19 Material Handling Material handling is a common task in each sector of industry. It is very common in the industry sectors that store, receive, and sell goods and materials such as the retail, wholesale, and warehousing sectors of the service industry. The handling of all types of materials may manifest itself in the individual worker’s effort to lift or move materials using large industrial cranes. No matter which procedure is used, there are hazards and safety concerns that need to be addressed. Almost every industrial sector has to address material handling issues, especially workplaces moving materials in and products out on a set schedule. Yet improper handling and storage of materials can result in grave injuries. Materials may be anything from boxes, parts , equipment, steel beams, aircraft engines, or manufactured homes. The efficient handling and storage of materials is vital to the function of industry. Material handling operations provide for the continuous flow of raw materials, parts, and products throughout the workplace and assure that materials and products are there when they are needed. Yet the improper handling and storage of materials can cause serious injuries. In most industry sectors, around 20%–25% of all injuries are caused by mat erial handling. The proper and safe handling of a wide variety of materials must be do ne in compliance with existing Occupational Safety and Health Administration (OSHA) regulatory guidelines for the equipment used, the methods or procedures followed, and the appropriate storage of each type of material. The one constant in the goods and materials sectors is the lifting and handling of merchandise of all types. ß 2008 by Taylor & Francis Group, LLC. The guidelines provided in this chapter should help prevent some of the material handling accidents that are occurring in the goods and material sectors. 19.1 HAZARDS INVOLVED Injuries faced by those performing material handling tasks may be something as simple as overexertion, which results in sprains or strains, to simple cuts and lacerations from sharp edges, or contact with moving parts on equipment. The pinch (nip) points or shear weight of items being handled can result in bruises, contusions, crushing, fractures, and amputations. The larger the objects, the larger the equipment being used, and the faster the movement of materials, the greater the risk for multiple injuries, suffocation, or, worst of all, death (Figure 19.1). Many of the materials being handled by workers include hazardous chemicals and have the potential for causing injuries and illnesses. Chemicals can cause fires or explosion hazards and can result in burns or concussion injuries. Others may present the potential for contact, ingestion, or inhalation exposures, which may cause allergic reactions or toxic (poisonous) effects in workers, when such materials are mishandled and=or spilled. It certainly seems safe to say that all of these scenarios have transpired at one time or another to workers hand ling hazardous chemicals. Certainly, if some materials are too heavy and when lifting becomes repetitious, the potential for overexertion will likely result in sprains and strains. But, materials that are improperly stored or handled have the potential to shift due to their weight, shape, or potential to flow. For example, sand being moved and stored at an unusual FIGURE 19.1 Handling goods and materials is the primary hazard faced by workers. ß 2008 by Taylor & Francis Group, LLC. angle of repose may engulf a worker. This is particularly a problem around stock- piles, surge bins, or excavations. When material shifts, it may physically strike a worker, p inning him=her between a stationary object and the moving materials. When using the wide variety of equipment available to move or handle the different types of materials that exist in the workplace, the unevenness, unsecured loads, and extreme weight of the loads being lifted or moved can cause equipment to malfunction, collapse, or, at least, function erratically. The load can potentially fall and strike a worker, swing into a worker, be caught under a piece of equipment, or under a load, which cannot be controlled. This is why it is important to regularly inspect and maintain equipment used for handling material. If a sling (wire rope, steel alloy chain, or webb ed sling) fails, a crane boom collapses, or the brakes fail on a forkl ift or other vehicle, the end results can be disastrous. The use of equipment to handle materials is controlled by preestablished lifting or load limits and restrictions on the supporting capacity of storage (shelving) units which can never be exceeded if safety is a primary