Job Hazard Analysis · General Contractor

Job Hazard Analysis: Material delivery and unloading

Receiving a flatbed or box-truck delivery of jobsite materials such as lumber bunks, drywall, block, and palletized supplies. Unloading by rough-terrain forklift or telehandler, plus hand unloading of loose items. Includes setting up the drop zone, backing the truck in, cutting bands, stacking, and cleanup. Work is outdoors on an active site, often near a street or sidewalk.

Published 2026-10-23

A general example for this task. Your JHA should reflect your crew, equipment and site — review it with a competent person before work starts.

Steps, hazards and controls

1. Plan the delivery and set up the drop zone
- Soft, sloped, or uneven ground causing forklift tip-over or load shiftHigh
  - Pick a firm, level staging area away from excavations, trench edges, and overhead power lines before the truck arrives.
  - Lay gravel or mats on muddy ground and keep a 10-ft minimum clearance from overhead lines.
  - Check the delivery ticket for load weight and confirm it is within the forklift's rated capacity chart.
- Pedestrians and other trades walking into the unloading areaMedium
  - Barricade the drop zone with cones and caution tape and post a sign.
  - Tell all trades on site when the truck is due and where it will unload.
2. Guide the truck into position
- Backing truck striking a worker or pinning someone against a fixed objectHigh
  - Assign one spotter only; the spotter stays in the driver's mirror view and never walks behind the moving truck.
  - Agree on hand signals with the driver before backing; if the driver loses sight of the spotter, the driver stops.
  - Confirm the truck's backup alarm works; wear a high-visibility vest.
- Public traffic when the truck stages on or next to the streetHigh
  - Set cones and signs to warn drivers; use a trained flagger if the truck blocks a lane.
  - Keep the crew on the curb side of the truck, never on the traffic side.
3. Prepare the load: inspect, remove straps and tarps
- Load shifted in transit and falls when straps are releasedHigh
  - Walk around the trailer and look for leaning or broken bundles before releasing any strap.
  - Release straps from the side away from the load; never stand in the fall path.
- Fall from the flatbed deck while removing tarps or strapsMedium
  - Pull tarps and straps from the ground whenever possible.
  - If you must climb up, use the truck's steps or a ladder with three points of contact; do not jump down.
4. Unload with forklift or telehandler
- Worker struck or crushed by the forklift or a falling loadHigh
  - Only a trained, authorized operator runs the forklift; do a pre-use inspection of brakes, horn, forks, and tires.
  - Keep everyone out of the swing and travel path; nobody stands under raised forks or a raised load.
  - Travel with the load low and tilted back; no riders on the forks or the machine.
- Forklift tip-over from overloading, high load, or turning on a slopeHigh
  - Stay within the load chart for the boom extension being used.
  - Drive straight up and down slopes, not across; operator wears the seat belt.
5. Hand unload loose materials
- Back strain from lifting drywall sheets, block, bags, or long lumberMedium
  - Use the forklift, a drywall cart, or a dolly instead of carrying when possible.
  - Two-person carry for full drywall sheets and anything over 50 lb; lift with your legs and keep the load close.
- Cuts from steel banding and pinched fingers between materialsMedium
  - Cut bands with proper band cutters, standing to the side; the band can spring back.
  - Coil cut banding right away and put it in the dumpster.
  - Wear cut-resistant work gloves when handling bands and rough lumber.
6. Stack and store materials
- Stacks collapsing or materials blowing off in windMedium
  - Stack on level dunnage, blocked and limited in height so the pile is stable.
  - Tie down or weight sheet goods like plywood and foam board.
- Stored materials blocking exits, walkways, or fire accessLow
  - Keep walkways, stairways, and hydrants clear; store away from floor openings and slab edges.
7. Release the truck and clean up
- Tripping over dunnage, banding, wrap, and debrisLow
  - Pick up all banding, wrap, and broken pallets before leaving the area.
- Truck pulling out with workers nearbyMedium
  - Use the spotter again for the truck to leave; remove barricades only after the truck is gone.
  - Park the forklift with forks on the ground, brake set, and key removed.

