving that the truck is suitable to drive on the
road.

4
Technical Vetting of truck (2/2)
• What to expect ?
▪ Dates must be valid and not expired (1 year validity from the date of initial inspection(Green
Status).

• Which decision to take ?

▪ If the document is not valid, the truck must be rejected.

5
Driver’s accreditations (1/2)

• What is it ?
▪ Driver’s driving license.

• Where to find them ?

▪ In the driver’s documentation

• Why is it important to safety ?

▪ The driver must have been properly trained in order to be allowed to drive a truck carrying
dangerous product.

6
Driver’s accreditations (2/2)

• What to expect ?
▪ Driving license must be of the
relevant class (correspond to size
and weight of the truck).
▪ Driving license date must be valid.

*For Trailer drivers, Restriction 8

should be indicated on the
• Which decision to take ? License
▪ If the driver has no driving license or the class doesn’t correspond to the size/weight of
the lorry, the truck must be parked safely and the drivers has to leave the site by his
own means.
▪ If the training certificate is overdue, the truck must be rejected.

7
Visibility (1/2)

• What is it ?
▪ They are all the elements that allow the
driver to have a clear view of the road.

• Where to find it ?
▪ windscreen
▪ windows
▪ side mirrors
▪ wipers
▪ dashboard
▪ horn

• Why is it important to safety ?

▪ The truck must be noticed at all time by the other road users.
▪ The driver must have a perfect view of the road at all time, nothing should prevent him from detecting a
danger as soon as possible.

8
Visibility (2/2)

• What to expect ?
▪ Screens and mirrors must be cleaned and cleared, not broken, properly fixed, no
pasting.
▪ Wipers and horn must be functional.
▪ Dashboard must be cleared.

 

• Which decision to take ?

▪ If any of the device is not meeting the requirements, give the transporter a warning
for the next loading.
▪ If the windscreen has a crack, give the transporter a warning for the next loading.

9
Safety belts (1/2)
• What is it ?

• Where to find it ?
▪ In the cabin
▪ At the driver seat
▪ At the passenger seat

• Why is it important to safety ?

▪ In case of accident, the fatality rate is 3 times higher if the seat belt is not worn.

10
Safety belts (2/2)
• What to expect ?
▪ One seat belt per seat, both for driver and passenger.
▪ Good working condition (easy to pull and roll back, easy to plug and unplug and
proper fastening arrangement).
▪ Pull strongly on the seat belt, it must completely block immediately.
▪ Pull down from the top and pull up on the plug.

• Which decision to take ?

▪ If any of the seat belts is absent or not working, the truck must be rejected.

11
Lighting (1/2)

• What is it ?
▪ They are the lights useful for the
driver to see the road or for the truck
to be seen by other road users.

• Where to find it ?
▪ Front headlights
▪ Rear lights
▪ Stop lights
▪ Brake lights
▪ Side indicators
▪ Turn signals

• Why is it important to safety ?

▪ The truck must be seen at all time.
▪ The driver must be able to see the road perfectly.
▪ The lights, as electrical devices, can generate sparks that could meet gaseous fumes, leading to
explosion and fire.

12
Lighting (2/2)

• What to expect ?
▪ The light must be functional (ask the driver to test all of them).
▪ The cover must be in place and clean.

▪ The cover must not be broken.

✓  
• Which decision to take ?
▪ If the cover is highly damaged, the truck must be rejected
▪ If one of the light is not working, give the transporter a warning for the next loading and stop the
vehicle until the daybreak.
▪ If the cover is slightly damaged, give the transporter a warning for the next loading

13
 Battery cut off switch (1/2)
• What is it ?

▪ The device switches off the truck battery

instantaneously, prohibiting any electricity to be
generated in the truck (no electric system remains ON
active).

◦ Where to find it ? OFF

▪ one is located outside,
▪ another one is located inside the cabin (ask the driver).
▪ On new vehicles, we find the battery switch in the
cabin only. The button acts directly on the battery
switch mechanism located near the battery.

