Materials Handling,
Storage, and Waste Disposal
These handouts and documents with attachments are not final, complete, or definitive instruments. This information is
for guidance purposes only. You should independently verify and satisfy yourself as to its accuracy. The AHBSIF does
not assume any liability for damages arising from the use of this information or exhibits and attachments thereto and
renders no opinion that any of the terms, conditions, and/or cited federal standards in this document and the exhibits
and attachments should be explicitly followed by the fund member. Seek specific guidance from the appropriate
regulator (OSHA) or professional advisor.
General Requirements For Manual
Handling
► Employees
should seek help when:
 A load is so bulky it cannot be properly grasped or
lifted
 An employee can’t see around or over it
 A load cannot be safely handled.
► Personal
Protective equipment is an integral part
of safe handling procedures.
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Boots with sturdy soles
Gloves
Forearm Protection
Safety Glasses
Manual Handling - Back Injury Facts
► There
are approximately 700,000 backrelated injuries in the United States each
year.
► Back injuries comprised 32% of all injuries
reported, but consumed more than 40%
of all workers' compensation dollars.
► Because they are often slow to heal and
are likely to reoccur, back injuries are a
costly injury.
The NIOSH Lifting Equation
► NIOSH
– National Institute for Occupational Safety
and Health
► Created a formula for evaluating on-the-job lifting
tasks
► The equation establishes an “RWL” or
Recommended Weight Limit for the individual
employee/task
► ( RWL = LC x HM x VM x DM x AM x FM x CM )
Components of the Equation
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LC (Load Constant) – Usually 51 lbs
HM (Horizontal Multiplier) – The distance of the
hands from the midpoint of the body (10 to 25 in)
► VM (Vertical Multiplier) – vertical distance from
hands to floor (0 to 70 in)
► DM (Distance Multiplier) – vertical distance of lift
from start to finish (10 to 70 in)
► AM (Asymmetric Multiplier) – measured angle of
twist of the lift from start to finish (0° to 135°)
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FM (Frequency Multiplier) – lifts per minute
CM (Coupling Multiplier) – ease of grasping the load
(rated as GOOD, FAIR, or POOR)
Using the Equation
the RWL is determined, the LI
(Lifting Index) is used;
► Once
 LI = Load Weight/RWL
► If
the Lifting Index is at or above 1.0, the
lifting task should be redesigned
► What factors can help create an easier
lifting task?
Mechanics of Proper Lifting
► The
following slides will demonstrate the basics
of proper lifting technique
► Don’t forget these basics;
 Warming up before attempting to lift is good practice,
don’t be afraid to get your blood flowing with some
simple stretches.
 There is no shame in the buddy system, get help if
you think you’ll need it!
 If management has provided equipment for helping
you lift something, use it. Never take a short cut or
put yourself in an unsafe position with a load.
- Establish a
solid base
- Bend your
knees
- Position
yourself close to
the load
- Lift with your
legs
-Complete the
lift before
twisting or
turning
General Requirements For Mechanical
Handling
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When moving materials avoid
overloading, consider the weight,
size, and shape of the material
Equipment capacity ratings must
be displayed on each piece of
equipment and must not be
exceeded.
Follow safe lifting procedures for
the specific machinery in use
OSHA requires that all machine
operators are trained.
Forklifts
► NIOSH
Fatality Statistics
 Average age of a fatally injured worker was 38
 The largest proportion of fatalities occurred to
workers in manufacturing followed by
transportation, communication and public
utilities.
 Three most common causes of fatalities
►forklift
overturn (operator not restrained)
►pedestrians struck by forklift
►workers crushed by forklift
Forklifts
► Operator
training was made
mandatory for all industries
as of March 1, 1999.
► Employer must train
operators using federal
guidelines for certification.
► Equipment that was
designed to move earth but
will accept forks is not
covered, nor are over the
road haulage trucks.
Which machine falls under
1926.602(d) ?
Exempt
Not Exempt
Forklifts
Training must incorporate the following subject matter:
 Familiarization with the Machine
 Understanding the basics of stability
 Understanding the forces that cause tip-over
Vehicle Inspection
 Vehicle Operation
 Load Handling
 Power Source

 LPG Handling and Use
 Battery Charging

Hands-On Training
Forklifts

Refresher Training must be
provided when:
 An operator has an incident or nearmiss incident
 An operator is asked to run a
different type of truck
 The operator has been evaluated as
not operating in a safe manner
Training records must be kept on
file after the date of completion
for at least three years
 Operators are not subject to
fitness tests
 OSHA does not require
certification cards

