Material Handling Safety

at Surface Mines, Mills, and Plants

 Introduction
Contents
• Introduction (Section 1, slide 3)
• Suggested Usage (slide 3)
• Background (slide 4)
• Course Objectives (slide 8)
• Accident/Injury Problem (slide 9)
• Conclusions/Summary (slide 14)
• Sample Quiz (slide 15)
• Manual Handling of Materials
(Section 2, slide 16)
• Lifting and Moving Material (slide 16)
• Risk Assessment (slide 30)
• Additional Discussion Topics (slide 33)
• Low-Back Injuries – Prevention and
Recovery (slide 38)
• Section Review Summary (slide 64)
• Sample Quiz (slide 65)
• Mechanical Handling of
Materials (Section 3, slide 68)
• Forklifts (slide 69)
• Hoists (slide 95)
• Dollies and Carts (slide 101)
• Jacks, “Come-Alongs,” Etc. (slide 102)
• Risk Assessment (slide 103)
• Section Review Summary (slide 106)
• Sample Quiz (slide 107)
• Stacking and Storage (Section 4,
slide 110)
• Storage (slide 111)
• Disposal (slide 119)
• Section Review Summary (slide 120)
• Sample Quiz (slide 121)
• Conclusion (Section 5, slide 123)
• Summary (slide 123)
• Sample Test (slide 124)
 Section 1
Introduction
Suggested Usage
• Tailor to Audience

• Presentation Techniques
– Small Segments (not all at once)
– Questions & Discussion
– Participation Exercises

• Presentation Time

• Mandatory & Non-mandatory Training

• Primarily for Surface Mining

– Regulations for surface areas of underground mines are handled differently for M/NM
and coal mines.
• Part 56 – Surface M/NM Mines, 30 CFR § 56.1 Purpose and scope.
• Part 57 – Underground M/NM Mines, 30 CFR § 57.1 Purpose and scope.
• Part 75 – Underground Coal Mines, 30 CFR § 75.1 Scope.
• Part 77 – Surface Coal Mines and Surface Work Areas of Underground Coal Mines,
30 CFR § 77.1 Scope.
 Section 1

Introduction

Background
This project was developed as part of
the alliance between

and the

in cooperation with
 Introduction -- Background Section 1

Handling and Storing Materials

Involves diverse operations, such as:

• Manual material handling

 Lifting or carrying bags or materials
 Unpacking materials

• Mechanical material handling

 Forklifts
 Hoists
 Other equipment

• Stacking or storing drums, barrels, kegs,

lumber, loose bricks or other materials
Internet Links1
Materials Handling and Storage – OSHA
Materials Handling and Storage – OSHA Construction Safety and Health Outreach Program

1Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
 Introduction – Background (continued) Section 1

Hazards
Hazards include:

• Improper manual lifting or carrying

loads that are too large or heavy

• Being struck by materials or being

caught in pinch points

• Being crushed by machines, falling

materials or improperly stored
materials

• Incorrectly cutting ties or securing

devices
 Introduction – Background (continued) Section 1

Workplace and Equipment Examinations

are important, and
are required.
See web links below:

Surface Metal and Nonmetal

30 CFR § 56.14100 Safety defects; examination, correction and records.

MSHA Policy on § 56.14100

30 CFR § 56.18002 Examination of working places.

MSHA Policy on § 56.18002

Surface Coal

30 CFR § 77.1606 Loading and haulage equipment; inspection and

maintenance.

30 CFR § 77.1713 Daily inspection of surface coal mine; certified person; reports
of inspection.
 Section 1

Introduction

Course Objectives
• Given statements of accident and injury problems the student will be
able to identify those that are historically true of material handling, with
at least 80% accuracy.

• Given statements about, and methods of accomplishing manual

materials handling, the student will identify correct statements and
safe methods, with at least 80% accuracy.

• Given statements about, and methods of accomplishing mechanical

materials handling, the student will identify correct statements and
safe methods, with at least 80% accuracy.

• Given statements about, and methods of accomplishing stacking and

storage of materials, the student will identify correct statements and
safe methods, with at least 80% accuracy.
 Section 1

Introduction

Accident/Injury Problem
 Introduction – Accident/Injury Problem (continued) Section 1

Material Handling Injuries

Manual material handling injuries

account for about 35% of all mining
injuries at surface locations.
 Introduction – Accident/Injury Problem (continued) Section 1

Manual Material Handling Injuries

In the U.S. Mining Industry
During the Eight-Year Period 1998 - 2005

MSHA Definition (for Accident Classification purposes)

Handling Material – Accidents related to handling packaged or

loose material while lifting, pulling, pushing, or shoveling.

NOTE: For the purposes of this course, we will refer to this

type of accident or activity as “manual material handling.”
 Introduction – Accident/Injury Problem (continued) Section 1

Injuries During Eight-Year Period 1998 - 2005

Manual Material Handling Injuries All Other Injuries

140,000
All Mining
120,000
Surface Locations
(focus of this course)
100,000

80,000 75848

60,000
52001 49867

40,000
32906

20,000 39209
34% 26929 34% 27294 35% 35%
17845
0
All Injuries Lost-Workday Injuries All Injuries Lost-Workday Injuries

NOTE: Source of data is MSHA’s BIQuery/Teradata system. Data includes reportable (degree 1 – 6) injuries for operators and contractors.
”Other” includes all accident classifications other than manual material handling. “Surface Locations” excludes only underground locations
and, therefore, includes surface areas of underground mines and office workers, as well as surface mines, mills, and plants.
 Introduction – Accident/Injury Problem (continued) Section 1

Surface Locations Comparing 2005 to 1998:

• All injuries were down 27%
(focus of this course)
• “Other” injuries were down 28%
1998 - 2005 • Manual Material Handling injuries were down 24%

12000
11631
All Injuries
10000 10804 10919
9840
8000 8988
8259 8236 8484

6000
Manual Material Handling Injuries
4000
3861 3683 3863 3641 3376
2000 3020 2927 2923

0
1998 1999 2000 2001 2002 2003 2004 2005
NOTE: Source of data is MSHA’s BIQuery/Teradata system. Data includes reportable (degree 1 – 6) injuries for operators and contractors.
”Other” includes all accident classifications other than manual material handling. “Surface Locations” excludes only underground locations
and, therefore, includes surface areas of underground mines and office workers, as well as surface mines, mills, and plants.
 Introduction Section 1

Conclusions
Summary
• Material handling is possibly the most serious
workplace safety problem.
• Manual material handling accidents consistently
account for at least 1/3 of all mining
accidents.
• Fatalities caused by manual material handling
are rare.
• The number of manual material handling injuries
decreased considerably over the eight-year
period, but the decrease was somewhat less
pronounced than the decrease in all injuries.
 Introduction Section 1

Sample Quiz
True or False?

1. The subject of material handling can be divided into manual material

handling and mechanical material handling.

2. Material handling is often considered to be the most serious safety

problem in the nation.

