MATERIAL HANDLING

AND STORAGE

Engr. Alexander B. Trillana

OSH Consultant 1
 TOPICS
• Objectives
• Introduction
• Material Handling Concerns
Manual
Mechanical
• Manual Handling
The Spine
Proper Lifting Techniques
• Safety Precautions
• Material Storage Safety & Practices
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 OBJECTIVES

To identify issues and hazards

associated with material handling
activities and develop programs that
will address the identified issues and
mitigate the hazards.

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 Introduction

 Manual handling is a common activity in most workplaces

 It includes lifting, lowering, pulling, pushing, carrying,

moving, holding or restraining an object

 Injuries and musculoskeletal disorders affect the back,

neck, shoulders, arms & hands

 It can be prevented through a systemic approach of

identification, assessment and control of risks associated
with manual handling

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 Introduction
Causes of Back Injuries and Back Pain

 Repeated Lifting of Materials

 Lifting Too Much Weight
 Sudden Movements, Shift of Load
 Whole Body Vibrations
 Lifting & Twisting at the same time
 Bending over for long periods of time

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 Introduction
Back Injuries…
• They are exceedingly painful, difficult to heal, and
have an affect on everything you do.
• After suffering one back injury, you are much more
likely to experience another one later.
• The most costly type of injury for the State of
Georgia.
• According to the Bureau of Labor Statistics, more
than one million workers suffer back injuries each
year; and back injuries account for one of every five
workplace injuries. 6
 Introduction
Our Backs
• The spine’s vertebrae are held together by
ligaments.
• Muscles are attached to the vertebrae by bands of
tissue called tendons (think of them as rubber
bands).
• Between each vertebra is a cushion known as a disc
(think of it as a pad or pillow).
• Spinal Column (think of the vertebrae as building
blocks).

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 Introduction
Our Backs
• Openings in each vertebra line up to
form a long, hollow canal.
• The spinal cord runs through this
canal from the base of the brain.
• Nerves from the spinal cord branch
out and leave the spine through the
spaces between the vertebra.

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 Introduction
Forces Involved in Lifting
Think of your back as a lever. With the
fulcrum in the center of the lever, how many
pounds would it take to lift a 10 pound
object?

5 pounds
10 pounds
15 pounds

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 Introduction

Forces Involved in Lifting:

You’re right!
It takes 10 pounds of pressure to lift a 10 pound
object.
Will it take more or less force to lift the same 10
pound object with the fulcrum shifted to one side?

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 Introduction
Forces Involved in Lifting
You’re right!
With the fulcrum shifted away from the object, it
takes more force to lift the object.

The human back operates on a 10:1 ratio, with

the waist acting as the fulcrum.

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 TYPES OF MATERIAL HANDLING
MANUAL MECHANICAL
• Individual Capacity –Powered Hand Truck
-25 kg…female –Crane
-50 kg…male –Hoist
• Accessories –Forklift
-2 wheeled hand trucks –Boom Truck
-4 wheeled hand trucks –Heavy - Duty Truck
-Crowbars –Tractors
-Shovel –Railroad Cars
–Conveyors
–Pipelines
–Pallets
–Carton Clamps
–Wire Ropes
–Lifting Bars
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 Planning Ahead
• Before moving a load, plan both the load and the
route (allows you to evaluate hazards, limitations,
route safety and final placement).
• Evaluate the weight and shape of the load in addition
to what the material is made of.
• Some items to check:
• Is PPE or other safety gear necessary?
• Size/shape/weight within your limits?
• Can you get a firm hand hold?
• Will you be able to see over the load?
• Will you need assistance (people, cart, forklift)?

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 Back Injury Prevention:
Plan your Lift
• Think about the weight, size, and
shape of the object and the
distance you will be moving it.
• Is the object bulky? Will you
need help?
• Do you see any hazards that can
be eliminated?
• Think about the route you’ll be
taking: any stairs, doors,
obstacles?
• If the object is heavy or awkward,
use a hand cart or pallet jack.

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 Planning Ahead
the Route
• Check the route you will take and the place you will put
the load down.
• Injuries and property damage can occur when
unexpected problems happen during the move.
• Considerations for the route:
- Are there steps, tripping hazards, closed doors, tight
doorways or passageways?
- Are there blind corners or wet/slippery floors?
- What is the traffic situation (people, vehicles, etc.)?

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 Planning Ahead
the Drop Off Point
Some considerations:

• Where will you place the load?

• Is there room for the load?
• Is the site strong enough to hold the load?
• Will the load block traffic or create a hazard when
placed?
• Will the load have to be placed elsewhere or will it
be in the right location after you set it down?

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 Lowering the Object
• When lowering an object
remember to bend at the
knees not at the waist and
avoiding twisting motions
while putting the load down.
(the picture shown
demonstrates how NOT to
put an object down!).

• If you must turn while

lowering an object, adjust
your feet rather than
twisting your back.
Not the correct way to lower a box!

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 Lifting Properly
Step One

 Stand close to the load

with your feet spread
about shoulder width
apart.
 One foot slightly in
front of the other for
balance.

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 Lifting Properly
Step Two

• Squat down, bending at

the knees (not your waist).
• Tuck your chin while
keeping your back as
vertical as possible.

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 Lifting Properly
Step Three

Get a firm grasp of the object before

beginning the lift.

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 Lifting Properly
Step Four

• Begin slowly, lifting with

your LEGS by straightening
them. Never twist your
body during this step!

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 Lifting Properly
Step Five
• Once lift is complete, keep
object as close to your
body as possible.

• As the load's center of

gravity moves away from
the body, there is a
dramatic increase in stress
to the lumbar region of
the back.