Mobile Cranes
Mobile Cranes
► Inspection
OSHA requires all mobile cranes to be
inspected regularly.
► A pre-operational (frequent) inspection must
be made by a competent person before each
use of the crane.
► OSHA also requires a monthly inspection of
critical items and a thorough inspection of the
entire crane at least annually.
► Stand-by cranes must also be inspected to a
pre-operational level at least every six
months.
►
Mobile Cranes
► Inspection
►
In accordance with federal regulations and the manufacturer’s
guidelines, the following items must be inspected at minimum;

Wire rope and reeving

Electrical equipment

All operational aids

Control mechanisms

Fluid Levels

Tires

Hooks and latches

Hydraulic system
Mobile Cranes
► Crane
Set-Up
The operator must be aware of
potential contact with power lines
and maintain an adequate
separation distance based on the
voltage of the line.
► Some form of highly visible physical
barrier must be erected around the
swing radius of the crane.
► Blocking under outriggers should
exceed the surface area of the float
by at least three times and have no
separation between lumber.
►
Mobile Cranes
► Crane
Set-Up
Load charts must be either posted or
bound and readily accessible in the
cab.
► Inspection records and operators
manual should also be on the vehicle
at all times.
► Accurate leveling of the crane is
essential for safe lifting. Also,
particular care must be taken to
insure the surface under crawler
cranes and cranes operating “on
rubber” are level before making the
lift.
►
Mobile Cranes
►Safe
►
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Operating Procedures
Enforce the “no rider” rule. There must be
approved seating for all personnel. Operators
must use seatbelts at all times.
Never use a crane to drag a load sideways.
(Sideloading)
If the operator has to leave the controls he/she
must:
 Land the load and place all control levers in
neutral
 Secure the crane against accidental travel
 Set all brakes and locking devices
 Shut off the engine
Mobile Cranes
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If crane operation is frequently
interrupted, the operator may
leave the crane with the engine
running so long as the crane
remains in view and unauthorized
entry is prevented.
Use tag-lines to control larger
loads and in conditions where the
weather is inclement.
Operator must take direction from
only one designated signaler.
Signaling
►Operators
must only respond to signals
given by the designated signal person.
►Unless radios are available, the
standard hand signals prescribed by
ANSI/ASME B30.5 are to be used.
►The following slides show basic hand
signals
Signaling
Signaling
Sling Safety
► Synthetic
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Web Slings
Can handle loads of up to 30,000 lbs
Will adjust to the load contour and
hold it with a tight, non-slip grip
Is not affected by mildew, rot, or
bacteria, resistant to most chemicals,
has excellent abrasion resistance
Has low cost and long service life
Can absorb heavy shocks without
damage
Is unaffected by temps up to 180°F
Comes equipped with warning threads
sewn into core to show wear and
prompt replacement.
Sling Safety
► Wire
Rope
Composed of individual wires
twisted to form strands
► Strands are then twisted to
form the rope
► Ropes utilizing wire cores have
good heat resistance
capabilities
► Factors such as bending
stresses, loading conditions,
jerking, abrasion, corrosion,
sling design, and materials
handled are all factors that
contribute to the shortened
service life of a wire rope sling.
►
Sling Safety
► Chains
Commonly used because of their
strength and ability to adapt to
the shape of the load.
► Are prone to damage through
sudden shocks
► Chain slings are ideal for high
heat applications, can be
exposed to temperatures of up
to 1000°F
►
Sling Safety
► Inspection
►
Check slings for;
 Severe corrosion.
 Localized wear(shiny worn spots or
frayed, isolated spots)
 Damage or displacement of end fittings,
hooks, rings, links, or collars.
 Distortion of eyelets, individual links, or
strands.
 Limited flexibility
 OSHA requires that wire rope slings be
removed from service if it contains 6
randomly distributed broken wires or 3
broken wires in one strand in one lay.
**Note** Proper storage is critical to
maximizing the life of a sling.
Rigging Hardware
Hooks
Clevis and Eye types are
most common
► Should be inspected for
spot wear and elongation
► Hooks should never be
painted, this can hide
cracks and other causes of
failure
► Latches should be in
working order if originally
equipped
►
Rigging Hardware
Shackles
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Chain or Anchor type
Shackle pins should never be
replaced with bolts
Pin side always goes to the
rigging hook, shims may be
necessary to maintain center
position
Inspection includes