◦ Why is it important to safety ?

▪ If there is no electricity on the truck, there will be no
chance of spark creation (a spark that meets gaseous
fumes can cause fire).

14
Battery cut off switch (2/2)

• What to expect ?
▪ The button must be very visible, preferably with signage/label indication.
▪ The ON/OFF positions must be indicated and very clear to the driver.
▪ The shape of the button can change.
▪ The way of acting it can change (push or twist).

• Which decision to take ?

▪ If ON/OFF positions not indicated, give the transporter a warning for the next
loading
▪ If there is no battery cut off switch or if it is not working, the truck must be
rejected.

15
 Fire extinguishers (1/2)

• What is it ?
▪ 12 kg Dry Chemical Powder Extinguishers (DCP) which can
be split in 2kg+6kg+6kg or 3kg+9kg.

• Where to find it ?
▪ one in the cabin.
▪ one around the tanker, in the prescribed box, or, due to
security issues, also in the cabin but available, easy to
remove and ready to use immediately.

• Why is it important to safety ?

▪ DCP extinguishers can fight against various classes of fire:
▪ A : solid (for example inside the cabin)
▪ B : liquid (hydrocarbons or tyres)
▪ C : gas
▪ A 6 kg extinguisher lasts around 16 seconds
▪ a tyre fire requires at least 2 extinguishers
▪ With these extinguishers, a driver can extinguish a small
fire or prevent a fire that has just started from developing
into a major disaster.

16
Fire extinguishers (2/2)

• What to expect ?
▪ 2 fire extinguishers with service tag.
▪ one of 6 kg minimum
▪ not older than 10 years
▪ pressure in the green zone (if equipped)
▪ Validated once a year (check date)
▪ easy to access, ready to use
▪ no corrosion
▪ sealed

• Which decision to take ?

▪ For any default noted, the truck must be rejected.
▪ If no extinguisher then the truck must be rejected.

17
Driver’s PPE (1/2)

• What is it ?
▪ Equipment designed to protect the driver against any
injury:
▪ Overall (antistatic, non flammable, long sleeves and pants)
▪ Helmet with chin strap
▪ Goggles
▪ Safety shoes
▪ Gloves suitable for hydrocarbons
▪ Handling gloves for LPG cylinders or packed Lub

• Where to find it ?
▪ Worn by the driver during all operations involving the
truck.

• Why is it important to safety ?

▪ In case of accident, PPE are driver’s last barrier against
injury.

18
 Driver’s PPE (2/2) ✓
• What to expect ?
▪ No PPE missing
▪ All in good condition (clean, not torn or
broken)
▪ Respect the lifetime of the helmet
▪ Size adapted to the driver
▪ Clothes in cotton

• Which decision to take ?

▪ If one of the PPE is missing, the truck
must be rejected


19
Wheels / Rims (1/2)

• What is it ?
Wheel = tyre + rim
Wheel nuts
Rim
• Where to find it ?
▪ On all the wheels, including spare tire

• Why is it important to safety ?

▪ If the nuts are not tight enough, the truck can lose its wheel while driving. The
latter cause damage or can kill a pedestrian.
▪ If the rim is cracked, it can completely break and it will make the truck overturn

20
Wheels / Rims (2/2)

• What to expect ?
▪ No crack on the rim
▪ No missing nuts
✓ 
▪ Nuts must be well tightened


• Which decision to take ?
▪ If there is any default, the truck must be rejected.

21
 Tires (1/3)

• What is it ?
▪ A tyre is designed to :
▪ Support
▪ Guide
▪ Transmit
▪ Soften/suspend
▪ The groove guarantees the adherence of the tyre and particularly on
wet road.

• Where to find it ?
▪ Check all the tyres
▪ Including the tyres on the inner side of the axles
▪ Including the spare tyres

• Why is it important to safety ?