Steps, hazards and controls
Step	Hazard	Risk	Controls
1. Plan the delivery and set up the drop zone	Soft, sloped, or uneven ground causing forklift tip-over or load shift	High	Pick a firm, level staging area away from excavations, trench edges, and overhead power lines before the truck arrives. Lay gravel or mats on muddy ground and keep a 10-ft minimum clearance from overhead lines. Check the delivery ticket for load weight and confirm it is within the forklift's rated capacity chart.
1. Plan the delivery and set up the drop zone	Pedestrians and other trades walking into the unloading area	Medium	Barricade the drop zone with cones and caution tape and post a sign. Tell all trades on site when the truck is due and where it will unload.
2. Guide the truck into position	Backing truck striking a worker or pinning someone against a fixed object	High	Assign one spotter only; the spotter stays in the driver's mirror view and never walks behind the moving truck. Agree on hand signals with the driver before backing; if the driver loses sight of the spotter, the driver stops. Confirm the truck's backup alarm works; wear a high-visibility vest.
2. Guide the truck into position	Public traffic when the truck stages on or next to the street	High	Set cones and signs to warn drivers; use a trained flagger if the truck blocks a lane. Keep the crew on the curb side of the truck, never on the traffic side.
3. Prepare the load: inspect, remove straps and tarps	Load shifted in transit and falls when straps are released	High	Walk around the trailer and look for leaning or broken bundles before releasing any strap. Release straps from the side away from the load; never stand in the fall path.
3. Prepare the load: inspect, remove straps and tarps	Fall from the flatbed deck while removing tarps or straps	Medium	Pull tarps and straps from the ground whenever possible. If you must climb up, use the truck's steps or a ladder with three points of contact; do not jump down.
4. Unload with forklift or telehandler	Worker struck or crushed by the forklift or a falling load	High	Only a trained, authorized operator runs the forklift; do a pre-use inspection of brakes, horn, forks, and tires. Keep everyone out of the swing and travel path; nobody stands under raised forks or a raised load. Travel with the load low and tilted back; no riders on the forks or the machine.
4. Unload with forklift or telehandler	Forklift tip-over from overloading, high load, or turning on a slope	High	Stay within the load chart for the boom extension being used. Drive straight up and down slopes, not across; operator wears the seat belt.
5. Hand unload loose materials	Back strain from lifting drywall sheets, block, bags, or long lumber	Medium	Use the forklift, a drywall cart, or a dolly instead of carrying when possible. Two-person carry for full drywall sheets and anything over 50 lb; lift with your legs and keep the load close.
5. Hand unload loose materials	Cuts from steel banding and pinched fingers between materials	Medium	Cut bands with proper band cutters, standing to the side; the band can spring back. Coil cut banding right away and put it in the dumpster. Wear cut-resistant work gloves when handling bands and rough lumber.
6. Stack and store materials	Stacks collapsing or materials blowing off in wind	Medium	Stack on level dunnage, blocked and limited in height so the pile is stable. Tie down or weight sheet goods like plywood and foam board.
6. Stack and store materials	Stored materials blocking exits, walkways, or fire access	Low	Keep walkways, stairways, and hydrants clear; store away from floor openings and slab edges.
7. Release the truck and clean up	Tripping over dunnage, banding, wrap, and debris	Low	Pick up all banding, wrap, and broken pallets before leaving the area.
7. Release the truck and clean up	Truck pulling out with workers nearby	Medium	Use the spotter again for the truck to leave; remove barricades only after the truck is gone. Park the forklift with forks on the ground, brake set, and key removed.

Required PPE

Hard hat — Wear at all times in the unloading area.
High-visibility vest — Class 2 or higher; required for spotters and anyone near the truck or street.
Safety glasses — ANSI Z87.1 at all times, especially when cutting bands.
Work gloves — Cut-resistant leather or coated gloves for banding, lumber, and block.
Safety-toe boots — Steel or composite toe for dropped materials and forklift traffic.

Training

Forklift or telehandler operator training and written employer authorization for the specific machine.
Spotter training on agreed hand signals and backing-vehicle safety.
Flagger training if the delivery blocks a public traffic lane.
Safe lifting and material stacking briefing for the whole crew.

Emergency

If someone is struck or pinned by the truck, forklift, or a falling load: yell STOP, shut down all equipment, and call 911. Give the site address and the closest gate. Do not move the person unless they are in more danger; only move the load if it is crushing them and it can be done safely. Give first aid and send someone to meet the ambulance.

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General information, not legal advice. Templates and examples should be reviewed by a competent person before use. HardHat Binder is not affiliated with or endorsed by OSHA.