Container and Flatbed Unloading Process

Geomembrane unloading process (flatbed and container)

Legal disclaimer

Solmax’s safe work methods are based on a general risk assessment and are advisory in nature, provided for informational purposes only. They do not create legal obligations or guarantee safety. The client is solely responsible for assessing site-specific risks and implementing all necessary preventive, protective, and control measures in compliance with applicable laws. Solmax disclaims all liability for reliance on, alteration of, or failure to apply these methods and for any resulting measures.

Introduction

Solmax geomembrane rolls are delivered via flatbed trucks, seaway, or intermodal containers and require controlled, well-planned unloading to protect both the crew and the product. Loads are securely fastened in accordance with Solmax's internal procedures and photographed before departure from our manufacturing sites.

These guidelines outline the minimum safety, equipment, and handling practices required to unload geomembrane rolls without damage and to prevent staff injuries.

Confirming site readiness

The delivery address is managed by the client or contractor. Before any unloading activity begins, verify the following critical points:

• The designated unloading area

• The planned unloading method

• The approved storage method for materials at the site

These points must be carefully assessed and planned to ensure a safe and efficient unloading process while preserving product quality.

The unloading process

1. Securing the perimeter

A safe unloading operation begins with establishing control of the working zone. Unloading operations introduce movement hazards, suspended loads, and rolling risks; therefore, the perimeter must be stabilised before any equipment engages with the load.

2. Unloading configuration

Always report to the unloading zone identified by the site or project manager. Ensure the area is level, stable, and suitable for the required equipment. If it is not safe, stop work and escalate immediately.

3. Collective protection

A clearly marked safety perimeter must be created around the truck or container to prevent workers from entering the hazard zone while rolls are being handled.

4. Personal protective equipment (PPE)

All personnel involved must wear the safety equipment required on the site, or at minimum:

• Safety helmet

• Safety boots

• Safety glasses

• High-visibility clothing

Choosing the right equipment and unloading procedure

Correct equipment selection is essential, as geomembrane rolls are heavy, cylindrical loads that behave unpredictably if unsupported. Each roll weighs approximately 2 tons, and the slings must be positioned correctly to maintain stability, ensure even load distribution, and prevent pendular oscillations during lifting.

Equipment selected must have a safe working load (SWL) in excess of the maximum roll weight and hold a valid lifting certificate.

This section outlines the minimum equipment expectations and procedural controls required to meet site risk-prevention requirements. Consult the Solmax Sling Procedures Manual if necessary.

Equipment options

Approved equipment includes:

• Forklift

• Front-end loader

• Backhoe

• Excavator

The construction or site manager determines the appropriate option based on availability and site conditions.

Procedure requirements

• Use controlled procedures for lifting, sling removal, lowering, and placement

• Prevent impact damage and maintain product quality throughout the unloading process

Additional requirement for flatbed unloading

• Before loosening straps, physically secure the rolls using the available lifting equipment to prevent them from falling.

• Loosen only the straps on the specific tier being unloaded

• Release straps roll by roll as each roll is lifted

• Never loosen straps in advance

• When the truck driver handles the straps, ensure the load is secured to prevent any possibility of rolls shifting or falling

Starting the unloading process

When the safety perimeter is installed and the equipment is positioned correctly, unloading may begin. The objective is to remove each roll in a stable, controlled manner, while maintaining full control over the suspended load.

Common steps

• Verify all sling points are properly secured before applying tension

• Clear the unloading area of personnel, tools, and obstacles

• Maintain a designated safety zone visible to the equipment operator

• Use a guide cable (tag line) if required to stabilise and orient the roll

• Lift slowly and smoothly in a controlled, steady motion

Flatbed unloading method

• Attach the 2 loose slings positioned on top of the roll and connect securely to the lifting equipment

• Raise the roll until it clears the flatbed and can be moved safely to the designated placement area

Container unloading method

• Attach the loose sling positioned on top of the roll and connect securely to the lifting equipment

• Personnel shall not remain in the container when the rolls are being moved

• Pull the roll slowly until it slides out of the container

Method A:

• Place the roll on the forks of a lift with the required capacity

Method B:

• Stabilize the roll on the ground or on a protective base with one end still in the container

• Remove pulling sling and adjust lifting sling to required position if necessary

• Lift slowly and smoothly until the roll is completely out of the container

Geomembrane roll transport to storage

After the roll is safely removed, it must be transported in a controlled manner, avoiding collision, excessive vibration, or sudden or uncontrolled movement.

The slings are intended solely for unloading; they are not designed nor approved for carrying rolls over long distances. Dynamic loads generated by ground irregularities during extended movement can exceed the sling’s maximum allowable strength and may result in failure.

Proper routing and adequate spacing during transport are essential to prevent damage prior to installation.

Standard safety measures

• Verify route conditions: ensure the path to the storage area is stable, level, and free of obstacles or ground hazards

• Maintain a pedestrian-free transport path

• Use a flagman if needed; the flagman must maintain continuous visual contact with the operator while remaining outside the vehicle and load “line of fire”

• Prohibit walking beside moving loads

Stacking the rolls

Specific recommendation for storage based on product type:
Geosynthetic storage recommendations | Solmax

Standard maximum stacking heights

• PE Smooth: up to 4 rolls high

• PE Textured: up to 3 rolls high

These guidelines represent general recommendations; however, site-specific conditions may limit the safe number of tiers. The pile height must never exceed what is reasonable for local safety conditions, including ground stability, slope, equipment access, and weather exposure.

Use proper support surfaces
Place all rolls on a raised, stable, and suitable surface to prevent moisture, scratches, and ground contamination.

Standard safety measures

• Apply chocks to the bottom tier rolls using high-visibility chocks (orange or yellow recommended)

• Do not walk between unsecured rolls

• Build subsequent tiers by nesting rolls between the two adjacent rolls of the tier below

• Upper tiers do not require chocks; stability is achieved by the interlocked arrangement

• Fully complete and secure the bottom tier before placing rolls on the next tier

• Respect maximum stacking heights to maintain product integrity and ensure safe handling during future installation

Two level storage platforms

Two‑level storage platforms allow slings to be removed directly from ground level. This method is recommended because it eliminates the need to climb onto the stored materials and reduces exposure to fall hazards.

However, several conditions can increase the risk level:

• Rain, moisture, or debris carried on footwear can make rollers and walking surfaces slippery.

• Repeated cycles of heat and cold can cause gaps to form between rollers, which may lead to unwanted movement or instability of stacked materials.

Because these factors can vary from one task to another, each work situation must be observed and evaluated by a competent person to ensure that conditions are safe and that appropriate controls are in place before beginning the activity.