Accident Prevention Manual
for Business & Industry:
Engineering & Technology
13th edition
National Safety Council
Compiled by
Dr. S.D. Allen Iske, Associate Professor
University of Central Missouri
CHAPTER 15
MATERIALS HANDLING AND STORAGE
Materials Handling and Storage
• Materials handling is conducted in every department,
warehouse, office, or facility of a company.
• Materials handling is a job that is performed by almost
every worker in the workforce as sole duty or part of
regular work and either by hand or with mechanical help.
• On an average, industry moves about 45 tons of material
for each ton of product produced.
Materials Handling and Storage (Cont.)
• Mechanized materials-handling equipment is commonly
used in many industries for assisting with materials
handling and storage due to higher efficiency and
productivity at lower cost.
• Although mechanical handling creates a new set of
hazards, the net result (without efficiency benefit) is fewer
injuries, lower workers’ compensation expenses, and a
more productive workplace.
Preventing Common Injuries
• Handling of material accounts for 20% to 45% of all
occupational injuries.
• Injuries can occur in any part of the operation, not limited
to stockroom or warehouse.
• Strains, sprains, fractures, and contusions are the most
common form of injuries resulting.
Personal Protection
• Overhead hoisting operators and maintenance
personnel are exposed to fall hazards.
• Certain items of protective equipment are desirable for
the prevention of various types of material handling
injuries.
• Because toe and finger injuries are among the most
common types of injuries, handlers should wear safety
shoes and stout gloves, preferable with leather palms.
• Other PPE such as goggles and aprons are
recommended for the handling of certain materials.
Personal Protection (Cont.)
• Hazard assessment should be conducted to determine
the required and recommended PPE.
• Gloves should be dry and free of grease and oil.
• Clean, leather-palmed gloves give you a better grip when
handling smooth metal objects.
• Do not wear gloves near certain machinery such as
conveyors or wherever there is a risk of gloves being
caught in the machine.
Personal Protection (Cont.)
• Where toxic materials are being handled, workers should
take daily showers to remove the material from their
person before they leave the facility.
• Encourage workers to wash thoroughly at the end of their
shift.
• Provide cleaning materials and PPE for workers (suits,
caps, coveralls).
Materials Handling Injuries
• To gain insight into the injuries caused by materials
handling, the safety professional should consider the
following:
• Can the job be engineered to eliminate or reduce manual handling?
• Can the material be conveyed or moved mechanically?
• Would protective clothing prevent injuries?
• Can employees be given handling aids?
• Would training and more effective management help reduce
injuries?
Materials Handling Injuries (Cont.)
• All of these questions serve as a start for an overall
assessment of injuries caused by materials handling.
• Break each job into separate tasks and examine each
task for ways to prevent injury.
• Manual handling of materials increases the possibility of
injury and adds to the product’s cost. Thus, minimize
manual handling of materials.
Materials Handling Injuries (Cont.)
• Since most injuries occur to feet and hands, give the
following general pointers to employees who handle
materials:
• Inspect materials for slivers, jagged or sharp edges, burrs, rough or
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slippery surfaces.
Grasp objects with a firm grip.
Keep fingers away from pinch and shear points.
Wipe off greasy, wet, slippery, or dirty objects before handling them.
Keep hands free of oil, dirt, or grease.
Materials Handling Injuries (Cont.)
• Manual lifting
• Conduct a Job Safety Analysis (JSA) and follow medical
recommendations when establishing lifting standards.
• Reference NIOSH Work Practices Guide to Manual Lifting.
• Before workers lift a heavy or bulky object and carry it to another
location, they should inspect the routes over which they will move
the object.
• Next, workers should inspect the object to decide how they will
grasp it, thus avoiding sharp edges.
• Wipe object if wet or greasy.
Materials Handling Injuries (Cont.)
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Manual Lifting
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Most lower back injuries come from tasks requiring lifting. Other
activities such as lowering, pushing, pulling, carrying material, or
twisting the body can also cause back injuries.
Back injuries are 2nd in number after injuries to the fingers and
hands.
Consider all three main factors in manual lifting: load location,
task repetition, and load weight when determining what is safe
or unsafe to lift.
NIOSH Applications Manual for Revised NIOSH Lifting
Guidelines (DHHS Publication 94-110)
Materials Handling Injuries (Cont.)
• Back belts
• Back injuries account for nearly 20% of workplace injuries and are
the leading cause of injuries to workers under the age of 45.