3. Manual material handling injuries account for about 50% of all mining
injuries at surface locations.

4. While manual material handling accounts for many injuries, these injuries
are minor and rarely result in any lost work time.

5. The number of manual material handling injuries in mining has been

increasing at surface locations.
 Section 2

Manual Handling of Materials

Lifting and Moving Material

Manual materials handling
is the principal source of
compensable injuries in
the U.S. work force, and
four out of five of these
injuries will affect the
lower back.1
Internet Links2
1OSHA Technical Manual, Section VII, Chapter 1 -- Back Disorders and Injuries
Bureau of Labor Statistics – Lost-Worktime Injuries and Illnesses:
Characteristics and Resulting Time Away From Work, 2004
OSHA Fact Sheet -- Back Injuries, Nation’s Number One Workplace Safety Problem
Bureau of Labor Statistics -- Injuries, Illnesses, and Fatalities
2Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
 Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Does this photo show the proper way

to lift?

What are some injuries that result Does this look better?
from improper material handling?
 Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Factors Associated with Back Disorders1

Slide 1 of 2
Back disorders result from exceeding the capability of the muscles,
tendons, or discs; or the cumulative effect of several contributors:

• Reaching while lifting

• Poor posture -- how one sits or stands
• Stressful living and working activities -- staying in one
position for too long
• Bad body mechanics -- how one lifts, pushes, pulls, or
carries objects
• Poor physical condition -- losing the strength and
endurance to perform physical tasks without strain
• Poor design of job or work station
• Repetitive lifting of awkward items or equipment
(continued on next slide)
Internet Link2
1OSHA Technical Manual, Section VII, Chapter 1, Back Disorders and Injuries

2Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
 Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Factors Associated with Back Disorders1

(continued) Slide 2 of 2

• Twisting while lifting

• Bending while lifting
• Maintaining bent postures
• Heavy lifting
• Fatigue
• Poor footing such as slippery floors, or
constrained posture
• Lifting with forceful movement
• Vibration, such as with lift truck drivers

Internet Link2
1OSHA Technical Manual, Section VII, Chapter 1, Back Disorders and Injuries

2Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
 Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Manual Handling
Seek help:
• When a load is too bulky to
properly grasp or lift
• When you can’t see around or
over the load
• When you can’t safely handle the
load

Attach handles or holders to

loads to reduce the chances of
getting fingers smashed.
Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Safe Lifting
• Can engineering solutions be used to
eliminate the lift or reduce the hazard?
• Break load into parts.
• Get help with heavy or bulky items.
• Lift with legs, keep back straight, do
not twist.
• Avoid lifting above shoulder level.
• Use handling aids - such as steps,
trestles, shoulder pads, handles,
wheels, lift gates, wheelbarrows,
come-alongs, chain falls, overhead
hoists, hydraulic jacks, & similar
devices.
Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Safe Lifting Training

What should be taught:
• How to lift safely
• How to avoid
unnecessary physical
stress and strain
• What you can
comfortably handle
without undue strain
• Proper use of
equipment
• Recognizing potential
hazards and how to
prevent/correct them
 Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Personal Protective Equipment (PPE)

Gloves & Footwear
• For loads with sharp or
rough edges, wear gloves
or other hand and forearm Coal Regulation – Gloves & Footwear
protection. [see linked items (c) & (e)]

• When loads are heavy or

bulky, wear steel-toed
safety shoes to prevent
foot injuries if the load is
M/NM Regulation - Footwear
dropped.
M/NM Policy - Footwear
• Metatarsal protection adds
an extra measure of safety.
Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Personal Protective Equipment

Hard Hats

• Hard hats need to be

worn where falling
objects may create a M/NM Regulation – Hard Hats
hazard.
Coal Regulation – Hard Hats
[see linked item (d)]
• This includes hazards
Coal Regulation – Hard Hats
from material stored or for Inexperienced Miners
handled overhead.
Coal Policy – Hard Hats

NOTE: A variety of other PPE is needed for other hazards at mining operations.
 Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Loading, Transporting, and Unloading Parts & Supplies

• Load/stack secured, not too high

• Proper lifting
• Human or mechanical help
• Pinched hand/finger hazard
• Personal protective equipment
• Tripping hazards/footing
 Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Housekeeping
How does good housekeeping
improve safety?
How does it reduce material
handling hazards?

Internet Links

MSHA Compliance Tips Page on Housekeeping

30 CFR § 56.4102 Spillage and leakage.
30 CFR § 56.11001 Safe access.
30 CFR § 56.16001 Stacking and storage of materials.
30 CFR § 56.20003 Housekeeping.
30 CFR § 77.205 Travelways at surface installations.
30 CFR § 77.208 Storage of materials.
30 CFR § 77.1104 Accumulations of combustible materials.
Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Moving Trailing Cables

• Protective rubber gloves
• Protective devices
• Examine cable before handling
• Human and/or mechanical help
• Tripping/slipping hazards
• Loose material hazards
Internet Links

30 CFR § 56.12014 Handling energized power cables.

30 CFR § 77.606 Energized trailing cables; handling.

30 CFR § 77.606-1 Rubber gloves; minimum requirements.
 Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Summary of Hazards

Persons responsible for material handling are subject to several types

of hazards and injuries including:

• Struck by materials
• Caught in pinch points
• Fractures, bruises, & crushing injuries
• Back injuries
• Stuck or frozen objects/parts
• Heavy & sometimes awkward loads
• Dropped material
• Uneven, cluttered, & slippery surfaces
• Slips, trips, & falls
• Truck loading & unloading hazards
• Restricted vision – equipment operators
• Falls of rock or ore
Manual Handling of Materials – Lifting and Moving Material (continued) Section 2

Ergonomics
 Manual Handling of Materials – Risk Assessment Section 2

Think
Ask Assess the Risk
Check Slide 1 of 3

Ask Yourself Questions Like –

What can go wrong?

• How much does it weigh?

• How much can I safely lift?
• Can I get a secure grip?
• Can I pinch my fingers?
• Can I be struck by loose,
Plan falling, or moving objects?
• Are there slip/trip hazards?
Implement Plan
• Are others clear?
Review & Revise • Am I clear of others? (continued on
next slide)
 Manual Handling of Materials – Risk Assessment (continued) Section 2

Think
Ask Assess the Risk
(continued) Slide 2 of 3
Check
Plan
Ask Yourself Questions Like –

• What is the best way to do this job?

• Do I need help?
• What tools or equipment do I need?
• Do I need mechanical aids?
• Do I have proper personal protective
equipment?
• Do I have a clear path?
Plan • How am I going to secure parts/objects?
• How can I safely lower/raise parts/objects?
Implement Plan • How can I communicate/coordinate work
efforts?
(continued on
Review & Revise next slide)
 Manual Handling of Materials – Risk Assessment (continued) Section 2

Think
Ask Assess the Risk
(continued) Slide 3 of 3
Check
Implement / Revise
Ask Yourself Questions Like –

•What instructions do I need?

•What information/skills are needed?
•Do I have required skills & training?
•Do supervisors check, coach, correct?

