1. Material Handling and Storage
November 8, 2002 1

2. Objectives Recognize material handling hazards
Manual material handling
Industrial trucks
Conveyors
(Cranes will be addressed later)
Become familiar with basic methods of controlling these hazards 2

3. Hazards 600,000 overexertion injuries, 27% of all lost- workday cases
370,000 injuries caused by lifting
93,000 pushing/pulling
Strains and sprains from loads that are too heavy or large
Fractures , cuts and bruises from improper storage 3

4. General Work Practices
Get help for large loads
When blocking a raised load:
Keep hands from underneath before releasing load
Use blocking materials of adequate strength
Look for cracks, splintered pieces, rounded corners, etc.
Attach handles or holder to loads
PPE
Gloves, eye protection, safety boots (for heavy loads) 4

5. Mechanical Material Handling
Do not overload equipment
Refer to equipment rated capacity
General forklift procedures
Center load on forks and close to mast
Do not overload
Do not add extra weight to counterbalance
Travel with load at lowest position 5

6. Materials Storage Stacked loads correctly piled and cross-tiered
Stored material must not create hazard
Areas free of accumulated material
In buildings, no stored materials within 6 feet of hoist ways or 10 feet of exterior building walls
Store non-compatible material separately 6

7. Materials Storage
Employees in silos, hopers or tanks equipped with lifeline and safety harness
Bound material stacked, on racks, blocked or interlocked to keep it from sliding, falling or collapsing
Don't exceed load capacity for the structure
Post load limits
Stacking height
Mark walls or posts to indicate maximum height 7

8. Lumber and Brick Storage
Maximum stack height
16 feet (manual handling)
20 feet (forklift)
Remove nails from used lumber
Stacks stable and self-supporting
Bricks
Maximum 7 feet high
Above 4 feet, taper stacks 2 inches per foot 8

9. Block and Bag Storage Masonry blocks Bags and bundles
Above 6 feet , taper stacks 2 block per tier
Bags and bundles
Stack in interlocking rows
Step back at least every 10 layers
Remove from top of stack first
Keep baled paper and rags at least 10 inches from walls, ceilings, or sprinkler heads 9

10. Box and Drum Storage Boxed materials Drums, barrels, kegs
Hold in place using cross-ties, or shrink plastic
Drums, barrels, kegs
Stacked symmetrically
If stored on side, block bottom tiers to prevent rolling
If stacked on ends, use planks, pallets, etc. between each tier
Block cylindrical material (bars, poles, etc.)
Use bins or shelves for materials that cannot be stacked 10

11. Manual Lifting Avoid manual lifting when possible
Limit vertical lifting (knuckle-to-shoulder height)
Be in good physical shape
Plan the lifting operation
Get a good grip
Keep the load close to the body
Do not twist or bend sideways
Get help for large or heavy loads 11

12. Manual Lifting Recommendations for specific tasks
Grasp opposite corners on boxes, cartons & sacks
Use mechanical assistance for barrels and drums
Wear leather gloves when handling sheet metal
Plate glass
Carry with bottom edge in gloved palm, other hand on top edge
Never carry plate glass under the arm
Use a team for long objects 12

13. 2-wheeled hand trucks Tip load forward and slip tongue underneath
Keep center of gravity low
Let the truck carry the load - don't lean it too far
Walk forward - keep load height low enough to see
Secure bulky items to the truck
Use specialty equipment
Drums
Appliances 13

14. Conveyers Hazards Nip points (rollers, near frame)
Material may fall from conveyor
Persons may be caught in the conveyor
Controls
Emergency stop button or pull cord
Must be reset after use
Never ride on conveyor
Guards over aisles or
work areas
Screw conveyors covered, interlocked 14

15. Powered Industrial Trucks (Forklifts)
100 annual deaths, 95,000 injured
Cause of fatality:
42% crushed by vehicle tipping
25% crushed between vehicle and surface
11% crushed between two vehicles
10% struck or run over by vehicle
8% struck by falling material
4% fall from platform or forks
2% accidental activation of controls 15