focus. It must be ensured that the appropriate equipment is used for the job, and that it is proper ly used by the operator. If an operator inadvertently contacts an electrical conductor, for example, electrocu- tion is a real possibility. Workers do not expect to be working under a load, have a load fall on them from above, or to be run over by a piece of material-handling equipment. These hazards are preventable using fundamental safety precautions. The last hazard is derived from the myriad of chemicals handled or stored within the workplace. Not only do they present the potential to cause physical harm (as noted earlier when chemical containers shift, roll, or strike a worker injuring or killing that worker), they also pose another type of hazard. They can potentially be toxic (poisonous) or cause burns if mishandled, spilled, or not properly controlled. Some chemicals may also creat e an explosion or fire. As can be seen, the movement, stacking, and storage of materials pose many hazards within the workplace. The philosophical approach to these hazards must be that they are identifiable, preventable, and the accidents, that result in injuries, illnesses, and deaths from improper material handling, can significantly be reduced. 19.2 SAFE HANDLING The efficient handling and storing of materials are vital to industries. In addition to raw materials, these operations provide a continuous flow of parts and assemblies through the workplace and ensure that materials are available when needed. Unfortunately, the improper handling and storing of materials often result in serious injuries. In addition to training and education, applying general safety principles—such as proper work practices, equipment, and controls—can help reduce workplace accidents involving the moving, handling, and storing of materials. Whether moving materials manually or mechanically, employees should know and understand the potential haz- ards associated with the task at hand and how to control their workplaces to minimize the danger. ß 2008 by Taylor & Francis Group, LLC. Because numerous injuries can result from improperly handling and storing mater- ials, workers should also be aware of accidents that may result from the unsafe or improper handling of equipment as well as from improper work practices. In addition, workers should be able to recognize the methods for eliminating or at least minimizing the occurrence of such accidents. Employers and employees should examine their workplaces to detect any unsafe or unhealthful conditions, practices, or equipment and take corrective action. Workers frequently cite the weight and bulkiness of objects that they lift as major contributing factors to their injuries. In 1999, for example, more than 420,000 work- place accidents resulted in back injuries. Bending, followed by twisting and turning, were the more commonly cited movements that caused back injuries (Figure 19.2). Other hazards include falling objects, improperly stacked materials, and various types of equipment. Employees should be made aware of potential injuries when manually moving materials, including the following: . Strains and sprains from lifting loads improperly or from carrying loads that are either too large or too heavy . Fractures and bruises caused by being struck by materials or by being caught in pinch points . Cuts and bruises caused by falling materials that have been improperly stored or by incorrectly cutting ties or other securing devices 19.2.1 MANUAL HANDLING SAFETY When moving materials manually, workers should attach handles or holders to loads. In addition, workers should always wear appropriate personal protective equipment FIGURE 19.2 Material handling tasks result in strain being placed on the back. ß 2008 by Taylor & Francis Group, LLC. and use proper lifting techniques. To prevent injury from oversize loads, workers should seek help when the following conditions exist: . When a load is so bulky that employees cannot properly grasp or lift it . When employees cannot see around or over a load (Figure 19.3) . When employees cannot safely handle a load Using the following personal protective equipment prevents needless injuries when manually moving materials: . Hand and forearm protection, such as gloves, for loads with sharp or rough edges . Eye protection . Steel-toed safety shoes or boots . Metal, fiber, or plastic metatarsal guards to protect the instep area from impact or compression Employees should use blocking materials to manage loads safely. Workers should also be cautious when placing blocks under a raised load to ensure that the load is not released before removing their hands from under the load. Blocking