Plan •Are material handling jobs evaluated?

•Are errors, mistakes, & weaknesses
Implement Plan corrected?

Review & Revise

 Manual Handling of Materials – Additional Discussion Topics Section 2

Consider common lifting and moving activities at your operation.

Assess the risk. Can you identify the hazards and safer ways of
doing the jobs? For example:

Changing Conveyor Rollers

Handling Guards During
Maintenance Work
 Manual Handling of Materials – Additional Discussion Topics (continued) Section 2

Consider common lifting and moving activities at your operation.

Assess the risk. Can you identify the hazards and safer ways of
doing the jobs? For example:

Handling
Cylinders
& Drums
 Manual Handling of Materials – Additional Discussion Topics (continued) Section 2

Consider common lifting and moving activities at your operation.

Assess the risk. Can you identify the hazards and safer ways of
doing the jobs? For example:

Rope &
Hose Handling Cable
Handling
 Manual Handling of Materials – Additional Discussion Topics (continued) Section 2

Consider common lifting and moving activities at your operation.

Assess the risk. Can you identify the hazards and safer ways of
doing the jobs? For example:

Handling
Quality Control Samples

Changing & Lifting

Screens
 Manual Handling of Materials – Additional Discussion Topics (continued) Section 2

Consider common lifting and

moving activities at your
operation. Assess the risk. Can
you identify the hazards and
safer ways of doing the jobs?
For example: Handling Used Oil
 Section 2

Manual Handling of Materials

Low-Back Injuries –
Prevention and Recovery
Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Common Types of Back Injuries

• Muscle Strain or Spasm

• Ruptured or Herniated Discs

Low back pain can have many other causes… follow the link:

Low Back Pain – WebMD.com

NOTE: Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Good Body Mechanics1,2

Slide 1 of 2

• Maintain proper posture.

• Change positions, walk, and stretch occasionally.
• Minimize bending and twisting.
• Avoid reaching out over an obstruction to lift, hold,
or lower an object.
• Store heavy and frequently used items at waist
height.
• Push, instead of pull. (continued on next slide)
Internet Links3
1SpineUniverse.com – Use Good Body Mechanics to Help Keep Your Spine Safe
2SpineUniverse.com – Preventing Injuries at Work
3Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Good Body Mechanics1,2

(continued) Slide 2 of 2

• Plan for lifting, carrying, and reaching.

– Test the weight.
– Plan your route, clear obstacles.
– Face the object and get close to it.
– Determine best way to hold the object.
– Get in a stable position with feet wide apart.
– Tighten your stomach, but don’t hold your breath.
– Use leg muscles for lifting power, not the back.
– Bend knees, keep back straight, lift smoothly, and keep good
posture.
– Do not bend and twist simultaneously.
– Repeat the same movements for setting the object down.
Internet Links3
1SpineUniverse.com – Use Good Body Mechanics to Help Keep Your Spine Safe
2SpineUniverse.com – Preventing Injuries at Work

3Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

More Tips for a Healthy Back

and
Exercises for Back Care
• Good body mechanics and exercise can be crucial to back
injury prevention, and in the treatment of, and recovery from,
back injuries.

• Your best back support is derived from your own back muscles.

• Physical conditioning and stretching programs reduce the risk of

muscle strain.

• Follow the exercise routine prescribed by your doctor.

There are several possible sources of low back pain. These tips
and exercises are not suitable in all cases, and could even be
harmful in some cases.

See “More Back Links” for Sources and for Additional Information.
NOTE: This link takes you to a later slide in the presentation. You will have to return to this slide manually.
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

Standing and Walking

• Toes straight

• Weight on heels

• Chest forward

• Stand tall

Correct Incorrect Correct Incorrect

 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

Sitting

• All the way back

Correct Incorrect
• Back, head, and
shoulders erect

• Don’t slouch
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

Driving

• Seat support

• Close to wheel

• Knees bent and

higher than hips

• Stop and walk Correct Incorrect

 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

Lifting
• Test weight Correct Incorrect
• Plan route
• Wide stance
• Bend knees
• Get close
• Best hold
• Stable position
• Tighten stomach
• Use legs
• Keep back straight
• Lift smoothly
Avoid or minimize:
• Bending and twisting
• Reaching out with weight
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

More About Lifting

Correct • Elevated storage Incorrect

• Practice

• Warm-up

• Breaks

• Communication
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

Lifting Light-Weight Items

or

Balance trunk by extending leg. Hold onto a firm object.

 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

Reaching Overhead

• Wide base of support

• Safe platform or step not

stool
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

Tripod Lift1
(an alternative for lifting bagged material)

• Slide bag to mid-thigh

• Less arm strength required • Lift onto opposite thigh
• Not for those with bad knees • “Hug” bag to stomach and chest
• Lift by extending your legs

Internet Link2
1Lifting Techniques – U.S. Army Center for Health Promotion and Preventive Medicine

2Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

Shoveling
• Wide base of support

• Knees bent

• Back straight

• Choke down on shovel

• Lift with legs

• Pivot instead of twisting

Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

Working - Standing
• Avoid long standing if possible

• Prop up a foot occasionally

• Lean on something occasionally

• Avoid bending forward

Correct Incorrect

Working - Stooping

• Avoid if possible

• Bend backwards regularly

Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

Using a Push-Broom

• Walk back and forth

• Handle against hip-bone

• Elbow bent

• Handle length
Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Tips for a Healthy Back

Sleeping
Correct

Incorrect

Correct, with acute back pain

 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Flexion Exercises
General Comment

The flexion exercises are often

recommended for alleviating and
preventing painful muscle spasms in the
low back.

Stay as active as possible. Muscles

tighten and stay in spasm if they are not
allowed to stretch.
Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Exercises for Back Care

Flexion

Pelvic Tilt
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Exercises for Back Care

Flexion

Cross-Arm Knee Pushing

The Curl
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Exercises for Back Care

Flexion

Knee Raising - Single Knee Raising - Double

Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Exercises for Back Care

Flexion

Head Raising Leg Raising

 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Extension Exercises
General Comment

The following extension exercises are

often helpful in alleviating discogenic pain.
Repeat these exercises at two hour
intervals, six to eight times per day.
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Exercises for Back Care

Extension

Extension
Exercise 1

Extension
Exercise 2
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

Exercises for Back Care

Extension

Extension Exercise 3 Extension Exercise 4

(a) (a)
(b)

(b)
 Manual Handling of Materials: Low-Back Injuries – Prevention and Recovery (continued) Section 2