▪ A tyre in bad condition has poor adherence, loses pressure, can burst
or catch fire, decreases the efficiency of braking, makes the driver
uncomfortable and waste fuel.
▪ A bursting tyre can kill a pedestrian.
▪ A burning tyre is very difficult to extinguish.

22
Tires (2/3)
• What to expect ?
▪ Correct pressure
▪ At least 2 mm depth of tread (check depth gauge)
▪ Use groove meter if available
▪ Same tread for tires on the same axle side

✓ 
Gauge showing Gauge showing
good tyre bad tyre

23
Tires (3/3)
 

 
•Which decision to take ?
▪ A low pressure tyre must be inflated before loading (wait for an hour before
loading to make sure it doesn’t deflate again)
▪ For any major default noted, the truck must be rejected.
▪ If the spare tyres (if any) are bad, the truck must be rejected.

24
Fifth wheel and king pin (1/2)
• What is it ?
▪ Fifth wheel is the name given to the platform on which
the front of a trailer (tank) is attached to a tractor (truck,
prime mover). When the tractor is backed into the nose of
a trailer, the fifth wheel pivots and slides underneath the
trailer's grid plate. The fifth wheel then locks onto the
trailer's king pin.
▪ Kingpin is a heavy metal cylindrical pin. The kingpin is the Fifth wheel
mechanism on the trailer that locks it to a road tractor. A
greased metal grid plate surrounds the kingpin. This grid
plate allows the fifth wheel to slide underneath the
trailer.

shank
• Where to find them ?
▪ Fifth wheel is located above the rear axle (or axles rear)
of the tractor, and is bolted or riveted to the tractor King pin
frame.
▪ Kingpin is located underneath the front end of the trailer.
It is typically positioned between 18" to 48" from the
trailer nose.

25
Fifth wheel and king pin
(2/2)
• Why is it important to safety ?
▪ The rotating attachment allows the tractor-trailer combination
to make turns and provides stability and manoeuvrability on the road.
▪ Prevents the trailer from being unhooked from the tractor and rolling over.

• What to expect ?
▪ The fifth wheel must be well greased
▪ The fifth wheel must be in proper position for coupling, no space between upper and
lower fifth wheel, the locking lever is in the "lock" position (see the drawing). The locking
handle must be in locked position, safely blocked by a lock or a snap.
▪ No cracks in frame

• Which decision to take ?

▪ Verify if there is no space between the kingpin plate and the fifth wheel. If there is space,
the kingpin may be on top of the fifth wheel jaws the truck must be rejected
▪ If the locking handle is not in a safely locked position, if there is no lock or snap : the truck
must be rejected

26
Connection prime mover–Semi-
trailer/trailer (1/2)
• What it is?
▪ To ensure the functioning of the braking system and the traffic lights, connections are needed between
the prime mover and the trailer (semi-trailer, trailer). These connections are pneumatic and electric
types.

• Where to find them?

▪ At the rear of the prime mover cab.
▪ Near the hitch of the rigid truck

• Why is it important to safety ?

▪ Without pneumatic connections of the braking system, the semi-trailer/trailer can not run.
▪ Without electrical connections, the operation of the signal lights is not possible.
▪ Without ABS connection, thereof cannot operate.

27
 Connection prime mover–
Semi-trailer/trailer (2/2)
• What to expect?
▪ To ensure that the air supply hoses (Red) and service (Yellow) are
connected between the prime mover and the semi-trailer/trailer
▪ To make sure that the electrical connection is made ​between the motor
vehicle and the semi-trailer/trailer.
▪ To ensure that if the semi-trailer/trailer is equipped with ABS grip, it is well
connected to the ABS socket of the prime mover.

Pneumatic connection
Pneumatic connection
ABS connection
Electrical connection

• Which decision to take?

▪ In case of no connection, the truck must be rejected

28
Parking Brake Test (1/2)
• What is it ?
▪ The parking brake is also called hand brake. This is a manual pneumatic brake, it is also
used as an emergency brake. It is very important to test it before to go on the road.
.