materials should be large and strong enough to support the load safely. In addition to materials with cracks, workers should not use materials with rounded corners, splintered pieces, or dry rot for blocking. FIGURE 19.3 The inability to see around a load creates a hazard. ß 2008 by Taylor & Francis Group, LLC. 19.2.2 MECHANICAL HANDLING EQUIPMENT Using mechanical equipment to move and store materials increases the potential for employee injuries. Workers must be aware of both manual handling safety concerns and safe equipment operating techniques. Employees should avoid over- loading equipment when moving materials mechanically by choosing the equipment based on the weight, size, and shape of the material being moved. All materials- handling equipment have rated capacities that determine the maximum weight the equipment can safely handle and the conditions under which it can handle that weight. Employers must ensure that the equipment’s rated capacity is displayed on each piece of equipment and is not exceeded except for load testing (Figure 19.4). Although workers may be knowledgeable about powered equipment, they should take precautions when stacking and storing material. When lifting items with a powered industrial truck (forklift), workers must do the following: . Center the load on the forks as close to the mast as possible to minimize the potential for the truck tipping or the load from falling. . Avoid overloading a lift truck because it impairs control and causes tipping over. . Do not place extra weight on the rear of a counterbalanced forklift to allow an overload. . Adjust the load to the lowest position when traveling. . Follow the forklift manuf acturer’s operational requirements. . Pile and cross-tier all stacked loads correctly when possible. Chapter 20 provides more detailed information on the safe use of forklifts. FIGURE 19.4 Care must be taken by operator to not overload stockpickers. ß 2008 by Taylor & Francis Group, LLC. 19.2.3 SAFE STORAGE OF MATERIALS Stored material s must not create a hazard for employees. Emplo yers should inform workers of such factors as the material s’ height and weight, accessibilit y of the stored materials, and the condit ion of the contai ners wher e the mat erials are being stored when stack ing and piling materials. To prevent creat ing hazards when storing materials, employers must do the follow ing: . Keep storage areas free from accum ulated materials that cau se tripping , fires, or ex plosions, or that may contribut e to the harbor ing of rats and other pests. . Place stor ed mat erials inside buildings that a re under const ruction and a t least 6 ft from hoist ways, or inside fl oor o penings and at least 10 ft away from exterior walls. . Separate noncom pati ble material . . Equip employees who wor k on stored grain in silos, h oppers, or tanks, wi th lifelines and safety harnes ses. . In addit ion, wor kers shoul d consi der placing bound material on racks, and secure it by stacking, blocki ng, or interlock ing to prevent it from sliding, falling, or collapsin g. 19.2.4 SAFE STACKING OF MATERIALS Stacking mat erials can be dan gerous if wor kers do not foll ow safet y guidelines . Falling materials and collapsin g loads can crush or pin wor kers, causi ng injuries or death. To help prevent inju ries when stack ing mate rials, workers must do the following: . Stack lum ber no more than 16 ft high if it is hand led manua lly, and no more than 20 ft if using a forklift. . Remove all nails from used lumber before stack ing. . Stack and level lumber on solidly supported bracing. . Ensure that stacks are stable and self-suppo rting. . Do not store pipes and bars in racks that face main aisles to avoid creating a hazard to passersby when removing supplies. . Stack bags and bundles in interlocking rows to keep them secure (Figure 19.5 ). . Stack bagged material by stepping back the layers and cross-keying the bags at least every 10 layers (to remove bags from the stack, start from the top row first) . During materials stacking activities, workers must also do the following: . Store baled paper and rags inside a building no closer than 18 in. to the walls, partitions, or sprinkler heads. . Band boxed materials or secure them with cross-ties or shrink plastic fiber. . Stack drums, barrels, and kegs symmetrically. ß 2008 by Taylor & Francis Group, LLC. . Block the bottom tiers of drums, barrels, and kegs to keep them from rolling if stored on their sides. . Place planks, sheets of plywood dunnage, or pallets between each tier of drums, barrels, and kegs to make a firm, flat, stacking surface when stacking on end. . Check the bottom tier of drums, barrels, and kegs on each