More Back Links1

• Back Pain Exercises – American Academy of Orthopaedic Surgeons
• How to Prevent Back Pain – American Academy of Orthopaedic Surgeons
• Low Back Exercise Guide – American Academy of Orthopaedic Surgeons
• Preventing Back Pain at Work and at Home – American Academy of Orthopaedic Surgeons
• PowerLift® – EmployerHealth.com
• PowerLift® – Michigan Technological University
• PowerLift® – South Central Technical College
• Lifting Techniques – U.S. Army Center for Health Promotion and Preventive Medicine
• Getting to Grips with Manual Handling – Health and Safety Executive (United Kingdom)
• Correct Lifting Techniques – Ergoboy.com
• Exercises to Reduce Low Back Pain – WebMD
• Exercises to Relieve Low Back Pain – Aetna InteliHealth
• Manual Handling of Materials – MSHA; Sand, Gravel, and Crushed Stone On-The-Job Training Modules
• "Watch Your Back" - Prevent Back Injuries – MSHA Health Hazard Information
• Musculoskeletal Disorders and Workplace Factors – National Institute for Occupational Safety and Health
• Low Back Exercise Program – Nicholas Institute of Sports Medicine and Athletic Trauma
• General Back Exercises – #1 Back Pain Site
• Lower Back Exercises – Beau Productions, Golf Swings Health Pages
• Common Causes of Back Pain – LowBackPain.com
• Non-Surgical Treatment – Exercise – LowBackPain.com
• Back Pain – About.com, Orthopedics
• Exercise for Back Pain – Spine-health.com
• Extend Yourself for Low-Back Pain Relief – The Physician and Sportsmedicine Online
• Low Back Disorders – Shasta Orthopaedics & Sports Medicine
• Summary of NIOSH Back Belt Studies - National Institute for Occupational Safety and Health
• Back Belts, Do They Prevent Injury? - National Institute for Occupational Safety and Health
• OSH Answers: Back Belts – Canadian Centre for Occupational Health and Safety
1Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
 Manual Handling of Materials Section 2

Section Review
Summary

Some of the major key points of this section are

summarized below:

Manual Handling of Materials

• Lifting “do’s”– minimize heavy lifting, stay close, wide

stance, use legs
• Lifting “don’ts” – bending, twisting, jerking, reaching out
• Body mechanics – posture, change positions, lean/prop
foot on something
• Consider back exercises.
 Manual Handling of Materials Section 2

Sample Quiz
Select All That Represent Correct Methods or Statements

a. Store heaviest objects on the floor.

b. No PPE is required.
c. Test the weight.
d. Split heavy loads into smaller parts when you can.
e. Obtain help (human or mechanical) for heavy objects.
1. Lifting
f. Get close and use a wide stance.
g. Use leg muscles for lifting.
h. Bend over with your knees straight and lift with the upper torso.
i. Jerk the load up quickly.
j. Reach out as far as possible to protect your trunk from the load.
a. Examine cable for damage.
b. Make sure area is free of tripping hazards.
c. Wear protective rubber gloves and use nonconductive hooks or other
2. Moving Trailing Cables
protective devices.
d. Straddle the cable, pick it up in both arms, and hold it close.
e. Use mechanical help, like slings attached to bulldozers, as necessary.

Quiz Continued on Next Slide

 Manual Handling of Materials Section 2

Sample Quiz (continued)

Select All That Represent Correct Methods or Statements

a. Make sure you have solid footing.

b. Start with legs apart, knees bent, and back straight.
c. Hold shovel as close as possible to end of handle so you can reach
3. Shoveling
further.
d. Lift with your legs.
e. Twist your trunk to throw material to the side.
a. Maintain good posture.
b. Don’t lean on anything when standing.
4. Standing, Walking,
c. Always keep both feet flat on the floor when standing.
Sitting, Driving
d. Sit all the way back in a firm-back chair.
e. When sitting or driving take occasional breaks to walk around.

Quiz Continued on Next Slide

 Manual Handling of Materials Section 2

Sample Quiz (continued)

Select All That Represent Correct Methods or Statements

a. Normal lifting techniques can be used for bagged material.

5. Handling Bagged Material
6. Doing Back Exercises
b. Only the “tripod lift” should be used for bagged material.
c. The “tripod lift” starts with one knee on the floor/ground.
d. The “tripod lift” requires increased arm strength.
e. The “tripod lift” is not recommended for persons with bad knees.
a. Always get complete bed rest until you have been pain-free for at
least a week.
b. Follow the exercise routine prescribed by your doctor.
c. Flexion exercises are often recommended to alleviate and prevent
muscle spasms.
d. Use the pelvic tilt to start many of the back exercises.
e. Extension exercises are often helpful in alleviating disc-related pain.
Section 3
 Mechanical Handling of Materials – Forklifts Section 3

Forklifts
• Center the load on the forks and as
close to the mast as possible to Internet Links

minimize the potential for the truck 30 CFR § 56.14206

tipping or load falling. Securing movable parts.

30 CFR § 56.16016
• Overloading a lift truck makes it Lift trucks.
hard to control and could make it tip
30 CFR § 77.1607
over. Loading and haulage
equipment; operation.
• Place the load at the lowest position [see subsection (s)]

for traveling.

• Don’t place extra weight on the rear

of a counterbalanced forklift to allow
an overload.
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Forklift Standards
Forklifts are considered to be powered haulage equipment
under MSHA standards. As such there are a number of
safety standards that apply, and MSHA training standards
apply to forklift operators.

Beyond the general rules and safe practices applicable to various types of
equipment, some forklift-specific standards are contained in the links1 below:
• MSHA, Surface M/NM Standards – 30 CFR § 56.16016 Lift trucks.
• MSHA, Surface Coal Standards – 30 CFR § 77.410 Mobile equipment;
automatic warning devices.
• MSHA, Surface Coal Standards – 30 CFR § 77.403 Mobile equipment;
falling object protective structures (FOPS).

• OSHA, General Industry Standards – 29 CFR § 1910.178 Powered industrial trucks.

• Appendix A -- Stability of Powered Industrial Trucks (Non-mandatory Appendix to
Paragraph (l) of § 1910.178
• OSHA, Construction Standards – 29 CFR § 1926.602 Material handling equipment.

• ITSDF Industrial Truck Standards

1NOTE: Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
Mechanical Handling of Materials – Forklifts (continued) Section 3

General
Information
Mechanical Handling of Materials – Forklifts (continued) Section 3

Platform
Lift Truck
Mechanical Handling of Materials – Forklifts (continued) Section 3

Motorized Hand Truck

(Pallet Jack)
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Design & Construction

Internet Links1
ITSDF Industrial Truck Standards

1Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
Mechanical Handling of Materials – Forklifts (continued) Section 3

• Capacity

• Power Sources

• Hazardous Atmospheres
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Overhead Protection

Internet Links

30 CFR § 56.14106
Falling object protection.

30 CFR § 77.403 Mobile

equipment; falling object
protective structures (FOPS).
[see subsection (b) re. forklifts]
Mechanical Handling of Materials – Forklifts (continued) Section 3

• Lights

• Internal Combustion Engines

• Battery Chargers
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Operating a Forklift Safely

• Keep arms and legs inside the truck.
• Handle only stable loads.
• Keep speed low - you may have to stop.
• Be careful when making sharp turns with a
raised load.
• If a load blocks your view, travel in reverse.
• No riders, unless there’s an approved seat.
• Don’t drive with forks raised.
• Wear safety belts or other restraint devices.
(more on next slide)
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Operating a Forklift Safely