• Why is it important to safety ?

▪ The parking brake is an indispensable component for the safe operation of the truck. It will
be critical when the truck is parked on a slope even on a flat area.
▪ Warning: the use of chocks should never hide a defective parking brake
▪ A run-away truck can have disastrous consequences.

29
Parking Brake Test (2/2)
• What to expect ?
▪ Make sure that nobody is in front of the vehicle less than 5 meters and not
close around it.
▪ With an automatic or manual gearbox, when the parking brake is tighten,
the driver accelerates gently to move the vehicle. The result is that the
vehicle must not move.
▪ With a manual gearbox, the engine takes strain it can also stall. With
automatic transmission, the engine takes strain but will never stall.
▪ With an automatic gearbox, during the test, the engine takes strain but do
not stall.

• Which decision to take ?

▪ If the truck fails the parking brake test, it must be rejected

30
Semi trailer/trailer automatic
brake test (1/2)
• What is it ?
▪ The semi-trailer/trailer automatic brake is a system which automatically brakes the trailer
in the event of trailer hitch breakdown.

• Where to find it ?
▪ The semi-trailer/trailer automatic brake activated by the disconnection of the air brake
cable. (disconnect or breaking of the red cable)

• Why is it important to safety ?

▪ The semi-trailer/trailer automatic brake ensures the stop of the towed vehicle in the event
of trailer hitch breakdown.
▪ The failure of the semi-trailer/trailer automatic brake highlights major malfunction in the
service brake of the towed vehicle.

31
 Semi trailer/trailer automatic
brake test (2/2)
• What to expect ?
▪ Make sure that nobody is in front of the vehicle less
than 5 meters and not close around it.

▪ Parking brake tighten, disconnect the red air cable,

of the towed vehicle.

▪ With an automatic or manual gearbox, when the brake is tighten , the driver accelerates
gently and reasonably in order to try to move the vehicle. The expected result is that the
truck does not run.
▪ With a manual gearbox, during the test, the engine penouille, it may even stall.
▪ With an automatic gearbox, during the test, the engine panouille but never stall.

Warning: Remember to replace the cable at the end of the test !

• Which decision to take ?

▪ If the truck fails the trailer automatic brake test, the truck must be rejected

32
marking and stickers (1/3)

• What is it ?
▪ The truck must show evidences that Dangerous Goods are transported in a manner
consistent to regulation
▪ Which product(s) is (are) in the tank trailer
▪ Which are the hazards and at what level

▪ There are different types of hazards which are identified with different labels

• Where to find it ?
▪ In ADR regulation countries
▪ The plate is in front of the tractor and at the back
▪ The hazard labels are at the back of the trailer and on the two sides of the truck
▪ In countries where the ADR regulation do not apply
▪ Have to adapt to local regulation

• Why is it important to safety ?

▪ People attention is attracted
▪ Fireman and Civil Rescue Services can better react in case of urgency

33
marking and stickers (2/2)
• What to expect?
In ADR regulation countries
✓
▪ At the back of the trailer
▪ 1 orange plate (UN code /danger code)
▪ 1 danger label (flame)
▪ At the front of the prime mover

✓
▪ 1 orange panel (UN code /danger code)
▪ On each side of the trailer
▪ 1 danger label (flame)

• Which decision to take ?

▪ If one element is missing, then the truck must be rejected

34
Emergency Phone number
• What is it ?
▪ A Phone number to call the transport Company for contracted fleet.

• Where to find them ?

▪ On the truck or on the tank or on truck cabin

• Why is it important to safety ?

▪ To be able to reach the Transport Company in case of emergency

• What to expect ?
▪ Number + mention « emergency »

• Which decision to take ?

▪ If the phone number is not present, give the
transporter a warning for the next loading.

35
condition of welds and absence of
cracks (1/2)
• What is it ?
▪ Surface of metal must not present any crack.
▪ Welds have to be in good apparent condition.

• Where to find them ?

