MATERIAL HANDLING,

STORAGE AND DISPOSAL

Manual Handling of materials account for
about 25% of all occupational injuries.
 Question you should ask about your present
operating practices to gain insight in your material
handling injury problem

1. Can the job be engineered so that manual

handling injury problem will be eliminated?
2. How do the materials being handled (such as
chemicals, dusts, rough and sharp objects)
hurt the people doing the handling?
3. Can employees be given handling aids, such
as properly sized boxes, adequate trucks, or
hooks, that will make their jobs safer?
4. Will protective clothing, or other personal
equipment, help prevent injuries?
Most Common Material
Handling Injuries
Strains and sprains
Fractures
Bruises
Back injuries
 They are caused by:
Unsafe work practices
Improper lifting
Carrying too heavy a load
Incorrect gripping
Failure to observe proper foot or hand
clearance
Failing to use or wear proper equipment
 Manual Handling Methods
1. Inspect materials for slivers, jagged edges,
burrs, rough or slippery surfaces.
2. Get a firm grip on the object.
3. Keep fingers away from pinch points,
especially when setting down materials.
4. When handling lumber, pipe or other long
objects, keep hands away from the ends to
prevent them from being pinched.
5. Wipe off greasy, wet, slippery, or dirty objects
before trying to handle them.
6. Keep hands free of oil and grease.
 Basic Rules and Instruction in
Lifting and Carrying
1. Never permit your people to overexert themselves
when lifting. If the load is thought to be more than a
person can handle, assign more than one to the job.
2. Lift gradually, without jerking, to minimize the effects of
acceleration in lifting.
3. Keep the load close to the body.
4. Lift without twisting.
5. Follow the 6-step lifting procedure:
a) Keep feet parted – one alongside, one behind the object.
b) Keep back straight, nearly vertical.
c) Tuck your chin in
d) Grip the object with the whole hand
e) Tuck elbows and arms in.
f) Keep body weight directly over feet.
Techniques when bulky object are to be handled or
when objects are to be carried on shoulder

