Module 4

Title: Introduction to OSH

Title of the Lesson: Materials Handling and Storage
Duration: 2 hrs
Introduction:
Most injuries in industry occur while employees move materials. In every day
operations, workers handle, transport, and store materials. They may do so by hand,
manually operated equipment, or power operated equipment

Objectives

Working on this module should help you to:

1. demonstrate methods of safe manual handling;
2. discuss safe procedures in mechanical handling; and,
3. enumerate standard requirements on materials storage.

Materials handling and storage

Is a technique which includes the art of lifting, placing, storing or movement of
materials through the use of one’s physical strength or appropriate handling
equipment.

Two general classification of materials handling:

• manual materials handling
• mechanical materials handling.

A. Manual Materials Handling (MMH)

Manual material handling means transporting or handling things by one or more

workers by lifting, carrying, pushing, pulling, holding, lowering or moving of a load.
MMH can result in fatigue, injuries of the back, neck, shoulders arms or other body
parts.
Remember to stop and think before lifting any load and ask yourself whether
there is an even safer way to do the job.

Factors that makes manual handling hazardous

Hazards in MMH depends upon the load that you are handling, the task that you are
doing and the environment at the workplace.

The load
The risk of back injury increases during lifting, carrying, pushing and pulling of loads,
if the load is:
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 1. Too heavy - In manual handling, there is no exact weight limit. If the load is
handled several times in an hour a weight of 20 to 25 kg is heavy to lift for most
people.
2. Too large – To keep the load close to the body as possible is one of the basic
rule for lifting and carrying which is difficult to do if the load is too large.
3. Difficult to grasp – Sharp edges loads are difficult to grasp, it can injure workers
particularly in the incident of collision..
4. Unbalanced, unstable or if the contents can move –Workers carrying
unbalanced load may lose their balance and fall, due to uneven loading of the
muscles and sudden movement of load.
5. Difficult to reach - Stretched arms or twisting the chest while lifting requires
more muscular force, which causes to hurt the spine

The Task
The risk of back injury increases if the task
• uses poor lifting techniques (lifting too fast, too often, too
long, with back bent, while twisting or reaching too far, etc.)
• has to move material over long distances with insufficient
rest.
• does not take appropriate rest breaks
• requires continuous lifting, carrying and lowering for long
distances

The environment
The conditions where you are working can also contribute to hazards of MMH and
result in injuries if it has:
• surfaces that are uneven, sloping, wet, icy, slippery,
unsteady, etc.
• differences in floor levels or elevations
• poor housekeeping
• inadequate lighting
• cold or very hot and humid working environment
• windy conditions
• fast pace of work
• restricted movement because of clothing or lack of space

Manual materials handling also involve pushing and pulling motions at work.
You use various pushing and pulling techniques in a wide range of activities, such as:

• using manual carts and trucks

• sliding objects such as cartons on flat surfaces (tables, floors,
etc.)
• operating tools and controls
• opening and closing doors
• wrapping or enclosing objects in packaging materials

Because these actions are among the most common work activities, they are
also the cause of many injuries. However, there are no comprehensive injury statistics.

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The injuries resulting from these activities are not always recorded very specifically as
well.

Most common are overexertion injuries (e.g., back strain). Injuries due to slips
and falls are also often associated with pushing and pulling. Additionally, injuries to
fingers and hands can result when caught in, on, or between objects (e.g., between a
cart and the wall) and to lower legs when bumped by carts. Therefore, existing
statistics do not reflect the importance of pushing and pulling as work factors causing
injury because the injuries fall into different categories making them difficult to analyze.

Because of the complex nature of body motion during pushing and pulling, no
numerical standard has yet been developed that can be directly applied in industry.

Many factors affect the amount of force that you exert in a horizontal push and
pull:
• body weight and strength
• height of force application
• direction of force application
• distance of force application from the body
• posture (bending forward or leaning backward)
• friction coefficient (amount of friction or grip between floors
and shoes)
• duration and distance of push or pull
DOLE BOSH Training Manual

What types of protective clothing should be worn?

DO WEAR
• lightweight, flexible, tear and puncture-resistant clothing,
safety boots with toe caps and slip-resistant soles, and
protective gloves, appropriate for the materials being
handled.