▪ On the chassis and on the tank

• Why is it important for safety ?

▪ Cracks on the tank will enable product to leak out of the reservoir and lead
to spillages.
▪ Cracks on chassis signify that the chassis can break and damage the
trailer/tank on the road.
▪ Welds in bad condition lead to same consequences as above.

36
Condition of welds and absence
of cracks (2/2)
• What to expect ?
▪ No apparent cracks on tank and chassis.


▪ Welds in apparent good condition.

Tank welding rear right side

• Which decision to take ?

▪ If any crack on the tank or on the chassis ➔ the truck must be rejected

37
General condition of electrical wiring
(1/2)
• What is it ?
▪ All the electrical wires and connections on the truck.

• Where to find it ?
▪ behind the lights
▪ between the tractor and tanker
▪ all along the tanker (mainly below)
▪ around the battery
▪ around the valve box

• Why is it important to safety ?

▪ If the electrical connections are in good condition, there is no chance of spark
creation (a spark that meets gaseous fumes can cause fire).

38
General condition of electrical wiring
(2/2) 
• What to expect ?
▪ wires must be insulated
▪ wires should be placed in protecting conduit particularly
around tanker
▪ the connections with the devices must be neat

✓ ✓
 

• Which decision to take ?

▪ For any default noted, give the transporter a warning for the
next loading.
▪ In following cases, the truck must be rejected:
▪ Naked wire
▪ Non protected connectors (“domino”)
▪ Wire protected with adhesive tape

39
Earthing studs (1/2)
• What is it ?
▪ Metallic bits allowing the earthing of the
✓
truck.
▪ The depot to be equipped with a specific pair
of pliers/crocodile clips.

• Where to find it ?
▪ On the sides of the tank and in front of or
behind the chassis.

• Why is it important to safety ?

✓
▪ Static electricity generates sparks that can
ignite a fire in presence of vapor fumes.
▪ Earthing studs are necessary to dissipate the
static electricity created during (off) loading
operations.

40
Earthing studs (2/2)

• What to expect ?
▪ 1 number minimum
▪ Located at a place suitable with the position of the truck
during loading and unloading
▪ Not painted

 
✓

• Which decision to take ?

▪ If the truck doesn’t have at least 1 fully complying earthing stud, the truck must be rejected

41
 Ladder, handrail, upper walkway (1/2)
• What is it ?
▪ The fittings that allow the driver to climb on top
of the truck and prevent any fall.

Handrail
Upper walkway, anti slippery
Ladder

• Where to find it ?
▪ on top of the tank, the handrail/walkway.
▪ At the rear or at the front , the ladder.

• Why is it important to safety ?

▪ A fall from the top of a truck can be fatal. The
driver must use a harness.

42
Ladder, handrail, upper walkway (2/2)

• What to expect ?
▪ The fittings should be in good condition (easy to manipulate, strong when set,
not rusted)
▪ The handrail should be strong and in good condition
▪ Walkway should be free of any obstacle, not slippery

 
• Which decision to take ?
▪ Handrail not working, not robust: the truck must be rejected
▪ Ladder not robust, un-welded to the tank: the truck must be rejected

43
Leaks (1/2)

• What is it ?
▪ Product flowing out of a valve, a pipe, the
tank.
▪ Any leak is to be considered because a small
leak can become a large leak instantaneously

• Where to find it ?
▪ on the tank
▪ along the pipes
▪ at the valves (do not forget to check bottom
valves below the tank)

• Why is it important to safety ?

▪ As soon as product is out of its container, it
can meet an ignition point or pollute
environmentally sensitive points

44
Leaks (2/2)
• What to expect ?

▪ Perfect leak proofness of tank, all valves and pipes,
whether before, while or after loading
▪ All valves should be equipped with Caps, put back in
place after loading

• Which decision to take ?

▪ If any apparent leak is detected, even small, the
truck must be rejected
▪ If the leak is detected while or after loading, the
truck must be offloaded before leaving the depot.