1. To place an object on a bench or table –

 First set the object on edge and push it far enough onto the
support to be sure it will not fall.
 Release it gradually as you set it down.
 Move it in place by pushing with the hands and body from in
front of the object. This method prevents fingers from getting
pinched.
2. To raise an object above shoulder height –
 Lift the object first to waist height.
 Rest the edge of the object on a ledge, stand, or hip.
 Shift hand position so object can be boosted after knees are
bent.
 Straighten out knees as object is lifted or shifted to the
shoulders.
3. To change direction, turn the lead foot in the
direction of travel before picking up the load.
Do not twist your body. In repetitive work, the
person will not have to twist his body when
moving the material.
4. If the object is too heavy to be handled by one
person –
 Get help.
 When two or more people are handling the same
object, one should “call the signals”.
 All who are on the lift should know who this head
person is and should warn him if any one of the
crew is about to relax his grip.
 Equipment for Handling
1. Hand tools
 Crowbar
 Roller
 Handles of tongs and pliers
 Hooks
 Shovels
2. Hand Trucks
 Two-wheeled
 Four-wheeled
3. Powered Hand Trucks
4. Powered Industrial Trucks
5. Conveyors
6. Cranes
7. Railroad Cars
8. Highway Trucks
9. Ropes, Chains and Slings
 Responsibilities
Supervisor
 Must make certain that the employee knows
how to move objects safely both by hands or
mechanical devices.
 Only trained and certified are permitted to
operate fork trucks, cranes or hoists.
 Must make sure that the equipment is kept in
good mechanical condition.
Employees
 Observe all establish safety regulations
relating to lifting.
 Must never manually lift or move objects that
exceed their limitations.
 General Provisions
All material in bags, containers, bundles, or
stored in tiers shall be stacked, blocked,
interlocked, and limited in height so that it is
stable and secured against sliding or collapse.
 Bagged materials shall be stacked by stepping back
the layers and cross keying the bags at least every 10
bags high.
 Material shall be stacked as low as practical and in no
case higher than 20 feet unless otherwise specified in
this section.
Material stored inside buildings under
construction shall not be placed within 6 feet of
any hoist way or floor opening, nor within 10 feet
of any exterior wall which does not extend above
the material stored.
Access ways shall be kept clear.
Flammable and combustible liquids in a storage
building shall be in a NO SMOKING area and
separated from combustible construction and
other stored materials by 50 feet.
Unauthorized persons shall be prohibited from
entering storage areas. All persons shall be in a
safe position while materials are being loaded or
unloaded from railroad cars, trucks, or barges.
Only the brake operator shall be in or on railroad
cars while they are being moved.
Material shall not be stored on scaffolds or
runways in excess of needs for normal
placement operations, or in excess of safe load
limits.
Non compatible materials shall be segregated in
storage.
Materials will not be moved over or suspended
above personnel unless positive precautions
have been taken to protect the personnel from
falling objects.
Persons shall not work or pass under elevated
work areas unless protected by overhead
projection.
A clearance of 24 inches shall be maintained
around the path of travel of fire doors unless a
barricade is provided. Material shall not be
stored within 36 inches of a fire door opening.
Where the movement of materials may be
hazardous to persons, taglines or other device
shall be used to control the loads being handled
by hoisting equipment. They shall be
nonconductive when used near energized lines.
The hoist rope shall not be wrapped around the
load. This requirement shall not apply to electric
construction when setting or removing poles.
When moving equipment under or near
energized lines, a designated person shall
assure that required clearance is maintained.
 Lumber
Lumber shall be stacked level and be supported
on stable sills.
Lumber shall be stacked to be stable and self-
supporting.
Reusable lumber shall have all nails withdrawn
before it is stacked for storage.
Lumber piles shall not exceed 20 feet in height
provided that lumber to be handled manually
shall not be stacked more than 16 feet high.
 Cement and Lime
Bags of cement and lime shall not be stacked
