1. Material Handling INSTRUCTOR’S NOTES:
This presentation is designed to assist trainers conducting OSHA 10-hour General Industry outreach training for youth workers. Since youth workers are the target audience, this presentation may cover hazard identification, avoidance, and control rather than specific standards. No attempt has been made to treat the topic exhaustively. It is essential that trainers tailor their presentations to the needs and understanding of their audience.
This presentation is not a substitute for any of the provisions of the Occupational Safety and Health Act of 1970 or for any standards issued by the U.S. Department of Labor. Mention of trade names, commercial products, or organizations does not imply endorsement by the U.S. Department of Labor.

2. Introduction Handling and storing materials
include a wide variety of tasks like:
Hoisting tons of steel with a crane
Driving a truck loaded with concrete blocks
Carrying bags or materials manually
INSTRUCTOR’S NOTES:
Handling and storing materials involve diverse operations such as hoisting tons of steel with a crane; driving a truck loaded with concrete blocks; carrying bags or materials manually; and stacking palletized bricks or other materials such as drums, barrels, kegs, and lumber. The efficient handling and storing of materials are vital to industry. 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 costly injuries.

3. Material Handling and Storage
When handling and storing materials, you need to be
aware of hazards such as:
Falling objects
Improperly stacked or stored materials
Twisting and turning
Unsupported bending
These hazards can result in injuries including:
Strains and sprains
Fractures
Cuts and bruises
INSTRUCTOR’S NOTES:
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 workplace incidents resulted in back injuries.
Bending, followed by twisting and turning, were the more commonly cited movements that caused back injuries. Other hazards include falling objects, improperly stacked materials, and various types of equipment. Students should be aware of potential injuries that can occur 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, and
Cuts and bruises caused by falling materials that have been improperly stored or by incorrectly cutting ties or other securing devices.

4. General Requirements
OSHA’s general requirements for material handling cover the following topics:
Using mechanical equipment
Secure storage
Housekeeping
Clearance limits
Guardrails and covers
Rolling railroad cars
INSTRUCTOR’S NOTES:
Handling materials -- general
(a) Use of mechanical equipment. Where mechanical handling equipment is used, sufficient safe clearances shall be allowed for aisles, at loading docks, through doorways and wherever turns or passage must be made. Aisles and passageways shall be kept clear and in good repair, with no obstruction across or in aisles that could create a hazard. Permanent aisles and passageways shall be appropriately marked.
(b) Secure storage. Storage of material shall not create a hazard. Bags, containers, bundles, etc., stored in tiers shall be stacked, blocked, interlocked and limited in height so that they are stable and secure against sliding or collapse.
(c) Housekeeping. Storage areas shall be kept free from accumulation of materials that constitute hazards from tripping, fire, explosion, or pest harborage. Vegetation control will be exercised when necessary.
(d) [Reserved]
(e) Clearance limits. Clearance signs to warn of clearance limits shall be provided.
(f) Rolling railroad cars. Derail and/or bumper blocks shall be provided on spur railroad tracks where a rolling car could contact other cars being worked, enter a building, work or traffic area.
(g) Guarding. Covers and/or guardrails shall be provided to protect personnel from the hazards of open pits, tanks, vats, ditches, etc.

5. Manual Material Handling
When moving material manually, take the following precautions:
Get help when necessary
Use handles or holders
Wear the appropriate personal protective equipment (PPE)
gloves
steel-toed shoes or boots
eye protection
hard hat
Use proper lifting techniques
INSTRUCTOR’S NOTES:
When moving materials manually, workers should attach handles or holders to loads. In addition, workers should always wear appropriate personal protective equipment and use proper lifting techniques. To prevent injury from oversize loads, workers should seek help in the following situations:
When a load is so bulky that employees cannot properly grasp or lift it
When employees cannot see around or over a load
When employees cannot safely handle a load
Using the following personal protective equipment (PPE) helps prevent 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.

6. Material Handling Equipment
Using mechanical equipment such as a pallet jack or a powered industrial lift truck to move and store materials increases the potential for employee injuries.
Employees must be aware of manual handling safety concerns and safe equipment operating techniques.
Pallet Jack
INSTRUCTOR’S NOTES:
Powered Industrial
Lift Truck

7. Material Handling Equipment
When using material handling equipment, take the following precautions:
Ensure the load is centered and stable on the equipment
Adjust the load to the lowest position when traveling
Do not exceed maximum weight restrictions
INSTRUCTOR’S NOTES:
Employees should avoid overloading equipment when moving materials mechanically by letting the weight, size, and shape of the material being moved dictate the type of equipment used. All materials handling equipment has 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-rated capacity is displayed on each piece of equipment and is not exceeded except for load testing.
Pallet Jack

8. Powered Industrial Trucks
To help you work safely around powered industrial trucks, you must:
Be 18 years of age and receive proper training before operating a powered industrial truck
Never place arms and legs between the uprights of the mast
Handle only stable and safely arranged loads
When dockboards are in use, make sure they are securely in place.
INSTRUCTOR’S NOTES:
When operating or maintaining powered industrial trucks, workers must consider the following safety precautions:
Secure dockboards or bridge plates properly so they won’t move when equipment moves over them.
Handle only stable and safely arranged loads.
Exercise caution when handling tools.
Disconnect batteries before repairing electrical systems on trucks.
Ensure that replacement parts on industrial trucks are equivalent to the original ones.
Do not place arms and legs between the uprights of the mast or outside the running lines of the truck.
Although workers may be knowledgeable about powered equipment, they should take precautions when stacking and storing material. When picking up items with a powered industrial truck, 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 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 truck manufacturer’s operational requirements, and
Pile and cross-tier all stacked loads correctly when possible.
Powered Industrial Lift Truck