(continued)
• All traffic rules must be observed.
• Drivers must slow down and sound the horn at cross aisles
and blind spots.
• Cross railroad tracks diagonally.
• When ascending or descending grades in excess of 10%,
loaded trucks must be driven with the load upgrade.
• No one should stand under the elevated portion of the
truck.
• Damaged or defective trucks must be removed from service
immediately.
• Fuel tanks shall not be filled while the engine is running.
• Trucks must be inspected prior to each shift.
• When unattended, lower forks, set brake, and take keys.
 Mechanical Handling of Materials – Forklifts (continued) Section 3

• Sufficient safe clearances

• Surface conditions

Internet Links

30 CFR § 56.9101 Operating speeds and control of equipment.

30 CFR § 56.9313 Roadway maintenance.
30 CFR § 56.11001 Safe access.
30 CFR § 56.20003 Housekeeping.
30 CFR § 77.205 Travelways at surface installations.
30 CFR § 77.1607 Loading and haulage equipment; operation. [see subsection (c)]
Mechanical Handling of Materials – Forklifts (continued) Section 3

Pedestrians
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Dockboards (Bridge Plates)

• Use
• Strength
• Secure
• Placement
• Handholds

Internet Link1

OSHA Standard – 29 CFR § 1910.30(a) Dockboards (bridge plates).

1Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
 Mechanical Handling of Materials – Forklifts (continued) Section 3

What is this worker doing and why?

Mechanical Handling of Materials – Forklifts (continued) Section 3

Prevent accidents.

• Chock wheels.

• Wear seat belt.

Mechanical Handling of Materials – Forklifts (continued) Section 3

Trailers
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Securing Trucks/Trailers Prior to Loading/Unloading with Forklifts

Summary of Hazards and Minimum Precautions
Hazards
• Creep
• Pull Away

Trailer Remains Coupled to Truck

• Truck Brakes Set AND
• Rear Wheels Chocked OR Trailer Effectively
Secured to Dock (dock lock system)
• Trailer Floor Inspected

Trailer is Uncoupled from Truck

• Trailer Brakes Set (if equipped) AND
• Rear Wheels Chocked OR Trailer Effectively
Secured to Dock (dock lock system)
• Jacks Supporting Semitrailer as Necessary
• Trailer Floor Inspected
Internet Link1

OSHA Standard Interpretation – 29 CFR § 1910.178(k)(1), § 1910.178(m)(7), & § 1910.178(l)

1Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
Mechanical Handling of Materials – Forklifts (continued) Section 3

Railroad Cars
Wheel Stops
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Powered Industrial Truck

Training
• Health & safety aspects
• Safe work procedures
• Pertinent regulations
• Observation/supervision by
a competent person
Internet Links1

MSHA – Part 48 Task Training Requirements2

MSHA – Part 46 Task Training Requirements3

OSHA – Powered Industrial Trucks - Training Materials

OSHA – Powered Industrial Trucks – Training Requirements

[Scroll all the way to section (l) after clicking this link.]

1Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
2For surface mines and surface areas of underground mines
3For shell dredging, sand, gravel, surface stone, surface clay, colloidal phosphate, and surface limestone mines
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Lift Truck Training

should include

Truck Related Topics

such as:
• Operating instructions, warnings,
& precautions
• Truck controls & instrumentation
• Engine or motor operation
• Steering & maneuvering
• Visibility
• Fork & attachment adaptation, operation, & use
limits
• Vehicle capacity, stability, inspection, &
maintenance
• Refueling and/or battery charging/recharging
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Lift Truck Training

should include

Workplace Related Topics

such as:

• Surface conditions where the vehicle will be used

• Composition of loads & load stability
• Load manipulation, stacking, & unstacking
• Pedestrian traffic
• Narrow aisles, ramps, & other restricted or sloped
places
• Potentially hazardous, closed, or unique
locations/environments
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Lift Truck Training

Consider/conduct

Retraining and Reevaluation

when:

• The operator has been observed operating vehicle

in an unsafe manner
• The operator has been involved in an accident or
close call
• The operator has received an evaluation that
reveals unsafe operation
• The operator is assigned to a different type of truck
• Conditions in the workplace change
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Internet Links

30 CFR § 56.9200
• Unauthorized Transporting persons.
Personnel
30 CFR § 56.14211
• Inappropriate Blocking equipment in a raised position.
Lifting
30 CFR § 56.15002
• Personal Hard hats.
Protective
30 CFR § 56.15005
Equipment Safety belts and lines.

30 CFR § 77.405
Performing work from a raised position;
safeguards.

30 CFR § 77.1601 Transportation of

persons; restrictions.

30 CFR § 77.1710 Protective clothing;

requirements. [see subparts (d) & (g)]
 Mechanical Handling of Materials – Forklifts (continued) Section 3

Additional Considerations

Fire Precautions Surface Conditions

Internet Links Internet Links

30 CFR § 56.4100 Smoking and use of open flames. 30 CFR § 56.9101 Operating speeds and control of
30 CFR § 56.4101 Warning signs. equipment.
30 CFR § 56.4102 Spillage and leakage.
30 CFR § 56.4103 Fueling internal combustion engines. 30 CFR § 56.9313 Roadway maintenance.
30 CFR § 56.4230 Self-propelled equipment.
30 CFR § 56.4502 Battery-charging stations. 30 CFR § 77.1607 Loading and haulage equipment;
30 CFR § 56.16005 Securing gas cylinders. operation. [see subsections (b) & (c)]
30 CFR § 56.16006 Protection of gas cylinder valves.
30 CFR § 77.208 Storage of materials.
30 CFR § 77.1102 Warning signs; smoking and open flame.
30 CFR § 77.1105 Internal combustion engines; fueling.
30 CFR § 77.1106 Battery-charging stations; ventilation.
30 CFR § 77.1109 Quantity and location of firefighting equipment.
[see especially subsections (c)(1) & (e)]
 Mechanical Handling of Materials – Forklifts (continued) Section 3

More Forklift Links1

Some forklift-specific links are provided below:

• OSHA, Safety & Health Topics: Powered Industrial Trucks

• Free-Training.com – Forklift Operation & Safety Course
• LSU CAMD – Forklift Safety
• Department of Agriculture, Forest Service – Job Hazard Analysis - Forklifts
• Texas Woman's University, Forklift Safety
• Montana Department of Labor & Industry, Occupational Safety & Health Bureau – Forklift Safety
Guide
• Radford University, Environmental Health & Safety – Powered Industrial Trucks
• Montex, Inc., Written Safety Plan – Forklift Operation Plan
• Naval Safety Center – Loading Docks – Danger Zones for Workers
• Department of Interior, Occupational Health & Medical Services Page – Forklift Safety
• MSHA, Safety Ideas – Rough Terrain Forklift Safety
• Pacific Employers – Safely Loading, or Unloading, Trucks & Trailers
• Government of Saskatchewan – Safe Operation of Forklifts
• Pacific Maritime Association – Safety Tips for Power Industrial Truck Operators
• Rite-Hite Holding Corporation – Securing Trucks with the Right Restraint