more than 10 feet high without setback, except
when restrained by walls of appropriate strength.
The bags around the outside of the stack shall
be placed with the mouths of the bags facing the
center of the stack.
During un -stacking, the top of the stack shall be
kept nearly level and the necessary setback
maintained.
 Brick
Brick shall be stacked on an even, solid
surface.
Brick stacks shall not be more than 7 feet
high. When a loose brick stack reaches a
height of 4 feet it shall be tapered back 2
inches in every foot of height above the 4-
foot level.
Unitized brick shall not be stacked more
than 3 units high.
Floor, Walls, and Partition Blocks
Blocks shall be stacked in tiers on solid,
level surfaces.
When masonry blocks are stacked higher
than 6 feet, the stack shall be tapered
back on-half block per tier above the 6-foot
level.
Reinforcing, Sheet and Structural
Steel
Reinforcing steel shall be stored in orderly
piles away from walkways and roadways.
Structural steel shall be stored piled to
prevent members sliding off or the pile
toppling over.
 Cylindrical Material
Structural steel, poles, poles, pipe, bar stock,
and other cylindrical materials, unless racked,
shall be stacked and blocked so as to prevent
spreading or tilting.
Pipe, unless racked, shall not be stacked higher
than 5 feet.
Either a pyramid stack or battened stack shall be
used.
Where battened stack is used, the outside pile or
pole shall be securely choked.
Battened stacks shall be tapered back at
least one pile or pole in each tier.
Unloading of round material shall be done
so that no person is required to be on the
unloading side of the carrier after the tie
wires have been cut or during the
unlocking of the stakes.
Sand, Gravel, and Crushed Stone
Operations
Standards for the safe sloping and control of pit
walls shall be established and followed by the
operator.
Loose, unconsolidated material shall be stripped
for a safe distance (at least 10 feet) from the top
of the pit or quarry walls, and shall be sloped to
the angle of repose.
To insure safe operation, the width and height of
benches shall be determined by the equipment
to be used and the operation being performed.
Safe means for scaling pit-banks shall be
provided. Hazardous banks shall be scaled
before other work is performed.
Persons shall not work near or under dangerous
banks. Overhanging banks shall be removed
and unsafe ground conditions shall be corrected,
or the areas shall be barricaded and posted.
Persons shall approach from above loose rock
and areas to be scaled and shall scale from a
safe location.
Baffle boards, screens, cribbing, or other
suitable barriers should be provided where
movement of material into cuts constitutes a
safety hazard.
Persons shall not work between equipment and
the pit wall or bank where the equipment may
hinder escape from falls or slides of the bank.
Unless the operator is otherwise protected,
slushers in excess of 10 horsepower shall be
provided with backlash guards. All slushers
shall be equipped with rollers and drum covers,
and anchored securely before slushing
operations are started.
Track guardrails, lead rails, and frogs shall be
protected or blocked to prevent a person’s foot
from becoming wedged.
Positive-acting stop blocks, derail devices, track
skates, or other adequate means shall be
installed wherever necessary to protect persons
from runaway or moving railroad equipment.
A quick-close type air valve shall be provided on
each piece of pneumatic-powered loading,
hauling, and dumping equipment. The valve
shall be closed except when the equipment is
being operated.
Rocker-bottom or bottom-dump rail cars shall be
equipped with locking devices.
Parked railcars, unless held effectively by
brakes, shall be blocked securely.
Persons shall not go over, under or between
cars unless the train is stopped and the operator
has been notified and the notice acknowledged.
Use of Mechanical Equipments
Where mechanical handling equipment is used,
sufficient safe clearance 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 or in aisled that could create a
hazard
Permanent aisles and passageways shall be
appropriately marked.
 Secure Storage
Shall not create hazard.
Bag containers, bundle, etc. stored in tiers
shall be stacked, blocked, interlocked and
limited in heights so that they are stable
and secure against sliding or collapse.
 Clearance Limits
Clearance signs to warn of clearance
limits shall be provided