• Estimates put the annual cost of back injuries at $20 billion to
$50 billion.
• The debate over back belts focuses on two issues:
1. Employees are rarely trained in proper lifting techniques or shown how
to use belts correctly.
2. Wearing a back belt can give a false sense of security.
• Scientific studies have failed to show that back belts prevent lifting
injuries. However, they are useful for protection and post injury.
• NIOSH states:
The best way to protect workers is through ergonomic approaches
designed to reduce the hazards of lifting.
Fall Protection
• The fall hazard approach constitutes:
• recognition of each fall hazard including access to the workstation
• control of the fall hazard through choice from a variety of fall
solutions
• selection and installation of fall protection including engineering if
required
• training sufficient to fulfill fall-protection program
• observation and enforcement of fall protection program
Fall Protection (Cont.)
• Fall protection measures include the following controls:
• elimination of the hazard by reorganizing the work
• prevention of falling by the use of guardrails, including aerial lifts
• fall arrest systems for horizontal and vertical travel
• warning lines 6 ft from an edge
Guidelines for Lifting
• Regardless of the approach taken to evaluate the physical
stress of lifting, a large individual variability in risk of injury
and lifting performance capability exists in any population.
• Resulting controls must be engineering and administrative
in nature.
• To specifically define these conditions, two limits are
provided based on epidemiological, biomechanical,
physiological, and psychophysical criteria.
Guidelines for Lifting (Cont.)
1. Maximum Permissible Limit (MPL)—defined to meet four
criteria:
• Musculoskeletal injury rates and severity rates have been shown to
increase significantly in populations when work is performed above
the MPL.
• Biomechanical compression forces on the L5/S1disc are not
tolerable over 1430 lbs (650 kg) in most workers. This would result
from conditions above the MPL.
• Metabolic rates would exceed 5.0 Kcal/minute for most individuals
working above the MPL.
• Only about 25% of men and less than 1% of women workers have
the muscle strength to be capable of performing work above the
MPL.
Guidelines for Lifting (Cont.)
2. Action Limit (AL)—Large variability in capacities between
individuals in a population indicates the need for
administrative controls when conditions exceed this limit
based on:
• Musculoskeletal injury incidence and severity rates increase
moderately in populations exposed to lifting conditions described
by the AL.
• A 770-lb (350 kg) compression force on the L5/S1 disc can be
tolerated by most young, healthy workers. Such forces would be
created by conditions described by the AL.
• Metabolic rates would exceed 3.5 for most individuals working
above the AL.
• Over 75% of women and over 99% of men could lift loads
described by the AL.
Guidelines for Lifting (Cont.)
• Three types of properly analyzed lifting tasks:
1. Those above the MPL should be viewed as unacceptable and
require engineering controls.
2. Those between the AL and MPL are unacceptable without
administrative or engineering controls.
3. Those below the AL represent nominal risk to most individuals.
Rules for Lifting
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There are no comprehensive and sure-fire rules for
“safe” lifting.
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Manual materials handling is very complex.
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DO engineer manual lifting and lowering out of task
DO be in good physical shape
DO think before acting
DO get a good grip on the load
DO get the load close to the body
DO NOT twist the back or bend sideways
DO NOT lift or lower awkwardly
DO NOT hesitate to get help (TEAM LIFTING)
DO NOT lift with your arms extended
DO NOT continue lifting when load is too heavy
Accessories for Manual Handling
• In handling materials, a variety of hand-operated
accessories is available.
• Each tool or device should be kept in good repair and
used only for the job for which it is designed.
• Most common hand tools:
• hooks
• crowbars
• rollers
Accessories for Manual
Handling (Cont.)
• Jacks
• Check capacity plate and load information.
• Workers should inspect jack before and after use.
• Workers should use protective footwear when operating the jack
• Proper use of jack: vertical lifts, centered for lift, base on
perfectly level surface, and quality match for head to surface.
• Hand trucks (dollies)
• two-wheeled trucks
• four-wheeled trucks
• flat-trucks
• appliance dollies
• platform
Accessories for Manual
Handling (Cont.)
• Safety procedures for two-wheelers:
• Tip the load to be lifted slightly forward to nudge the tongue of the
truck underneath load
• Push truck all the way under the load to be moved.
• Keep center of gravity of load as low as possible. Place heavy
objects below lighter objects.
• Place load well forward so weight of load will be carried by axle not
the handles.
• Place load so it will not slip, shift, or fall and fill only to an
appropriate height.