45
 Bottom valves (1/2)

• What is it ?
▪ It is the 1st of the 3 safety devices that contain the
product inside the tank

• Where to find it ?
▪ below the tank

• Why is it important to safety ?

▪ As soon as product is out of its container, it can
meet an ignition point or pollute environmentally
sensitive points
▪ The bottom valve is the most reliable of the 3
safety devices that prevent product from leaking,
especially with the emergency cut-off switch.

46
Bottom valves (2/2)
• What to expect ?
▪ Each compartment must be equipped.
▪ No leak
▪ In case of a tank equipped with pneumatic bottom valves, the emergency cut off switch must be available
and tested working (test : open all the bottom valves using the handles and press the emergency cut-off
switch)


▪ All the handles must instantaneously and automatically come back into closed position)

• Which decision to take ?

▪ If the truck is not fully equipped with bottom valves, the truck must be rejected.
▪ If the emergency cut off switch is not available or not working, the truck must be rejected.

47
Composite hoses (1/2)

• What is it ?
▪ Hose adapted to liquid hydrocarbon transfer

• Where to find it ?
▪ Ideally, found in the hose housing
▪ They are also very often positioned on the side of the
tank strapped.

• Why is it important to safety ?

▪ Composite hose is electrically bonded during
manufacture, which prevents static electricity
accumulation.
▪ Composite hoses ensure leak proof connection with
truck and customer valves.
▪ Composite hoses are perfectly leak proof themselves.
▪ Composite hoses can stand a certain pressure.

48
 Composite hoses (2/2)
• What to expect ?
▪ Electrical continuity : it is
guaranteed by the wires wound
round the length of the hose.
▪ The wires are 2, one internal and

one external.
▪ Coupling at each end

➢Control could be done by random sampling.

➢If one hose is found defective, all the hoses

need to be checked.

• Which decision to take ?

▪ For any default noted, the truck
must be rejected

49
Flame arrestor (1/2) ✓
• What is it ?
▪ It is used to prevent any spark or flame to get
out of the exhaust Pipe.

• Where to find it ? ✓
▪ At the end of the exhaust pipe.

• Why is it important to safety ?

▪ When the truck is moving inside the depot, if a
spark or flame gets out of the exhaust pipe and
meets gaseous fumes, it can explode and
spread fire. ✓

50
Flame arrestor (2/2)


• What to expect ?
▪ it can be a metallic grid or a wire mesh.
▪ the device should not be damaged or
deformed with extra holes.
▪ the device should be tightly fixed to the
exhaust pipe so that it is not blown away when
starting the engine and no air flow can get out
without passing through it.

• Which decision to take ?

▪ The measures to be taken are left to the
affiliate decision.

51
 equipments (1/2)

• What is it ?
▪ Anti spill set

▪ First aid kit

▪ Flash light FLP (flameproof)

▪ Reflective Jacket

▪ Eyewash or bottle of water

▪ 2 blocks/wedges

▪ Shovel, bucket, collector tank and sewer

isolation

52
equipments (2/2)
▪ Absorbent

▪ 2 flash light or triangles or signal cone

▪ Safety instruction

• Which decision to take ?

▪ The list of equipments must be determined by the affiliate. If one of the required
elements is missing, the affiliate must establish sanction to be taken.

53
 General outlook (1/2)

• What is it ?
▪ Clean outlook of the truck, both tractor and tank
▪ Reflective stickers all around the truck

• Where to find it ?
▪ All around the truck

• Why is it important to safety ?

▪ Clean outlook of Filoil trucks helps reinforce our image.

54
 General outlook (2/2)

• What to expect ?
▪ Clean outlook of the tractor, tanker and inside the cabin.
▪ Good white appearance without dent, dust or mud.
▪ Wheels must have mudguards all around.
▪ Check for reflective stickers all along the sides and at the
back of the tank

✓  

• Which decision to take ?

▪ For any default noted, give the transporter a warning for the next loading.

55