1NOTE: These links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
Mechanical Handling of Materials – Hoists

Hoists
Section 3

Internet Link
MSHA IG 40 Module 15 – Using an Overhead Hoist to Handle Material
 Mechanical Handling of Materials – Hoists (continued) Section 3

Hoists (General)
• Capacity marked
• Attachment to supports
• Adequate supports
• Persons operating
• Inspection
• Limiting devices
• Proper lifting procedure
• No riders
 Mechanical Handling of Materials – Hoists (continued) Section 3

Electric Hoist

• Control cords
• Distinct contours & marking
• Inspection
• Automatic “off”
• Control circuit voltage
• Limit stop
• Remaining rope on drum
 Mechanical Handling of Materials – Hoists (continued) Section 3

Air Hoist
• Sufficient air supply
• Positive hose connections Gearing

• Upper & lower limits Inlet Air

Swivel
• Positive hook attachment to
support
• Piston secured to rod
(check when overhauled)

Brake
Vane
Motor
Speed
Adjustment
Limit Lever
Screws

Internet Links

30 CFR § 56.13021 High-pressure hose connections.

Policy on 56.13021 High-pressure hose connections.
30 CFR § 77.412 Compressed air systems.
 Mechanical Handling of Materials – Hoists (continued) Section 3

Hand-Operated Chain Hoist

• Strong/dependable/durable
• Types
– Spur-geared [most efficient] [auto load brake]
– Differential [least efficient] [self locking]
– Screw-geared (worm-drive) [self locking]
• Load safety factor
• Supports sufficiently strong
• Safe lifting/handling procedures
 Mechanical Handling of Materials – Hoists (continued) Section 3

Other Hoist-Related Links1

30 CFR § 56.14205 Machinery, equipment, and tools.
30 CFR § 56.16007 Taglines, hitches, and slings.
30 CFR § 56.16009 Suspended loads.
30 CFR § 56.16011 Riding hoisted loads or on the hoist hook.
30 CFR § 56.16014 Operator-carrying overhead cranes.
30 CFR § 56.16015 Work or travel on overhead crane bridges.
30 CFR § 56.18002 Examination of working places.
30 CFR Part 56 Subpart R – Personnel Hoisting, § 56.19000 Application.

30 CFR § 77.210 Hoisting of materials.

30 CFR § 77.404 Machinery and equipment; operation and maintenance.
30 CFR § 77.1713 Daily inspection of surface coal mine; certified person; reports of inspection.

MSHA IG 40 Module 15 – Using an Overhead Hoist to Handle Material

29 CFR § 1926.554 Overhead hoists.

OSHA Standard Interpretations, 08/04/2000 - Alloy steel chain slings must not be loaded beyond
working load limit.
29 CFR § 1926.553 Base-mounted drum hoists.
29 CFR § 1926.552 Material hoists, personnel hoists, and elevators.

Michigan Safe Work Requirements [This is a large document. Find Sections 12.4.5.9, 12.5.5.1,
12.5.5.3, 12.5.6, and 12.9.5.1.1 only.]

1Non-MSHA links are not meant to imply enforceability by MSHA. They are for informational and educational purposes only.
 Mechanical Handling of Materials Section 3

Dollies (Hand Trucks) and Carts

Nonpowered Hand Powered Hand
Trucks & Carts Trucks & Carts

• Get Help • Training

• Heavy Objects on Bottom • Manufacturer’s Manual
• Load over Axles • Heavy Objects on Bottom
• Not above Eye Level • Face Travel Direction
• Secure to Truck • Hand on Handle
• Firm Grip • Handle-Release Shut-Off
• Back Straight • Traffic Rules
• Lean & Walk • Stop & Look
• Push Forward • Watch for:
• Watch for: • Obstructions
• Obstructions • Vehicles
• Vehicles • People
• People • Ground/Floor
• Ground/Floor • Tight Spaces
• Moving Parts
• No Riders
• Parking
 Mechanical Handling of Materials Section 3

Jacks, “Porta-Powers,” “Come-Alongs,” Etc.

Internet Links1

30 CFR § 56.14100 Safety defects; examination, correction and records.

[See subsections (b) & (c)]

30 CFR § 77.404 Machinery and equipment; operation and maintenance.

29 CFR § 1910.244 Other portable tools and equipment. [Jacks]

29 CFR § 1915.114 Chain falls and pull-lifts.

1Non-MSHA links are not meant to imply enforceability by MSHA.

They are for informational and educational purposes only.
 Mechanical Handling of Materials – Risk Assessment Section 3

Think
Ask Assess the Risk
Check Slide 1 of 3

Ask Yourself Questions Like –

What can go wrong?

• How much does it weigh?

• How much can the equipment handle?
• Are there suspended load hazards?
• Can the equipment upset?
• Can an object fall on me?
• Can I be pinned or crushed?
• Are there slip/trip hazards?
Plan • Are others clear?
• Am I clear of others?
• Have I secured the area?
Implement Plan • Have I secured or blocked parts that
could slip or move? (continued on
Review & Revise • Can I contact electrical wires? next slide)
 Mechanical Handling of Materials – Risk Assessment (continued) Section 3

Think
Ask Assess the Risk
(continued) Slide 2 of 3
Check
Plan
Ask Yourself Questions Like –

• What is the best way to do this job?

• What tools or equipment do I need?
• Is the equipment operating correctly, including
safety equipment?
• Do I need to adjust the equipment?
• Do I have proper personal protective equipment?
• Do I have a clear aisle/passageway?
• How am I going to secure parts/objects?
Plan • How can I safely handle parts/objects?
• Have I secured trailer or rail car?
• Have I inspected trailer or rail car for safe entry?
Implement Plan • How can I communicate/coordinate work?
(continued on
Review & Revise next slide)
 Mechanical Handling of Materials – Risk Assessment (continued) Section 3

Think
Ask Assess the Risk
(continued) Slide 3 of 3
Check
Implement / Revise
Ask Yourself Questions Like –

•What instructions do I need?

•Do I have the necessary information,
skills, training, and experience?
•Do supervisors check, coach, and
correct?

Plan •Are material handling jobs assessed for

risk?
Implement Plan •Are errors, mistakes, & weaknesses
corrected?
Review & Revise
 Mechanical Handling of Materials Section 3

Section Review
Summary
Some of the major key points of this section are
summarized below:
Mechanical Handling of Materials

• Forklifts – inspect each shift; if defective, remove from

service.
• Watch for struck-by/crushed-by dangers.
• Forklifts – load low, speed slow, load uphill on grades.
• Maintain safety equipment, no unauthorized
modifications.
• Docks – brakes set, chocks &/or dock locks, dock plate,
trailer floor & “nose” secure.
• Inspect hoists frequently & thoroughly, & abide by load
limits.
 Mechanical Handling of Materials Section 3

Sample Quiz
True or False?

1. Mechanical alternatives to manual handling of materials should be used

whenever possible to minimize lifting and bending requirements.

