Safer Cutting and Handling of Steel Strapping Under Tension

Steel strapping is used where packages are heavy, rigid or difficult to secure with lighter packaging materials. It can provide high tension and strong load containment, but those same characteristics mean it needs to be handled carefully.

Cyklop steel strap is intended for heavy or sharp-edged packages and is available for manual and machine applications. Depending on the product and application, steel strapping can be subjected to very high tension.

The risk does not end once the strap has been applied. Workers may also be exposed when tensioning the strap, moving a strapped load, receiving a delivery or cutting the strap during unpacking.

Understand the energy stored in the strap

A tensioned steel strap contains stored energy. When it is cut or released, that energy can cause the strap to recoil or move suddenly.

The load itself may also move. Strapping may be holding sheets, lengths of timber, metal products or other materials in position. Removing it without first considering the stability of the load can allow products to shift, spread or fall.

This is why cutting strapping should be treated as a planned part of the handling process rather than a routine final step.

Check the load before applying tension

Before strapping begins, confirm that the package is stable and capable of withstanding the intended tension.

Check whether:

• The products are aligned and adequately supported
• Sharp edges require suitable protection
• The strap is appropriate for the load
• The tool matches the strap width and specification
• Workers can maintain stable footing
• Other people can be kept clear
• The strap path is free from obstructions

The correct amount of tension depends on the package and the complete packaging system. Excessive force can damage products, deform cartons or place unnecessary stress on edges and joints. Insufficient tension may allow the package to loosen during handling.

Workers should follow the tool and strapping manufacturer’s instructions rather than relying on assumptions or improvised settings.

Keep clear of the likely movement path

During tensioning, hands and other parts of the body should be kept clear of pinch points, cutting components and the path the strap may follow if something fails.

Workers should avoid positioning their face or body directly over a tensioned strap. They should also have enough space to use the tool without overreaching, losing balance or placing excessive force through an awkward posture.

WorkSafe Victoria has identified manual steel strapping as a task that can involve wrist bending, reaching, force and repetitive ratcheting. Suggested controls include powered tools, suspended equipment and automatic strapping where appropriate.

Battery-powered or pneumatic tools may reduce some manual force, but they still require correct setup, maintenance and operator training. Powered equipment does not remove the need to assess the load or keep clear of potential movement.

Stabilise the load before cutting

Before releasing a strap, inspect the package from a safe position.

Look for leaning products, damaged pallets, bowed materials, broken packaging or gaps that suggest the load has moved. Where the strap is helping to keep an unstable product upright, another restraint or support may be needed before it is cut.

The consequences of overlooking this step can be severe. In one Victorian incident, workers cut PET strapping holding porcelain sheets to wooden A-frames. The sheets toppled and seriously injured a worker. The court heard that a retaining strap should have remained in place while the transport strapping was removed.

Although that case involved PET rather than steel strap, the lesson applies more broadly. A strap should not be removed until the potential movement of the load has been understood and controlled.

Use a purpose-designed cutting tool

Open-blade knives are not an appropriate default tool for every packaging task. Workplace Health and Safety Queensland recommends suitable safety cutters for opening packaging and cutting strapping rather than exposed blades.

The selected cutter should suit the strap and allow the worker to maintain control without placing their hands near the cutting point.

The exact release method should be based on the load, strap position and workplace procedure. In general, the worker should remain outside the likely recoil or collapse zone and ensure other people are clear before cutting begins.

Damaged or partially broken strapping requires particular caution because its remaining tension may be difficult to judge.

Control the offcuts

Once steel strap is removed, it can remain hazardous. Cut ends may be sharp, and long lengths can spring outward, create trip hazards or become caught in equipment.

Provide a designated container close to the unpacking area so workers do not leave loose offcuts on the floor. The collection method should prevent sharp ends from projecting into walkways or creating risks for the person emptying the container.

Gloves, eye protection and other personal protective equipment may form part of the control measures, but PPE should support rather than replace safer tools, load support and work procedures.

Match the equipment to the application

Cyklop Australia offers steel strapping tools for different strap widths and applications, including manual, battery-driven and pneumatic options. The tool should be selected as part of the complete system, taking into account the load, strap, joint, operating frequency and working environment.

A safe strapping process considers what happens before, during and after tensioning. It also accounts for the person who will eventually receive the package and cut it open.

This article provides general information only. Businesses should conduct their own risk assessment and follow applicable safety requirements and manufacturer instructions.