• Let the truck carry the load. Operator should only balance and
push.
• Never walk backward with a hand truck.
• Control truck at all times and stay at a safe speed.
Accessories for Manual
Handling (Cont.)
• Safety procedures for four-wheelers:
• Similar procedures to two-wheel truck.
• Pay special attention to loading to prevent tipping.
• Arrange load to prevent falling or damage if bumped.
• Push rather than pull—less stress on the back, and it protects
worker’s heel from being caught under the truck back.
• Keep height of load low enough to observe travel path.
• Handles should be placed to protect the operator’s hands from
scrapes, crushes, or hits.
Storage of Specific Materials
• Storage of materials should be secure, neat, and orderly
to eliminate hazards and conserve space.
• A good plan for storing materials reduces the amount of handling
needed both to bring materials into production and to remove
finished products from production to shipping.
Storage of Materials
• Planning Materials Storage
• Allow adequate ceiling clearance under sprinklers. See NFPA 13,
Installation of Sprinkler Systems.
• Keep automatic sprinkler system controls and electrical panel
boxes free and clear.
• Make sure material does not obstruct fire hoses or fire
extinguishers.
• Keep exits and aisles clear at all times.
• Use bins or racks to facilitate storage and reduce hazards.
• Material stored on racks, pallets or skids is easily movable with less
damage and fewer injuries to employees.
• Protect personnel with proper procedures.
• Special equipment required for high-bay facilities.
Storage of Materials (Cont.)
• Rigid containers
• large metal containers and box pallets
• fiberboard/cardboard cartons
• barrels and kegs
• rolled paper and reels
• compressed gas cylinders
• Uncrated stock
• lumber
• bagged material
• pipe and bar stock
• sheet metal
• burlap sacking
• spontaneous combustion hazard—heat from weight from stacking
Storage of Hazardous Materials
• Advise local fire departments and emergency planning
committees when storing hazardous materials.
• Comply with EPA requirements.
Containers for Liquids
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Drums
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Store filled drums containing hazardous liquids in a protected
area out of the sun.
Tanks
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Storage tanks for hazardous liquids are preferably stored
outside.
Review and ensure building structure is safe for tanks.
Confined space, access ladders or stairs, content protection
procedures, proper tanks for materials, grounding and bonding
Pipelines
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Install pipelines in trenches or tunnels that carry chemicals.
If they must be installed overhead, isolate them so they will not
drip.
Pipelines that carry flammables should not be installed in
tunnels.
Three major sources of injury: failure of packing in valve system,
valves closed, locked and lines drained before release of bolts,
and opening wrong valve.
Containers for Liquids (Cont.)
• Portable Containers
• Drums, barrels, tote bins, and carboys
• Keep only a minimum amount of liquid at point of operation.
• If corrosive, provide isolation protection and protect from spilling
into storm sewer system.
• Storage area must be well ventilated.
• Separate racks for each material if stacked in racks.
• Barrels stacked vertically with dunnage between the tiers.
• Control storage areas for materials with compatibility.
Tank Cars
• Isolate tank cars on sidings by derails and by blue stop
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flags or blue lights.
Secure tank car.
Bond tank car before car is opened.
Ground the track and loading or unloading rack.
Properly follow procedures for specific materials during
unloading process.
Use proper safety measures to monitor process.
Containers for Hazardous Solids
• Silos
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check silo structural integrity for materials
fall protection
confined space entry permit
dust problems
ventilation
• Combustible solids
• dust problems—keep below lower explosive limit
• good housekeeping
• control ignition sources
• prevent electrical shock, ground metal to frames
• blank atmosphere with inert gas
Containers for Hazardous
Solids (Cont.)
• Portable containers
• Same principle for handling of liquids as for solids
• Handle carefully to prevent damage to machines as well as control
exposure to dust.
• Use ventilation to control dust.
• Magazines
• Store explosives in magazines of approved fireproof and
bulletproof construction.
• Locate magazines at a safe distance from railroads and other
buildings.
• Keep magazines clean, dry, and well ventilated.
• Follow NFPA 45 and other regulations.
• Advise local fire departments and emergency planning committees.
• Do not allow matches, flammables, and metal tools.
• Control access by animals, children, and people.
Containers for Gases
• Compressed gas cylinders should be stored in an upright
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position on a smooth floor with valve covers in place.
All cylinders should be chained or otherwise fastened
firmly against a wall, post, or other solid object.
Different kinds of gases should be separated by aisles or
stored in separate sections of the building.
