Tanker Truck & Railcar Loading

Loading racks and rail spurs handle gasoline, chemicals, oil, food liquids and gases. A static spark, an overfilled tank, a leaking hose or a moving railcar can cause fires, explosions, toxic releases and fatal falls. Written procedures, interlocks, grounding and trained people make loading safe.

• Terminal & Plant Operators
• Tank Truck Drivers
• Rail Crews
• Maintenance Techs
• Supervisors

Main hazards

• Static electricity: flowing liquid builds static charge. A spark can ignite flammable vapors. See Static, Bonding & Grounding.
• Overfilling that causes spills, fires and exposures.
• Vapor release: flammable and toxic vapors from top loading and venting. See Flammable Liquids.
• Falls from tank tops, ladders, catwalks and railcar platforms. See Truck & Trailer Falls.
• Chemical exposure and splashes from hoses and fittings. See Hazard Communication.
• Moving vehicles: trucks pulling away with hoses attached, and railcars being moved while workers are on or between them. See Rail Yards & Railcar Movers.
• Pressure releases, hot products and cryogenic liquids. See Cryogenic Liquids.
• Confined space hazards inside tanks.

Tank truck loading

• Follow the site's written loading procedure and driver orientation. Check shipping papers and verify the product and compartment.
• Set the brake, chock the wheels, shut off the engine and use wheel-chock or vehicle restraint systems or interlocks that prevent drive-away.
• Bond and ground the truck to the rack before connecting hoses. Use interlocks that prevent loading unless the ground connection is verified.
• Inspect hoses and couplings for damage and proper connection. Make dry-break couplings fully engaged.
• Use vapor recovery systems where required, and bottom loading where possible to reduce static and vapors.
• Prevent overfill with level detectors, shutoffs and metered loading. Never leave loading unattended. Stay with the load and be ready to stop it.
• If top loading, use fall protection such as gantry rails or lanyards, and approach the hatch safely. Open hatches slowly to release pressure.
• Wear FR clothing, safety glasses, gloves and a respirator as the product requires. Avoid synthetic clothing in flammable atmospheres. See Flame-Resistant Clothing.
• Use spill containment, emergency shutoff buttons and fire protection, and know the emergency plan. See Spill Response.

Railcar loading and unloading

• Protect the track with blue signal (blue flag) protection: a blue flag or light at the end of the track and derails or locked switches so no one can move cars while workers are on or between them. Follow the railroad's and your site's rules.
• Set handbrakes and chock railcar wheels. Don't couple or move cars without authorization.
• Connect bonding and grounding to the rail and tank. Use walkways with rails, and fall protection on tank tops.
• Use the correct unloading connections and procedures for the product, and verify valves with checklists. Stay clear of pressure relief devices.
• Release pressure and vent safely before opening hatches. Inspect the car for leaks, damaged fittings and placards.
• Know the emergency response plan and hazardous materials rules. See HAZWOPER and Hazmat Placards.

Loading checklist

• The vehicle is braked, chocked or restrained and bonded and grounded before loading
• Hoses, couplings and valves are inspected and connected correctly
• Overfill protection works and someone attends the load
• Fall protection is used on tank tops; railcars have blue flag protection
• Emergency shutoffs, spill kits and the response plan are ready

Last updated: October 8, 2026