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
Pin seats
Straightness
Signs of spreading
Overall wear
Rigging Hardware
Turnbuckles
► Clevis,
eye, and
hook types
► Unit can have any
combination type
on ends
► Observe working
load limits for safe
use
Flammable and Combustible Liquids
► The
quantity of flammable or combustible
liquid that may kept outside of a storage
room or cabinet inside the building shall not
exceed:
 25 gallons of Class IA liquids in containers
 120 gallons of Class IB, IC, II, III liquids in
containers
 660 gallons of Class IB, IC, II, III liquids in a
single portable tank
Flammable Liquid Classification
Flammable Liquid refers to any liquid
having a flash point below 100° F
FP - Flash Point BP - Boiling Point
Class IA
Class IB
Class IC
FP < 73°
FP < 73°
FP ≥ 73°
BP < 100°
BP ≥ 100°
BP < 100°
Combustible Liquid Classification
Combustible Liquid refers to any liquid
having a flash at or above 100° F
FP - Flash Point
Class II
Class IIIA
Class IIIB
FP ≥ 100°
FP ≥ 140°
FP ≥ 200°
FP < 140°
FP < 200°
Inside Storage Rooms
► Shall
be of fire resistant construction
► Liquid tight were the walls join the floor
► Have approved self closing doors at all
openings
► At least 4” sills, ramps, or depressed floors
or open integrated trench which drains to
safe location
Inside Storage Rooms
►A
ventilation system that provides at least
six room changes / hour
► For Class I liquids, electrical wiring approved
for hazardous locations
► Explosion resistant lighting fixtures
► Wood at least 1 inch nominal thickness for
shelving, racks, dunnage, scuffboards, floor
overlay, and similar installations
Flammable Storage
► All
solvent wastes and flammable liquids must
be kept in fire-resistant, covered containers until
they are removed from the worksite
► Firm separation should be placed between
containers of combustibles or flammables, when
stacked one upon another, to assure their
support and stability
► Permanently installed sprinkler system heads
must not spray into operating electrical switch
boards and equipment
Flammable Liquids
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Spills of flammable or combustible liquids must be
cleaned up promptly
Storage tanks must be adequately vented to prevent the
development of excessive vacuum or pressure as a result
of filling, emptying, or atmosphere temperature
changes
Storage tanks must also be equipped with emergency
venting that will relieve excessive internal pressure
caused by fire exposure
Insure that all connections on drums and combustible
liquid piping and vapor are liquid tight
Flammable Liquids
► Use
approved metal safety cans for handling of
any flammable liquids in quantity greater than a
gallon
► Keep flammable liquids in closed containers
when not in use (example: parts cleaning tanks,
pans, etc.)
► Ground
and bond
bulk drums of
flammable liquids
to containers
during dispensing
Combustible Storage
► Combustible
scrap, debris, and waste materials
(oily rags, etc.) should be stored and removed
from the worksite as promptly as possible
► Proper storage practiced to minimize the risk of
fire including spontaneous combustion
► Keep combustible materials away from potential
ignition sources
► Never store flammable or combustible liquids in
access or egress areas
General Storage Requirements
► Storage
areas must be kept free from materials
that may cause tripping, fires, or explosions.
► Storage areas should not block or intrude on
facility pathways
► When stacking and piling materials consider
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Height
Weight
Accessibility
Condition of the container
General Requirements For Storage
► Consider
availability of materials, safe
movement of material handling equipment,
and personnel.
► Employees required to work in stored
material vessels shall be equipped with a
personal fall arrest system.
► When a difference in work levels exists,
some means of smooth transition must be
employed, i.e. grading, ramps, blocking.
General Requirements For Storage
► Compressed
gas cylinders must be secured and
upright. Different gases must be separated by at
least 20 ft. or by partition with specific dimension
and fire retardant capabilities.
► Observe height limitations for stacked materials.
 Ex. Lumber must be stacked no more than 16 ft. high if
it is handled manually, 20 ft. for forklift use
► Used
lumber must have all nails removed before
stacking.
► Lumber must be stacked and leveled on solidly
supported bracing.
General Requirements For Storage
► Bags
and bundles must be stacked in interlocking
rows.
► Drums, barrels, and kegs must be stacked
symmetrically. If stored on their sides, the bottom
tiers must be blocked.
► Boxed materials must be banded and baled.
► Paper or rags stored inside a trailer must not be
closer than 18 inches to walls, partitions, or
sprinkler heads.
► Non-compatible materials must be separated in
storage.
General Storage Requirements
► If
space above office or any other elevated
area is used for storage, handrails must be
installed per the OSHA’s handrail
requirements
 Top Rail height: 42” (+ or – 3”)
 Mid Rail height: 21” (+ or – 3”)
 Must be able to support 200 lbs of outward
and downward force on the top, 150 lbs on
the mid rail
 Toe Boards are necessary only if an exposure
exists for those below
Disposal of Waste Materials
Materials dropped more than 20 feet to any point lying
outside the exterior walls of the building, require an
enclosed chute.
► Signs warning of the hazard of falling materials shall be
posted at each level.
► All scrap lumber, waste material, and rubbish should be
removed from the immediate work area as the work
progresses.
► Disposal of waste material or debris by burning must
comply with local fire regulations, borough ordinances,
and project management requirements.
► All solvent waste, oily rags, and flammable liquids shall be
kept in fire resistant covered containers until removed
from the worksite.
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