side to prevent shifting in either direction when stacking two or more tiers high. . Stack and block poles as well as structural steel, bar stock, and other cylindrical materials to prevent spreading or tilting unless they are in racks. In addition, the following recommendations should be followed to make this easier for workers: . Paint walls or posts with stripes to indicate maximum stacking heights for quick reference. . Observe height limitations when stacking materials. . Consider the need for availability of the material. . Stack loose brick s no more than 7 ft in height. (When these stacks reach a height of 4 ft, taper them back 2 in. for every foot of height above the 4 ft level. When masonry blocks are stacked higher than 6 ft, taper the stacks back one-half block for each tier above the 6 ft level.) 19.2.5 HOUSEKEEPING The importance of preventing the type of accide nts that can be caused by poor housekeeping practices is an integral part of good material handling practices. FIGURE 19.5 Proper stacking of bags. ß 2008 by Taylor & Francis Group, LLC. The typical accidents that frequently result from inadequate housekeeping are as follows: . Tripping over loose objects on floors, stairs, and platforms . Slipping on wet, greasy, or dirty floors . Bumping against projecting or misplaced materials . Puncturing or scratching hands or other parts of the body on protruding nails, hooks, or rods . Injuries from falling objects Employees tend to take housekeeping for granted and may sometimes be careless. Housekeeping is the one area of accident prevention in which all employees (blue- collar, white-collar, administrative, etc.) must share the responsibility. The emphasis on housekeeping should be at . Work areas: Avoid unnecessary clutter (Figure 19.6). . Machines and equipment: Avoid crowding; provide racks or containers for tools, jigs, and fixtures. . Aisles: Keep free of material, finished parts, and scrap. . Floors: Make sure they are vacuumed and scrubbed regularly; spills should be cleaned up immediately. . Walls and ceilings: See to it that they are scrubbed and painted when necessary; clothing and supplies should be hung on racks; clutter should be confined to a bulletin board. FIGURE 19.6 Poor housekeeping is a primary cause of accidents. ß 2008 by Taylor & Francis Group, LLC. . Storage facilities: Follow appropriate storage procedures. . Employee facilities: Keep personal belongings in lockers; washrooms should be cleaned regularly. Housekeeping inspections should occur regularly. It should be easy to recognize the benefits of good houseke eping since it . Reduces operating costs: Once a housekeeping system has been estab- lished, less time and effort are required to keep the work area clean. . Increases production: Delays and interference from excess materials, loose tools, etc., are avoide d. . Improves production control: Material and parts do not get lost or mixed up. . Conserves materials and parts: Unused materials are easily and quickly removed to the proper place. . Saves production time: There is no need to search for tools, parts, etc. . Lowers accident rates since open aisles permit faster traffic with fewer collisions; clean floors mean less slipping, tripping, and falling; reduction of object hazards results in fewer injuries. . Reduces fire hazards: Fires result from, or are spread by, poor housekeeping conditions. Some common sense tips for good housekeeping are as follows: . Give your immediate work area a good cleaning at the end of each day. Sweep up rubbish and put tools away. . Dispose of combustible rubbish in fire-resistant receptacles. . Dispose of oily rags in closed metal containers. Maintain regular disposal. . Clean oily deposits from walls, ceilings, exhaust ducts, and mechanical equipment periodically. . Remove combustible lint and dust from ledges, beams, and equipment as it accumulates. . Remove oily metal chips and rubbish to outside storage locations on schedule. . Keep aisles and passageways clear of stock and other obstr uctions at all times. . Do not block valves, hose stations, fire extinguishers, or fire exits. . Keep packing material in metal-lined bins with self-closing covers. . Follow the clean-out schedules for electric motors, switch enclosures, contacts, etc. . Keep solvents, thinners, etc., in approved safety containers . . Avoid drippings—clean up spills promptly. . Keep spray residues in covered containers and remove at the end of each day. . Limit flammable liquids, cement, paint, etc., to only one day’s supply at the working area. . Empty drip pans and replace absorbent compounds frequently. ß 2008 by Taylor & Francis Group, LLC. [...]