9. Conveyors
Conveyors can make moving materials easier, but there are hazards involving their use.
When working around conveyors:
Be sure you know where the emergency stop button or pull cord is located
Never sit or ride on a conveyor
INSTRUCTOR’S NOTES:

10. Storing Materials
To prevent hazards when storing materials, employers must:
Keep aisles and passageways clear
Separate non-compatible materials
Place bound material on racks and secure by stacking, blocking or interlocking
INSTRUCTOR’S NOTES:
Stored materials must not create a hazard for employees. Employers should make workers aware of such factors as the materials’ height and weight, how accessible the stored materials are to the user, and the condition of the containers where the materials are being stored. To prevent creating hazards when storing materials, employers must do the following:
Keep storage areas free from accumulated materials that cause tripping, fires, or explosions, or that may contribute to the harboring of rats and other pests;
Place stored materials inside buildings that are under construction and at least 6 feet from hoist ways, or inside floor openings and at least 10 feet away from exterior walls;
Separate non-compatible material; and
Equip employees who work on stored grain in silos, hoppers, or tanks, with lifelines and safety belts.

11. Stacking Techniques
Stacking materials can be dangerous if safety guidelines are not followed. When stacking materials:
Secure the material to prevent it from sliding, falling or collapsing
Observe OSHA stacking height limitations
Remove all nails from used lumber
Consider the need for availability of the material.
Material that cannot be stacked due to size, shape, or fragility can be safety stored on shelves or in bins
INSTRUCTOR’S NOTES:
Safe stacking techniques are important. Stacking materials can be dangerous if workers do not follow safety guidelines. Falling materials and collapsing loads can crush or pin workers, causing injuries or death. Workers should consider placing bound material on racks, and secure it by stacking, blocking, or interlocking to prevent it from sliding, falling, or collapsing.
To help prevent injuries when stacking materials, workers must do the following:
Remove all nails from used lumber before stacking;
Stack and level lumber on solidly supported bracing;
Ensure that stacks are stable and self-supporting;
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; and
Stack bagged material by stepping back the layers and cross-keying the bags at least every ten layers (to remove bags from the stack, start from the top row first).
Some stacking height limitations:
Stacks of loose bricks should not be more than 7 feet in height.
When masonry blocks are stacked higher than 6 feet, the stacks should be tapered back one-half block for each tier above the 6-foot level.
Stack lumber no more than 16 feet high if it is handled manually, and no more than 20 feet if using a forklift;
For quick reference, walls or posts may be painted with stripes to indicate maximum stacking heights.

12. Summary
Hazards exist any time you are moving or storing materials. Key safety practices to remember are:
Use proper lifting techniques; avoid bending and twisting.
Don’t lift heavy objects alone.
You must be 18 and have the proper training before operating powered industrial trucks.
Stack materials so that they are stable and self-supporting.
INSTRUCTOR’S NOTES:

13. Materials Handling, Storage, Use, and Disposal, Subpart H

14. Injuries
Lifting objects is a major cause of back injuries in the workplace. Other injuries include being struck by and/or crushed by equipment that is improperly stored and handled.
Potential hazards relating to injuries include:
Improper, manual lifting or carrying loads that are too large or heavy
Being struck by materials or caught in pinch points
Being crushed by machines, falling materials, or improperly stored materials
Incorrectly cutting ties or securing devices

15. Injuries
When manual handling of materials is required, you should seek help if:
A load is too bulky to properly grasp or lift
You can’t see around or over the load
You can’t safely handle the load
The best way to prevent a back injury is to store heavy objects at waist level.

16. Preventing Injuries To practice safe lifting: Break loads into parts
Get help with heavy or bulky items
Lift with your legs, keep the back straight, and do not twist
Use handling aids such as steps, trestles, shoulder pads, handles, and wheels
Avoid lifting above shoulder level

17. Materials Handling Equipment
As well as knowing how to prevent injuries when manually handling materials, employees must also be trained in the proper use and limitations of the machines they operate.
Forklift: Center the load on the forks and place it as close to the mast as possible in order to minimize the risk of the lift tipping or the load falling. Overloading a forklift makes a load hard to control and easy to tip. Place the load at the lowest possible position when moving the forklift.

18. Materials Handling Equipment
Crane: Remember to be careful to:
Check the load chart in the cab
Inspect cranes frequently
Never lift people
Check overhead power lines
Ensure your area of travel is clear
Slings: You should inspect slings carefully each day before use and also whenever service conditions warrant a special inspection. If they are damaged or defective, you should remove them from service.

19. Eliminating Hazards While Storing Materials
When storing materials in tiers, you should secure them by stacking, racking, blocking, or interlocking them to prevent them from falling. You should also post safe load limits for each floor, and keep aisles and passageways clear.
To dispose of materials, use an enclosed chute or drop into an enclosed area. You should also remove all scrap lumber, waste material, and trash from the immediate work area as the work progresses. Keep all solvent waste, oily rags, and flammable liquids in fire-resistant containers until you can remove them from the worksite.