Materials Handling Safety Basics

Manual Materials Handling

Proper Lifting Technique

• Plan the lift before starting
• Get close to the load
• Maintain a wide base of support (feet shoulder-width apart)
• Bend at knees and hips, not waist
• Tighten core muscles
• Lift with your legs, not your back
• Hold load close to your body
• Avoid twisting while lifting
• Move your feet to turn

Weight Limits

• No single "safe" weight limit for everyone
• Consider your own capabilities and limitations
• Use the 51-pound guideline as a maximum for ideal conditions
• Reduce weight for:
  • Awkward objects
  • Poor grip
  • Above shoulder or below knee lifting
  • Extended reaches
  • Repetitive lifting
  • Twisting while lifting

Team Lifting

• Use when loads are too bulky or heavy for one person
• Choose workers of similar height and strength
• Designate one person as team leader
• Coordinate movements and communicate clearly
• Lift and lower simultaneously
• Use counting ("1-2-3-lift") to coordinate

Carrying Techniques

• Keep load close to body at waist level
• Maintain good posture
• Look ahead, not down at load
• Take small steps
• Change direction with your feet, not by twisting
• Set load down using same technique as lifting
• Use proper gloves for better grip

Mechanical Materials Handling

When to Use Mechanical Assistance

• Loads over 50 pounds
• Awkward or bulky items
• Repetitive lifting tasks
• Long carrying distances
• Lifting above shoulder height
• Lifting below knee height
• Limited access or confined spaces

Hand Trucks and Dollies

• Load heaviest items on bottom
• Keep load centered and balanced
• Push rather than pull when possible
• Maintain clear visibility over the load
• Use proper securing methods (straps, bungees)
• Inspect wheels before use

Pallet Jacks

• Check for proper function before use
• Center forks in pallet
• Don't overload (check capacity)
• Pull in traffic areas, push in tight spaces
• Keep hands inside handle area
• Lower forks when parking
• Use wheel chocks on slopes

Forklifts

• Only operated by trained, certified operators
• Never walk under raised loads
• Stay clear of operating area
• Make eye contact with operators
• Follow site-specific pedestrian routes
• Know hand signals for communication with operators

Cranes and Hoists

• Only operated by qualified personnel
• Use proper rigging techniques
• Never walk under suspended loads
• Use tag lines to control loads
• Establish clear communication with operator
• Inspect all equipment before use

Material Storage

General Stacking Rules

• Place heaviest items on bottom shelves
• Keep stacks straight and aligned
• Limit stack height (usually 4 feet without mechanical stacking)
• Cross-tie where appropriate for stability
• Leave adequate aisle space (minimum 3 feet)
• Keep routes clear for emergency access

Pipe and Lumber Storage

• Stack on level ground
• Use chocks or stakes to prevent rolling
• Remove nails and screws before stacking lumber
• Don't store pipes or lumber near electrical lines
• Distribute weight evenly
• Consider wind conditions for outdoor storage

Brick and Block Storage

• Limit height to 7 feet for manual stacking
• Taper back stacks over 4 feet high
• Place on firm, level surface
• Secure loose blocks
• Remove damaged blocks from stacks

Hazardous Materials

• Store according to SDS requirements
• Maintain proper ventilation
• Provide proper containment for spills
• Keep incompatible materials separated
• Ensure proper labeling
• Store only minimum amounts needed

Loading and Unloading

Delivery Zones

• Designate specific areas for deliveries
• Keep clear of traffic and pedestrians
• Ensure firm, level ground
• Consider weather protection
• Provide adequate lighting
• Establish safe routes to storage areas

Truck Loading/Unloading

• Set brakes and chock wheels
• Inspect truck bed before entering
• Use dock plates/bridges in good condition
• Ensure forklifts are rated for the loading surface
• Maintain load balance across truck bed
• Secure load before moving truck

Material Handling Equipment Safety

• Inspect all equipment before use
• Don't exceed rated capacities
• Use proper attachments for the task
• Keep loads low when traveling
• Travel at safe speeds
• Use spotters for limited visibility
• Follow designated travel routes

Common Injuries and Prevention

Back Injuries

• Most common materials handling injury
• Often result from improper lifting
• Can cause long-term disability
• Prevent through:
  • Proper lifting technique
  • Using mechanical aids
  • Planning lifts
  • Stretching before heavy work

Hand and Finger Injuries

• Crushing between materials
• Cuts from sharp edges
• Prevent through:
  • Proper gloves
  • Hand placement awareness
  • Using hand tools rather than hands
  • Coordinating with coworkers

Foot Injuries

• Dropped materials
• Rolling objects
• Prevent through:
  • Safety-toe footwear
  • Clear communication during team lifts
  • Proper storage techniques
  • Awareness of surroundings

Strains and Sprains

• Result from overexertion
• Often affect shoulders, knees, wrists
• Prevent through:
  • Warming up before heavy work
  • Task rotation
  • Using mechanical aids
  • Taking breaks between heavy lifts

Worker Rights and Responsibilities

Employer Responsibilities

• Provide proper equipment for material handling
• Train workers on safe handling techniques
• Assess workplace for material handling hazards
• Implement controls to reduce manual handling
• Provide appropriate PPE
• Investigate material handling incidents

Worker Responsibilities

• Follow proper lifting procedures
• Use equipment provided
• Ask for help when needed
• Report hazardous conditions
• Participate in training
• Suggest improvements to material handling procedures