2. If rear forklift wheels come off the ground when you try to lift a load,
always add weights to the rear.

3. Lift truck (forklift) training should include both truck related topics and
workplace related topics.

4. “Come-alongs” can be used interchangeably with hoists.

Quiz Continued on Next Slide

 Mechanical Handling of Materials Section 3

Sample Quiz (continued)

Select the Most Correct Method or Statement to Complete Each Item

a. Not carry it.

5. On a forklift, if a load blocks your view you should b. Raise forks until you can see under it.
c. Travel in reverse.

a. Uphill.
6. If using a forklift to transport a load up a 12% grade, the
b. Downhill.
load should be
c. Not carried at all.

a. Setting the truck brakes.

7. At a loading dock, an effective dock-lock system can be
b. Using wheel chocks.
accepted in place of
c. Using a dockboard.
d. Inspecting the trailer floor.

a. Two inches
8. When transporting loads with a forklift, try not to raise the
b. Eight inches
load more than about ___________ from the ground.
c. Two feet
d. Eight feet

Quiz Continued on Next Slide

 Mechanical Handling of Materials Section 3

Sample Quiz (continued)

Select ALL Correct Methods or Statements to Complete Each Item

a. Air conditioned cab

9. Lift trucks should have the b. Overhead protection
following safety equipment:
(Select all that apply.) c. Brakes
d. Seat belts
e. Air bags

10. Recommended safe procedures a. Place heavy objects on bottom of load.

for using nonpowered hand trucks
& carts include: (Select all that
apply.)
11. Select ways to eliminate hazards
that may lead to injury when using
hoists to handle materials. (Select
all that apply.)
b. Don’t pile items above eye level.
c. Secure bulky, awkward, or delicate objects to the truck.
d. Always pull, don’t push.
a. Train employees in inspection, proper use, and operation.
b. Intentionally overload hoists occasionally to be sure they can
handle the normal loads.
c. Abide by load limits.
d. Inspect frequently.
e. Have specialized person inspect, as required.
f. Leave loads hanging to provide a clear walkway underneath.
g. Never lift people.
 Section 4

Stacking and Storage

 Stacking and Storage (continued) Section 4

Storing Materials
• Secure materials stored in
tiers by stacking, racking,
blocking, or interlocking to
prevent sliding or collapse.

• Post safe load limits of

floors.

• Keep aisles and

passageways clear.

Internet Links

30 CFR § 56.16001 Stacking and storage of materials.

30 CFR § 56.20003 Housekeeping.

30 CFR § 77.208 Storage of materials.

 Stacking and Storage (continued) Section 4

Storing Materials
• Smoking & Open Flames, Warning Signs
• Rooms or Buildings
• Containers
• Bins, Hoppers, Silos, & Tanks

Internet Links

30 CFR Part 47 — Hazard Communication (HazCom)

30 CFR § 56.4100 Smoking and use of open flames.
30 CFR § 56.4101 Warning signs.
30 CFR § 56.4104 Combustible waste.
30 CFR § 56.4531 Flammable or combustible liquid storage buildings or rooms.
30 CFR § 56.15005 Safety belts and lines.
30 CFR § 56.16002 Bins, hoppers, silos, tanks, and surge piles.
30 CFR § 56.16003 Storage of hazardous materials.
30 CFR § 56.16004 Containers for hazardous materials.
30 CFR § 56.16012 Storage of incompatible substances.
30 CFR § 77.208 Storage of materials.
30 CFR § 77.1102 Warning signs; smoking and open flame.
30 CFR § 77.1103 Flammable liquids; storage.
30 CFR § 77.1104 Accumulations of combustible materials.
30 CFR § 77.1710 Protective clothing; requirements. [see subpart (g)]
 Stacking and Storage (continued) Section 4

Injuries from Falling Materials

 Stacking and Storage (continued) Section 4

Pallet Loads

Is this pallet load secure and stable?

What is likely to happen when it is

moved with a lift truck?
 Stacking and Storage (continued) Section 4

Brick & Block Storage

• Stack bricks in a manner that will
keep them from falling.
– Do not stack them more than
seven feet high.
– Taper back a loose brick stack
after it is four feet high.

• If masonry blocks are stacked

higher than six feet, taper back
one-half block for each tier above
the six-foot level.

Internet Links

30 CFR § 56.16001 Stacking and storage of materials.

30 CFR § 77.208 Storage of materials.

 Stacking and Storage (continued) Section 4

Lumber

• Remove nails before stacking.

• Stack on sills.

• Stack lumber so that it is

stable and self supporting.

Internet Links

30 CFR § 56.16001 Stacking and storage of materials.

30 CFR § 77.208 Storage of materials.

Stacking and Storage (continued) Section 4
Stacking and Storage (continued) Section 4
 Stacking and Storage (continued) Section 4

Disposal of Waste Materials

• Rope off or barricade and
post the area below if
material is dropped.

• A safer alternative is to
lower material with a
crane, or through a chute
as shown here.

Internet Links

30 CFR § 56.11012 Protection for openings around travelways.

30 CFR § 56.16010 Dropping materials from overhead.
30 CFR § 56.20011 Barricades and warning signs.
30 CFR § 77.203 Use of material or equipment overhead; safeguards.
30 CFR § 77.204 Openings in surface installations; safeguards.
 Stacking and Storage Section 4

Section Review
Summary

Some of the major key points of this

section are summarized below:

Stacking and Storage

• Good housekeeping – keep aisles,

passageways, & work areas clear

• Store/stack materials safely to avoid

struck-by/crushed-by/fire hazards.
 Stacking and Storage Section 4

Sample Quiz
Select All That Represent Correct Methods or Statements

a. Limited heights
b. Wider layers near top
c. Removing items from bottom first
d. Secure loads
1. Methods to reduce hazards associated with
e. Interlocked packages
stacked or tiered materials include:
f. Removing nails before stacking lumber
(Select all that apply.)
g. Shrink wrapping
h. Stacking combustible material as close as
possible to overhead sprinklers
i. Always storing drums on their side
a. Never store inside.
b. Separate from other material.
2. Which items should apply to storage of c. Prohibit smoking in the area.
flammable liquids? (Select all that apply.) d. Only plastic containers can be used.
e. The National Fire Protection Association is a
good source of information.

Quiz Continued on Next Slide

 Stacking and Storage Section 4

Sample Quiz (continued)

Select All That Represent Correct Methods or Statements

a. Use an enclosed chute when you drop material

more than twenty feet outside of a building.
3. Which items represent good
b. When debris is dropped through holes in the floor
practice for disposal of waste
without chutes, enclose the drop area with
materials?
barricades.
(Select all that apply.)
c. Keep oily rags and solvent waste in open containers
to allow ventilation.
 Conclusion Section 5

Summary
Some of the major key points of the course are summarized below:

Accident/Injury Problem
• Material handling – possibly the most serious safety problem
• Manual material handling injuries – 35% of injuries at surface mine/facility locations

Manual Handling of Materials

• Lifting “do’s”– minimize heavy lifting, stay close, wide stance, use legs
• Lifting “don’ts” – bending, twisting, jerking, reaching out
• Body mechanics – posture, change positions, lean/prop foot on something
• Consider back exercises.