16. Forklift Fatalities,
120
114 95 89 86
1992
1993
1994
1995
1996

17. Industries Where Powered Industrial Truck Accidents Occurred

18. Powered Industrial Trucks (Forklifts)
ANSI Approved
Identifying label
Owner modification
Only with mfg. Approval
New label required
Front-end attachments
Should have new label 18

19. Classes of forklifts
Class 1CElectric Motor, Sit-down Rider, Counter-Balanced Trucks (Solid and Pneumatic Tires)
Class 2CElectric Motor Narrow Aisle Trucks (Solid Tires)
Class 3CElectric Motor Hand Trucks or Hand/Rider Trucks (Solid Tires)
Class 4CInternal Combustion Engine Trucks (Solid Tires)
class 5CInternal Combustion Engine Trucks (Pneumatic Tires)
Class 6CElectric and Internal Combustion Engine Tractors (Solid and Pneumatic Tires)
Class 7CRough Terrain Forklift Trucks (Pneumatic Tires) 19

20. Trucks for Hazardous Locations
D--Diesel , minimum safeguards against fire hazards
DS--Diesel-powered with additional safeguards
DY--Diesel-powered, no electrical equipment
E--Electrically powered, minimum safeguards
ES--additional safeguards
EE--completely enclosed electrical equipment
EX--for atmospheres with flammable vapors or dusts
G--Gasoline-powered with minimum safeguards
GS--additional safeguards
LP--similar to the G, but liquefied petroleum gas fuel
LPS-- additional safeguards 20

21. Hazardous Examples
OSHA specifies which type of truck is acceptable for hazardous locations:
Examples
Flammable gases or liquids handled, but contained
DS, EE, EX only
Suspended combustible dusts
EX only 21

22. Powered Industrial Truck Safety
Fuel - liquid or gas
Handled in accord with NFPA standards
Batteries
Specially designated battery charging area
Spill control, fire protection, ventilation, etc.
Mechanical battery handling equipment
No smoking
Trucks and Railroad cars
Brakes set, wheel chocks (trucks)
Wheel stops (railroad cars) 22

23. Powered Industrial Truck Operation
Never drive toward a person standing in front of a fixed object
No person under any elevated portion
Do not place arms or legs in the mast or outside the truck
Unattended trucks must be shut off with lowered load
Set brakes and wheel blocks when loading vehicles (trucks, rail cars, etc.)
Maintain headroom under lights, sprinkler systems, etc.
Use overhead guard to protect from falling objects
Use load backrest when necessary 23

24. Powered Industrial Truck Operation
Cross railroad tacks on the diagonal
Sound horn at blind intersections
Back down ramps, drive forward up ramps
Operate at safe speed, avoid quick turns
Personnel on loading platform must have an emergency shut- off for truck power
Secure dockboards and bridge plates
Loads must be stable and safely arranged
Disconnect battery before repairing electrical system
Replacement parts must be equivalent to original 24

25. Forklift Training New OSHA standard, 1919.178(l) OSHA specified topics
Effective March 1, training required by Dec. 1, 1999
OSHA specified topics
Stability, operation, etc.
Formal training program
Initial training before use
Refresher training (based on observations)
Employer must certify 25

26. Forklift Training Stability Triangle: Vehicle Center of
Gravity (Unloaded) B A
Center of Gravity
of Vehicle and
Maximum Load
(Theoretical) C
Notes:
1. When the vehicle is loaded, the combined center of gravity (CG) shifts toward line B-C. Theoretically the maximum load will result in the CG at the line B-C. In actual practice, the combined CG should never be at line B-C.
2. The addition of additional counterweight will cause the truck CG to shift toward point A and result in a truck that is less stable laterally. 26

27. Forklift Training Stability Triangle Load CG Load CG Vertical
Line
(Line of Action)
Combined CG
Combined CG
Vertical
Stability
Line
(Line of Action)
Truck CG
Truck CG
This vehicle is unstable and
will continue to tip over
The vehicle is stable 27