How to Load IBC Totes on Dry Vans, Flatbeds & Box Trucks

by Repackify
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Loading IBC Totes on a Truck: A Comprehensive Guide

As a warehouse manager, ensuring that Intermediate Bulk Containers (IBC) totes are loaded correctly and safely on a truck is crucial. Proper techniques not only enhance efficiency but also ensure compliance with safety and regulatory standards. This guide provides a detailed step-by-step process to load IBC totes on a truck, focusing on safety, compliance, and best practices.

Understanding IBC Totes

IBC totes are large, reusable containers used for storing and transporting bulk liquids and solids. Common in industries like agriculture, chemicals, food and beverage, and pharmaceuticals, the standard IBC tote measures 48 inches long, 40 inches wide, and 46 inches high, holding approximately 275-330 gallons.

Pre-Loading Preparations

1. Inspect the Truck and Equipment

  • Truck Condition: Verify that the truck is in good condition with no damage to the loading area.
  • Pallet Jack/Forklift: Ensure the pallet jack or forklift is operational and can handle the weight of the IBC totes.
  • Safety Gear: Equip staff with gloves, safety shoes, and high-visibility vests.

2. Plan the Load

  • Weight Distribution: Distribute weight evenly across the truck to maintain balance and avoid overloading any axle.
  • Load Order: Plan the loading order based on delivery stops, placing the last delivery items first for easy access.

3. Prepare the IBC Totes

  • Inspect Totes: Check each IBC tote for damage or leaks, and ensure lids and valves are securely closed.
  • Labeling: Verify that all totes are correctly labeled with contents, handling instructions, and hazard warnings if applicable.

Loading Process

1. Position the Truck

  • Park the truck on a flat, stable surface. Engage the parking brake and turn off the engine.
  • Lower the tailgate or open the rear doors, ensuring enough clearance for the forklift or pallet jack.

2. Load the First Row

  • Using a Forklift:
    • Insert the forklift forks under the pallet of the IBC tote.
    • Lift the tote carefully and position it at the desired spot on the truck bed.
    • Lower the tote gently, ensuring it is stable and positioned correctly.
  • Using a Pallet Jack:
    • Position the pallet jack under the pallet of the IBC tote.
    • Lift the tote slightly off the ground and maneuver it onto the truck bed.
    • Carefully lower the tote into place.

3. Secure the Load

  • Straps and Chains: Use ratchet straps or chains to secure each IBC tote to the truck. Attach the straps to the truck’s anchor points and tighten them to prevent movement during transit.
  • Corner Protectors: Place corner protectors under the straps to prevent damage to the IBC totes.

4. Load Subsequent Rows

  • Continue loading the remaining IBC totes, following the same procedure as the first row.
  • Ensure that each row is securely strapped before loading the next row.
  • Double-check the weight distribution to maintain balance.

5. Final Inspection

  • Conduct a final inspection of the loaded truck. Ensure all IBC totes are securely fastened and that there is no risk of shifting during transit.
  • Verify that all labels are visible and that there are no leaks or damages.

Safety and Compliance

UN Hazmat Information

Transporting hazardous materials requires strict adherence to United Nations (UN) regulations. These regulations ensure the safe transport of hazardous materials through proper classification and labeling.

Hazard Classes

The UN categorizes hazardous materials into nine classes:

  • Explosives
  • Gases
  • Flammable Liquids
  • Flammable Solids
  • Oxidizing Substances and Organic Peroxides
  • Toxic and Infectious Substances
  • Radioactive Material
  • Corrosive Substances
  • Miscellaneous Dangerous Goods

Each class requires specific handling and documentation. Ensure that all hazardous materials are correctly classified and labeled according to UN standards.

Safety Placards

Safety placards are essential for identifying the type of hazardous materials being transported. Placards must be displayed on all four sides of the truck and comply with the regulations of the Department of Transportation (DOT) and the UN.

  • Placard Size: Standard placards are 10.75 inches on each side.
  • Placard Placement: One placard on the front, back, and each side of the truck.
  • Hazard Labels: Ensure that each IBC tote is labeled with the appropriate hazard class symbol and UN number.

Safety Data Sheets (SDS) or Material Safety Data Sheets (MSDS)

For all hazardous materials, maintain Safety Data Sheets (SDS) or Material Safety Data Sheets (MSDS) on-site and with the shipment. These documents provide critical information about the properties, handling, and emergency measures for hazardous materials. Ensure that all staff are trained to understand and use SDS/MSDS.

Loading Capacities

53-Foot Dry Van

A 53-foot dry van can accommodate up to 60 IBC totes. This calculation is based on the standard dimensions of IBC totes and the interior space of the dry van.

Flatbeds

Flatbeds offer more flexibility in loading but require careful securing of the totes to prevent shifting. The number of IBC totes that can fit on a flatbed depends on the flatbed’s length and the configuration of the load. Typically, a 48-foot flatbed can carry approximately 48-50 IBC totes.

Box Trucks

Box trucks vary in size, but a standard 26-foot box truck can typically hold up to 20-24 IBC totes. Ensure proper weight distribution and secure the totes to prevent movement during transit.

Equipment Needed to Load Trucks

Proper equipment is essential for safely loading IBC totes onto trucks. Here’s a list of equipment you’ll need:

  • Forklift: Essential for lifting and placing heavy IBC totes onto the truck.
  • Pallet Jack: Useful for maneuvering IBC totes in tight spaces.
  • Ratchet Straps or Chains: Necessary for securing the totes to prevent movement during transit.
  • Corner Protectors: Protects the IBC totes from damage caused by straps.
  • Safety Gear: Includes gloves, safety shoes, and high-visibility vests for personnel.

IBC Tote Recycling Companies

Recycling IBC totes is an environmentally responsible practice that helps reduce waste and conserve resources. These companies below will end out truck to your facility and pick up your totes. Typically they will also provide payment for tote which can range from $5-25/Tote for used containers.

Centurion Container

Centurion Container offers comprehensive recycling and reconditioning services for IBC totes. They ensure that the totes are cleaned, repaired, and made ready for reuse, adhering to industry standards.

Website: Centurion Container

Mauser Packaging Solutions

Mauser provides sustainable packaging solutions, including the reconditioning and recycling of IBC totes. Their services help extend the life of the containers and reduce environmental impact.

Website: Mauser Packaging Solutions

Reused USA

Reused USA focuses on recycling and reconditioning IBC totes to promote sustainability. They offer various services to ensure the totes are safe for reuse.

Website: Reused USA

Conclusion

As a warehouse manager, ensuring the safe and efficient loading of IBC totes on a truck is paramount. By following the steps outlined in this guide, adhering to UN hazmat regulations, and utilizing proper equipment, you can minimize the risk of accidents and damage. Properly loaded IBC totes will help maintain compliance with transportation regulations and ensure that goods arrive at their destination in excellent condition. Additionally, partnering with reputable recycling companies for IBC tote disposal can contribute to sustainability efforts and reduce environmental impact.

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