Store empty cylinders away from full cylinders.
Restrict traffic activity and handle with care.
Follow OSHA, NFPA, Compressed Gas Association, and
other agency standards.
Storage and Handling of
Cryogenic Liquids
• Most gases used in facilities are also available as
cryogenic liquids.
• Among the most common are oxygen, nitrogen, argon,
helium, and hydrogen.
• The key to expanding use of cryogenic liquids is
economics.
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The cost of delivering and storing the liquid is lower than buying
the gas in compressed cylinders.
• At room temperature (70°F or 20°C) and atmospheric
pressure, nitrogen occupies 700x as much space as the
same amount in liquid form.
Storage and Handling of
Cryogenic Liquids (Cont.)
• Handling liquefied gases requires specific knowledge and
special precautions.
• Characteristics of cryogenic liquids:
• normal boiling point below -238°f (-150°c)
• both liquid and boil-off vapor can freeze human tissue
• vessel valve damage and potential hazard
• produce large volumes of vapors
• vaporized in sealed containers, high pressure
• most are odorless, colorless, and tasteless
Storage and Handling of
Cryogenic Liquids (Cont.)
• General safety practices:
• Always handle cryogenic liquids carefully. They can cause
frostbite on skin or eyes. If spilled, the vapors are extremely cold
and can damage tissues.
• Stand clear of boiling or splashing liquid and its vapors. Vapors
occur when a warm container is charged or when warm objects
are inserted into a liquid
• Never allow unprotected body parts to touch uninsulated pipes
or vessels that contain cryogenic fluids. The cold metal will
cause flesh to stick fast to surface and tear when withdrawn.
Storage and Handling of
Cryogenic Liquids (Cont.)
• Special precautions
• combustion accelerant, ignition, and electrostatic charge precaution
• Inert gas precautions
• container, pipeline, or system rupture or asphyxiation
• Flammable gas precautions
• prevent ignition sources and ground equipment
• Asphyxiation
• displaces breathable air in enclosed workplaces
• requires specific air monitoring to detect
Storage and Handling of
Cryogenic Liquids (Cont.)
• Training
• nature and properties of the cryogen (liquid and gaseous states)
• operation of equipment
• approved, compatible materials
• use and care of protective equipment and clothing
• first aid and self-aid techniques for medical emergencies
• handling emergency situations such as fire, spills, and leaks
• Good housekeeping practices
• essential to safety when handling cryogenics
• ignition of gases, properties of gases compared to air, and
maintenance of safety and firefighting equipment
Cryogenic Safe Handling
• Safe storage and handling requirements
• should not be handled in open containers
• storage vessels: non-pressurized dewar containers and
pressurized liquid cylinders
• Transfer lines
• two methods of transfer: gravity and pressurized transfer lines
• vacuum jacketed lines
Shipping and Receiving
• Floors, ramps, and aisles
• All must be level.
• Check strength of ramps. Keep them in good shape.
• Ramps should have handrails.
• Aisles should be wide enough to enable employees to move freely
while handling material and to allow safe passage of loaded
equipment.
• Keep aisles leading to sprinkler valves and fire-extinguishing
equipment clear. Keep space around sprinkler head free of
materials.
Shipping and Receiving (Cont.)
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Lighting
Machines and tools
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Machines used in receiving and shipping such as shears, saws,
and nailing machines should have protective guards, and
workers need to have PPE.
Dock boards
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Design dock boards used in trailer and railcar loading and
unloading to carry 4x the heaviest expected load and to be
wide enough to permit easy maneuvering of hand or power
trucks.
Stock picking
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Employees must never climb racks or shelves.
Use only approved materials-handling ladders.
Shipping and Receiving (Cont.)
• Steel and plastic strapping
• Train workers in both the application and removal of steel and
plastic strapping.
• Follow proper outlined procedures and protect employees in the
area.
• Use safety goggles and leather gloves or other required PPE.
• Burlap and sacking
• special precautions in handling due to wire wrap
• Glass and nails
• broken glass hazard, flying nails, house keeping
Shipping and Receiving (Cont.)
• Barrels, kegs, and drums
• safety issues with handling items that can lead to infections
• Boxes and cartons
• Use proper cut resistant gloves and safety goggles.
• Use proper cutting tool to open boxes.
• Construction of boxes and cartons
• Broken or damaged containers of consumables
• Loading railcars
• proper shipping of material inside railcars
• proper techniques for working with railcars
• housekeeping and cleaning of railcars