... ammonia 191 0.109—Explosives and blasting agents 191 0.110—Storage and handling of liquefied petroleum gases Subpart J—General environmental controls 191 0.144 Safety color code for marking physical hazards 191 0.145—Specifications for accident prevention tags Subpart N—Material handling and storage 191 0.176—Handling materials general 191 0.178—Powered industrial trucks 191 0.179—Overhead and gantry crane 191 0.180—Crawler,... associated with materials handling and storing and must be accountable for employee training An ongoing safety and health management system can motivate employees to continue using necessary protective gear and observing proper job procedures Instituting such a program, along with providing the correct materials- handling equipment, can enhance worker safety and health in the area of materials handling and storing... storing 19. 5 MATERIAL HANDLING REGULATIONS Specific regulations, applicable to material handling within General Industry (29 CFR 191 0) Standards are as follows: Subpart H—Hazardous materials 191 0.101—Compressed gases 191 0.102—Acetylene 191 0.103—Hydrogen 191 0.104—Oxygen ß 2008 by Taylor & Francis Group, LLC 191 0.105—Nitrous oxide 191 0.106—Flammable and combustible liquids 191 0.107—Storage and handling... design, maintenance, and use of these trucks For more details on these requirements refer Chapter 20 19. 4 TRAINING AND EDUCATION OSHA recommends that employers establish a formal training program to teach workers how to recognize and avoid materials- handling hazards Instructors should ß 2008 by Taylor & Francis Group, LLC be well versed in safety engineering and materials handling and storing The training... locomotion, and truck cranes 191 0.181—Derricks 191 0.183—Helicopters 191 0.184—Slings Subpart Q—Welding, cutting, and brazing 191 0.253—Oxygen-fuel gas welding and cutting Although other 29 CFR 191 0 regulations are tangential, related to material handling, and apply to most workplaces, the previous list includes the ones most applicable to material handling 19. 6 SUMMARY Employers can reduce injuries resulting form... lifted and suspended Do not engage in shock loading Avoid sudden crane acceleration and deceleration when moving suspended loads 19. 3.4 FORKLIFTS Workers who handle and store materials often use fork trucks, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electrical motors or internal combustion engines Employers must make these workers aware of the safety. .. supply of lubricants in the work area 19. 3 MATERIAL-HANDLING EQUIPMENT Probably few facets of safety and health have such a wide variety of equipment with which to be concerned as material handling Some equipment are as simple as a handcart or dolly and some as complex as industrial robots Examples of nonpowered equipment are dollies, hand trucks, carts, dockboards, and ramps A mechanical advantage can... contribute to an accident and how to avoid the unexpected Safe postures for lifting and timing for smooth, easy lifting Aids such as stages, platforms, or steps, trestles, shoulder pads, handles, and wheels Body responses—warning signals—to be aware of when lifting To have an effective safety and health program covering materials handling and storing, managers must actively participate in its development... proper use and limitations of the equipment they operate In addition to powered industrial trucks, this includes knowing how to safely and effectively use equipment such as conveyors, cranes, and slings The following are some commonly used material-handling equipment 19. 3.1 CONVEYORS When using conveyors, workers may get their hands caught in nip points where the conveyor medium runs near the frame or over... reset before the conveyor can be restarted Ensure that appropriate personnel inspect the conveyor and clear the stoppage before restarting a conveyor that has stopped due to an overload Prohibit employees from riding on a materials- handling conveyor Provide guards where conveyors pass over work areas or aisles to keep employees from being struck by falling material (If the crossover is low enough for workers . stored or handled have the potential to shift due to their weight, shape, or potential to flow. For example, sand being moved and stored at an unusual FIGURE 19. 1 Handling goods and materials is. moving, handling, and storing of materials. Whether moving materials manually or mechanically, employees should know and understand the potential haz- ards associated with the task at hand and how. controls 191 0.144 Safety color code for marking physical hazards 191 0.145—Specifications for accident prevention tags Subpart N—Material handling and storage 191 0.176—Handling materials general 191 0.178—Powered