Guarding
Cover and/or guardrails shall be provided
to protect personnel from the hazards of
open pits, tanks, ditches, etc.
 Weight Limits
DOLE-BWC recommends a 50-lbs (23 kg)
limit for compact objects that are regularly
lifted.
 Manual Lifting and Handling
Use only those methods that ensure the
safety of both the employee and the
materials.
Never attempt to lift that are either too
heavy or bulky to handle safely.
Whenever possible, push rather than pull
loads – pushing uses the stronger leg
muscles, while pulling uses the easily
strained back muscles.
Mechanical Lifting and Handling
Mechanical devices must be used for lifting and
moving objects that are too heavy or bulky for
safe manual handling; however, only employees
who have been properly trained are permitted to
operate the equipment.
Fork truck operators are limited to using fork
trucks with a rated capacity of 3 tons or less. In
addition, fork truck operators must possess a
valid state drivers license.
Incidental crane and hoist operators are
normally limited to 500 lb without restriction and
2,000 lbs with supervisory approval for loads
that do not require special rigging.
Mechanical Lifting Equipment
Periodically inspect and, when necessary, repair all
mechanical lifting or moving devices. Never, under
any circumstances, operate defective equipment.
Drive fork trucks forward when going up a ramp and
backward when going down.
Do not allow anyone to pass under a raised load;
call out a warning if necessary.
Check floor load-limits before mobile lifting
equipment enters an area, and do not exceed these
limits.
Do not carry passengers on lifting equipment unless
it is specifically equipped for that purpose.
 Material Storage
Materials that are radioactive, fissile, flammable,
explosive, oxidizing, corrosive, or pyrophoric
must be stored only under conditions that have
been approved by the Hazards Control
Department.
Segregate and store incompatible materials in
separate locations.
Store other materials such as cartons, boxes,
drums, lumber, pipe and bar stock, etc., in racks
or stack them in stable piles that are appropriate
for the type of material. To prevent earthquake
damage, secure the racks with tie-downs.
 Storage Facilities
Material to be stored must not exceed either the
rated floor capacity for the area or the weight
capacity of the storage racks.
Post in a conspicuous location the load limit and
the maximum height to which material may be
stacked.
Mark traffic lanes and loading areas
appropriately and keep them clear.
The floors in these areas must always be
maintained in good condition.
 Suspended Loads
Do not stand under a load suspended by
mechanical devices. In addition, an equipment
operator should plan the pathway that will be
used to transport a load so that it does not travel
over personnel
Ensure that the lifting device has a redundant
supporting system that could prevent the
suspended material from falling if the device
fails.
Never leave a suspended load unattended;
lower the object to the floor of working surface
and secure the handling or lifting device before
leaving.
 Packing and Crating
Packing and crating for off-site shipment
shall be performed only by personnel of
the Shipping Department.
 Truck Loading
All objects loaded onto trucks must be
firmly secured to the truck to prevent the
load from shifting in transit.
Block the wheels of trucks being loaded or
unloaded at a loading dock to prevent
movement.
 Housekeeping
All stairways, passageways, gangways and
access ways shall be kept free of materials,
supplies, and obstructions at all times.
Loose or light material shall not be stored or left
on roofs or floors that are not closed in, unless it
is safely secured.
Tools, materials, extension cords, hoses, or
debris shall not cause tripping or other hazard.
Tools, materials, and equipment subject to
displacement or falling shall be adequately
secured.
Empty bags having contained lime, cement, and
other dust-producing material shall be removed
periodically as specified by the designated
authority.
Protruding nails in scrap boards, planks, and
timbers shall be removed, hammered in, or bent
over flush with the wood unless placed in
containers or trucks for removal.
Walkways, runways, and sidewalks shall be kept
clear of excavated material or other obstructions
and no sidewalks shall be undermined unless
shored to carry a minimum live load of one
hundred and twenty-five (125) pounds per
square foot.
Containers shall be provided for storing or
carrying rivers, bolts and drift pins, and secured
against accidental displacement when aloft.
When rivet heads are knocked off, or backed
out, they shall be kept from falling.
Form and scrap lumber and debris shall be
cleared from work areas, passageways, and
stairs in and around building storage yards and
other structures.
All storage and construction sites shall be kept
free from the accumulation of combustible
materials. Weeds and grass shall be kept down.
A regular procedure shall be established for
cleanup of the area as specified by the
designated authority.
Rubbish, brush, long grass, or other combustible
material shall be kept from areas where
flammable and combustible liquids are stored,
handled, or processed.
Accumulation of flammable and combustible
liquids on floors, walls, etc., is prohibited. All
spills of flammable and combustible liquids shall
be cleaned up immediately.
Contractors shall provided sufficient personnel
and equipment to insure compliance with all
housekeeping requirements.
Work will not be allowed in those areas that do
not comply with the above-mentioned
requirements.
Contractors will inspect the work area daily for
adequate housekeeping and record
unsatisfactory findings on the daily inspection
report.
Storage of materials shall be kept free from
accumulation of materials that constitute
hazards from tripping, fire, explosion, or pest
harborage.
Vegetation control shall be exercised when
necessary.
 Waste Material Disposal
Scrap material shall be placed in piles or
containers. Waste material and rubbish shall be
placed in containers.
Chutes for debris shall be enclosed except fro
openings equipped with closures at or about
floor level for the insertion of materials. The
openings shall not exceed 48 inches in height
measured along the wall of the chute. Openings
at all stories below the top floor shall be kept
closed down when not in used.
Whenever materials are dropped to any point
lying outside the exterior walls of the building, an
enclosed chute of wood, or equivalent material,
shall be used.
Waste material and rubbish shall not be thrown
down from a height of more than 6 feet unless
the subsequent provision is complied with.
When debris that cannot be handled by chutes is
dropped, the area onto which the material is
dropped shall be enclosed with barricades not
less than 42 inches high and not less than 6 feet
back from the projected edge of the opening
above. Signs warning of the hazard of falling
material shall be posted at each level.
Separate covered non-flammable/non-reactive
labeled containers shall be provided for the
collection of garbage, oily, flammable, and
hazardous wastes (such as caustics, acids, and
harmful dust). The contents shall be properly
disposed of daily.
Used roofing mops shall be stored outside the
building away from combustible materials.