Mechanical Handling of Materials

• Forklifts – inspect each shift; if defective, remove from service
• Watch for struck-by/crushed-by dangers.
• Forklifts – load low, speed slow, load uphill on grades
• Maintain safety equipment, no unauthorized modifications.
• Docks – brakes set, chocks &/or dock locks, dock plate, trailer floor & “nose” secure
• Inspect hoists frequently & thoroughly, & abide by load limits.

Stacking and Storage

• Good housekeeping – keep aisles, passageways, & work areas clear
• Store/stack materials safely to avoid struck-by/crushed-by/fire hazards.
 Section 5

Conclusion
Sample Test
True or False?

1. The subject of material handling can be divided into manual material

handling and mechanical material handling.

2. Material handling is often considered to be the most serious safety

problem in the nation.

3. Manual material handling injuries account for about 50% of all mining
injuries at surface locations.

4. While manual material handling accounts for many injuries, these injuries
are minor and rarely result in any lost work time.

5. The number of manual material handling injuries in mining has been

increasing at surface locations.

Test Continued on Next Slide

 Conclusion Section 5

Sample Test (continued)

Select All That Represent Correct Methods or Statements

a. Store heaviest objects on the floor.

b. No PPE is required.
c. Test the weight.
d. Split heavy loads into smaller parts when you can.
e. Obtain help (human or mechanical) for heavy objects.
6. Lifting
f. Get close and use a wide stance.
g. Use leg muscles for lifting.
h. Bend over with your knees straight and lift with the upper torso.
i. Jerk the load up quickly.
j. Reach out as far as possible to protect your trunk from the load.
a. Examine cable for damage.
b. Make sure area is free of tripping hazards.
c. Wear protective rubber gloves and use nonconductive hooks or other
7. Moving Trailing Cables protective devices.
d. Straddle the cable, pick it up in both arms, and hold it close.
e. Use mechanical help, like slings attached to bulldozers, as
necessary.

Test Continued on Next Slide

 Conclusion Section 5

Sample Test (continued)

Select All That Represent Correct Methods or Statements

a. Make sure you have solid footing.

b. Start with legs apart, knees bent, and back straight.
c. Hold shovel as close as possible to end of handle so you can reach
8. Shoveling
further.
d. Lift with your legs.
e. Twist your trunk to throw material to the side.
a. Maintain good posture.
b. Don’t lean on anything when standing.
9. Standing, Walking,
c. Always keep both feet flat on the floor when standing.
Sitting, Driving
d. Sit all the way back in a firm-back chair.
e. When sitting or driving take occasional breaks to walk around.

Test Continued on Next Slide

 Conclusion Section 5

Sample Test (continued)

Select All That Represent Correct Methods or Statements

a. Normal lifting techniques can be used for bagged material.

b. Only the “tripod lift” should be used for bagged material.
c. The “tripod lift” starts with one knee on the floor/ground.
10. Handling Bagged Material
d. The “tripod lift” requires increased arm strength.
e. The “tripod lift” is not recommended for persons with bad
knees.
a. Always get complete bed rest until you have been pain-free for
at least a week.
b. Follow the exercise routine prescribed by your doctor.
c. Flexion exercises are often recommended to alleviate and
11. Doing Back Exercises
prevent muscle spasms.
d. Use the pelvic tilt to start many of the back exercises.
e. Extension exercises are often helpful in alleviating disc-related
pain.

Test Continued on Next Slide

 Conclusion Section 5

Sample Test (continued)

True or False?

12. Mechanical alternatives to manual handling of materials should be

used whenever possible to minimize lifting and bending requirements.

13. If rear forklift wheels come off the ground when you try to lift a load,
always add weights to the rear.

14. Lift truck (forklift) training should include both truck related topics and
workplace related topics.

15. “Come-alongs” can be used interchangeably with hoists.

Test Continued on Next Slide

 Conclusion Section 5

Sample Test (continued)

Select the Most Correct Method or Statement to Complete Each Item

a. Not carry it.

16. On a forklift, if a load blocks your view you should b. Raise forks until you can see under it.
c. Travel in reverse.

a. Uphill.
17. If using a forklift to transport a load up a 12% grade, the
b. Downhill.
load should be
c. Not carried at all.

a. Setting the truck brakes.

18. At a loading dock, an effective dock-lock system can be b. Using wheel chocks.
accepted in place of c. Using a dockboard.
d. Inspecting the trailer floor.

a. Two inches
19. When transporting loads with a forklift, try not to raise the b. Eight inches
load more than about ___________ from the ground. c. Two feet
d. Eight feet

Test Continued on Next Slide

 Conclusion Section 5

Sample Test (continued)

Select ALL Correct Methods or Statements to Complete Each Item

a. Air conditioned cab

20. Lift trucks should have the b. Overhead protection
following safety equipment: c. Brakes
(Select all that apply.) d. Seat belts
e. Air bags

21. Recommended safe procedures a. Place heavy objects on bottom of load.

for using nonpowered hand
trucks & carts include: (Select all
that apply.)
22. Select ways to eliminate hazards
that may lead to injury when
using hoists to handle materials.
(Select all that apply.)
b. Don’t pile items above eye level.
c. Secure bulky, awkward, or delicate objects to the truck.
d. Always pull, don’t push.
a. Train employees in inspection, proper use, and operation.
b. Intentionally overload hoists occasionally to be sure they can
handle the normal loads.
c. Abide by load limits.
d. Inspect frequently.
e. Have specialized person inspect, as required.
f. Leave loads hanging to provide a clear walkway underneath.
g. Never lift people.

Test Continued on Next Slide

 Conclusion Section 5

Sample Test (continued)

Select ALL That Represent Correct Methods or Statements

a. Limited heights
b. Wider layers near top
c. Removing items from bottom first
d. Secure loads
23. Methods to reduce hazards associated
e. Interlocked packages
with stacked or tiered materials include:
f. Removing nails before stacking lumber
(Select all that apply.)
g. Shrink wrapping
h. Stacking combustible material as close as possible to
overhead sprinklers
i. Always storing drums on their side
a. Never store inside.
b. Separate from other material.
24. Which items should apply to storage of
c. Prohibit smoking in the area.
flammable liquids?
d. Only plastic containers can be used.
(Select all that apply.)
e. The National Fire Protection Association is a good
source of information.

Test Continued on Next Slide

 Conclusion Section 5

Sample Test (continued)

Select ALL That Represent Correct Methods or Statements

a. Use an enclosed chute when you drop material more

25. Which items represent good than twenty feet outside of a building.
practice for disposal and b. When debris is dropped through holes in the floor
demolition? without chutes, enclose the drop area with barricades.
(Select all that apply.) c. Keep oily rags and solvent waste in open containers
to allow ventilation.