Product Overview

Summary: This Safe Operating Procedure sets out a clear, step-by-step process for safely inspecting intermodal containers before loading, during handling and on arrival. It helps Australian businesses identify structural defects, contamination, load‑shift risks and biosecurity issues early, protecting workers, freight and equipment while supporting WHS and regulatory compliance.

Intermodal containers move through ports, rail terminals, depots and distribution centres every day, often passing between multiple operators and jurisdictions. Damaged, improperly ventilated or contaminated containers present serious risks, including crush injuries, falls, hazardous atmospheres, load collapse and breaches of biosecurity or dangerous goods requirements. This Inspecting Intermodal Containers SOP provides a robust, repeatable inspection process that can be applied at each handover point, from arrival in the yard through to loading, transport and unloading.

The procedure guides workers through external and internal inspection steps, including structural integrity checks, door operation, locking gear, flooring, roof and wall condition, signage and placarding, odour and atmosphere assessment, and verification of cleanliness and suitability for the intended cargo. It also addresses how to identify and respond to suspected dangerous goods, fumigation, pests, leaks and incompatible residues. By implementing this SOP, businesses can reduce incident rates, minimise damage and demurrage costs, and demonstrate due diligence under Australian WHS and chain of responsibility laws across road, rail and port operations.

Key Benefits

• Ensure consistent, documented container inspections at every handover point across your supply chain.
• Reduce the risk of worker injury from structural failure, load shift, hazardous atmospheres and falling doors.
• Support compliance with WHS, dangerous goods, biosecurity and chain of responsibility obligations.
• Minimise costly delays, damaged freight, equipment downtime and insurance claims arising from undetected defects.
• Improve training quality by providing clear visual and procedural guidance for new and existing staff.

Who is this for?

• Warehouse Supervisors
• Yard Supervisors
• Logistics and Operations Managers
• Stevedores and Wharf Supervisors
• Container Forklift and Reach Stacker Operators
• Truck Drivers and Owner Drivers
• Freight Handlers
• Customs and Biosecurity Compliance Officers
• WHS Managers and Safety Advisors
• Supply Chain and Transport Managers

Hazards Addressed

• Crush injuries from falling or misaligned container doors
• Structural collapse due to severe damage, corrosion or compromised corner posts
• Falls from height when accessing container roofs or elevated containers
• Exposure to hazardous atmospheres, including fumigants, off‑gassing cargo and oxygen deficiency
• Manual handling injuries from attempting to force jammed doors or locking gear
• Struck-by incidents from unstable or shifted loads when doors are opened
• Slips, trips and falls due to damaged flooring, debris or spills inside containers
• Exposure to hazardous substances from leaks, residues or incompatible previous cargoes
• Biosecurity risks from soil, plant material, pests or contaminated residues
• Vehicle and mobile plant interaction risks in container yards and terminals

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Intermodal Containers
• 3.0 Roles and Responsibilities
• 4.0 Required Competencies and Training
• 5.0 Required PPE and Inspection Tools
• 6.0 Pre-Inspection Planning and Site Safety
• 7.0 External Container Inspection Procedure
• 8.0 Door, Locking Gear and Hinge Inspection
• 9.0 Internal Container Inspection Procedure
• 10.0 Assessment of Structural Integrity (Roof, Walls, Floor, Corner Posts)
• 11.0 Hazardous Atmosphere and Fumigation Checks
• 12.0 Cleanliness, Contamination and Biosecurity Inspection
• 13.0 Dealing with Suspected Dangerous Goods and Leaks
• 14.0 Criteria for Rejecting, Tagging Out or Quarantining Containers
• 15.0 Documentation, Labelling and Photographic Evidence
• 16.0 Communication and Escalation Requirements
• 17.0 Interaction with Mobile Plant and Traffic Management Controls
• 18.0 Emergency Procedures (Structural Failure, Exposure, Spills)
• 19.0 Review, Audit and Continuous Improvement
• 20.0 References and Related Documents

Legislation & References

• Work Health and Safety Act 2011 (Cth) and mirror state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) – Hazardous chemicals, plant and manual handling provisions
• Heavy Vehicle National Law (HVNL) – Chain of Responsibility (where applicable)
• AS 3711.1: Freight containers – Handling and general requirements
• AS/NZS 4801: Occupational health and safety management systems (superseded but still widely referenced)
• AS 2865: Confined spaces (for entry into enclosed or potentially hazardous containers)
• Australian Code for the Transport of Dangerous Goods by Road & Rail (ADG Code)
• Safe Work Australia – Managing risks of plant in the workplace Code of Practice
• Safe Work Australia – How to manage work health and safety risks Code of Practice
• Department of Agriculture, Fisheries and Forestry (DAFF) biosecurity requirements and Import Conditions (BICON), as applicable