5.2 Materials Handling

Rules for materials handling aim to reduce injuries from poor handling and bad storage, whether the work is done by hand or with manual or powered equipment.

Safe operating procedures

• Leave enough clearance for aisles, loading docks, doorways and turns wherever mechanical equipment is used.
• Store materials so that they create no tripping, fire, explosion or pest hazard. Bags, containers and bundles stored in rows should be stacked, blocked, interlocked and limited in height so that they do not slide or collapse.
• Use clearance signs to warn of limited height or width.
• Fit derail or bumper blocks on spur tracks where a rolling railcar could hit other cars or enter a work or traffic area.
• Cover or guard open pits, tanks, vats and ditches.

Servicing tyres and rim wheels

Tyre servicing can cause explosive separation of wheel parts. The employer must make sure that:

• no one services a rim wheel without training for that type of wheel
• a restraining device is used when inflating a tyre on a multi-piece or single-piece wheel, unless the wheel is bolted to the vehicle while it is inflated
• an air line assembly is used for inflation
• only the tools that the rim manual recommends for the type of wheel are used
• a safe operating procedure for servicing multi-piece wheels is in place

Powered industrial trucks

Powered industrial trucks, such as forklifts, must be built to the American National Standard, with the exception of earth moving and over the road hauling vehicles. They come in a number of designations, which show the fuel or power and the protection against fire hazards. The employer must make sure that an operator has completed the required training before the operator uses a truck, except for training itself. Training combines:

• formal instruction, such as lectures, discussion and interactive learning
• practical training, such as demonstrations and exercises by the trainee
• evaluation of the operator's performance at work

Each type of truck has its own characteristics and hazards, so training must address the type of truck that the worker will drive. The employer also re-evaluates each operator at least every three years.

Overhead and gantry cranes

An overhead crane has a railed support structure, called a bridge, and a wheeled trolley that travels across it. Only a qualified and trained employee may operate a crane. Frequent inspections, daily to monthly, check that the crane still operates safely, and periodic inspections, at intervals of one to twelve months, check the wear, deterioration or malfunction of important parts. A preventive maintenance program based on the maker's advice must be followed, and a crane that needs repair must not be used until a qualified technician has done the work.

Crawler, locomotive and truck cranes

These cranes are powered by engines or motors and use drums and ropes. Only designated employees who know the crane should operate it. Frequent inspections check control adjustments, contamination by lubricants, and deterioration or leaks in hydraulic systems.

A study aid, not published or endorsed by IOSH or OSHA. Laws and limits differ between countries.