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 Other Considerations

• Team Lifting – When more than one person may be

required to lift a load, consider having a team of folks and
have one person “call” the directions and lifting steps so
everyone will move at the same pace.

• Stacking – Overlap and interlock rows and never stack

above the crush height or above the height limits for the
facility in which you’re working. Make certain the base is
clean and level and can support the weight.

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 Other Considerations
Drums
• Use a lift truck with drum forks or a drum dolly to
move, even a short distance.
• If moving individual, empty drums, roll on the side
not the rim and always work on the down side of the
drum with the hands on the “belly” of the drum not
the rim.

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 Considerations

Cylinders:
• Compressed gas cylinders are like bombs
with very short fuses!
• Valves must be protected by a proper safety
cap.
• Use a special hand truck to move individual
cylinders, and “walk” them only short
distances to align them.
• Cylinders must be stored in designated areas
and secured with safety chains or bars.

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 Considerations
Mechanical Aids
• Often the best way to move loads is with a mechanical
aid, like a hand truck or rolling cart.
• Choose the right aid for the job and inspect it before
use.
• Place the heaviest items on the bottom, with the
weight concentrated between the wheels.
• Keep your hands away from the edges so they won’t be
scraped or crushed in doorways.

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Principles for reducing heavy lifting

• Reduce the weight

• Use mechanical equipment

• Slide instead of manual lift

• Team lifting [Buddy System]

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Reducing heavy lifting
Reduce the weight of the load

Wood pallet Plastic pallet

60 pounds 20 pounds 28
Reducing heavy lifting
Use mechanical assistance

Pneumatic conveyor
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Reducing heavy lifting

Slide instead of lifting

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 Principles for reducing frequent lifting

•Use mechanical assistance

•Avoid unnecessary lifting

•Use mobile storage shelves

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 Reducing frequent lifting

Use mechanical assistance…

… instead of lifting
by hand 32
Reducing frequent lifting

Use mobile storage:

Parts stay on racks as they

move from one
manufacturing process
to the next.

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 Principles for reducing awkward lifting/
Reaching

• Remove obstacles
• Slide closer
• Reduce shelf depth
• Reduce package size
• Use mechanical assistance
• Team lifting

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Reducing awkward lifting/
Reaching
Slide objects closer

“Homemade” hook
for pulling small
boxes to edge of
shelf.

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Reducing awkward lifting/
Reaching

Reduce package size

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Principles for reducing awkward lifting/Bending

• Use mechanical assistance to raise the load

• Add handles
• Arrange storage
• Avoid unnecessary lifting

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Reducing awkward lifting/Bending
Use mechanical assistance to raise the load

Scissor-lift cart 38
Reducing awkward lifting/Bending

Add handles

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Reducing awkward lifting/Bending

Rearrange storage

Heavy items at waist level

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Reducing awkward lifting/Bending

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 Reducing awkward lifting/Bending
Avoid unnecessary lifting

Tire hanger keeps

wheels up off the
floor in auto shop

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Principles for reducing awkward lifting/ Reaching
above shoulders

• Arrange storage

• Use mechanical assistance

• Use a rolling stair or “safety ladder”

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 Reducing awkward lifting/
Avoid reaching above shoulders
Arrange storage

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 Reducing awkward lifting/
Twisting

Use conveyors

Allows boxes to be unloaded and

checked in with minimal lifting
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USE of MECHANICAL LIFTING AIDS

• EQUIPMENT & ACCESSORIES INSPECTION

• MAINTENANCE

• LICENSED OPERATORS

• EXPERIENCED RIGGER / SPOTTER

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 Lifting Techniques Training
Teach lifting techniques to employees:
•Training alone is not
effective.
•Making changes to jobs and
equipment is better.
•Making changes along with
training is most effective.

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 Lifting Techniques Training

• Job-specific, on-site, hands-on

training is more effective than
classroom.

• Have employees demonstrate

proper lifting techniques before
“graduating.”

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Other factors in back injuries

• Age of employee

• Improper postures when sleeping, standing, sitting

• Physical condition of employee

• Repetitive motions

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 Exercises you can do at work

Be safe - check
with your
doctor before
attempting any
of these
exercises!

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 Bottom Line

If the load you are trying

to manually lift is too
heavy for you to handle,
get help from coworkers
or a mechanical aid
– don’t risk getting
injured!

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PROPER STORAGE PROCEDURES
• TEMPORARY & PERMANENT STORAGE SHOULD BE SECURE, NEAT &
ORDERLY

• ALLOW ADEQUATE CEILING CLEARANCE UNDER THE SPRINKLERS (18-36”)

• KEEP ALL THE EXITS & AISLES CLEAR AT ALL TIMES

• USE BINS & RACKS TO FACILITATE STORAGE & REDUCE HAZARDS

• SEGREGATION & ISOLATION

• 8 M SAFE DISTANCE
• Cartons…..Lumbers…..Bagged Materials…..Barrels…..Pipes…..Liquid
Containers…..Paints & Thinners…..Gasoline / Diesel…..Oxygen &
Acetylene Cylinders

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 STORE ONLY COMPATIBLE
HAZARDOUS MATERIALS

• FLAMMABLE
• COMBUSTIBLE
• ACID
• GASES
• OXIDIZER

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MATERIALS HANDLING, STORAGE, USE AND
DISPOSAL

• Make sure no flames, sparks, smokes are

near flammables.
• Keep only a small amount of flammables in
work area.
• Store (and dispose of) flammables safely.
• Dispose of debris at DENR approved
dumping site.
• IN AN EMERGENCY: evacuate area; turn off
all flames, sparking equipment; clean up
flammables; ventilate area thoroughly.
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 Transporter
Generator

Material Handling
Cycle

Disposer Secondary
Consumer

Secondary Transporter
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