Do not wear:
Apron, coats
Clothing with exposed buttons, zippers or loose flaps or heavy-duty mitts

B. Manual handling guides

1. Shoveling guidelines

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 Put weight on front foot. Use leg to push shovel.

Shift weight to rear foot. Keep load close to body.

Keep feet wide apart. Place front foot close to shovel

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Turn feet in direction of throw
Source: https://www.ccohs.ca/oshanswers/ergonomics/shovel.html

2. Digging guidelines

Push spade down using leg muscle

Slide load close to body. Ensure load is loose from ground before lifting
3. Lifting Guidelines
Make sure you do some safety precautions before carrying out a manual handling
task.

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Think before lifting/handling – plan the lift

 what you're going to be lifting

 where it needs to go.
 Plan your route,
 clear the way/ remove obstruction
 plan any rest stops you might need on a table or bench to change grip
Adopt a stable position - The best way to do this is :

 by standing with your feet apart,

 one foot slightly in front to help you maintain your balance.
 If the load you're going to be lifting is on the ground, your foot should
be to the side of it.
 Be prepared to move your feet during the lift to maintain your stability.
 Avoid tight clothing or unsuitable footwear, which may make this
difficult.
Get a good hold. - Wherever possible:

 Hug the load as close as possible to your body. This will usually provide more
stability than gripping it tightly with hands only.

Start in a good posture- Before lifting the load:

 Slight bending of the back, hips and knees is better to fully flexing the back
(stooping) or fully flexing the hips and knees (squatting).
 Make sure that you don't flex your back more throughout the lift. This can
occur if you straighten your legs before lifting the load

Source: https://www.pennyhydraulics.com/help-guides/manual-handling-guidelines-safe-
manual-lifting-at-work/

Don’t flex the back any further while lifting. - This can occur if the legs begin to
straighten before starting to raise the load.
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Keep the load close to the waist.
 While lifting keep the load close to the body for as long as possible.
 Keep the heaviest side of the load next to the body.
 Try to slide the load towards the body before attempting to lift it.
Avoid twisting the back or leaning sideways, especially while the back is bent.
 Try to avoid twisting or leaning sideways, especially while your back is
bent during the lift.
 Shoulders should be kept at equal level and facing in the same
direction as the hips.
 Turning by moving the feet is much better than twisting and lifting at the
same time. This may help you avoid injury.
Keep the head up when handling. Look forward, instead of looking down at the
load, as soon as it has been held tightly.

Move smoothly. The load would not be jerked or snatched as this can make it very
hard to keep control and can increase the risk of injury.
Don’t lift or handle more than can be easily managed.

 You must always lift loads that you can manage.

 Over-loading yourself is unsafe make the task

 Seek advice from your superior. if you're in hesitation about whether you're
able to lift a particular load,

Put down, then adjust. If accurate positioning of the load is needed, put the load
down first, then slide it into the preferred position.

Source: https://www.pennyhydraulics.com/help-guides/manual-handling-
guidelines-safe-manual-lifting-at-work

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The Manual handling operations or procedures can cause a wide range of the acute and the
chronic injuries to the workers. The Acute injuries usually head to the sick leave from the
work and the period of rest during which time the damage recover or heals.

Chronic injuries build up over the long period of the time and are irreversible, producing
illnesses such as the person with arthritis and spinal disorders.

a. Lifting a Compact Load

A compact load can be lifted between the knees.

Remember to:
 Stand close behind the load.
 Straddle the load:
 Place the leading foot flat beside the load in the direction of travel.
 Place the rear in the direction of travel.
 Bend the hips and knees.
 Keep your back straight.

When lifting…

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 • Grasp the load with elbows inside the thighs:
o Use a power grasp for loads with handles.
o Use slings or hooks to improve grasp when
loads do not have handles.
o Use blocks under loads without
handles to make lifting them up easier and
safer. o Use a ledge grasp for loads
without handles.
• Grasp with one hand at the outer, upper corner,
over the leading foot and the other hand on the
lower, opposite corner.
• Lean forward with the rear arm straight. This
position gets the load moving.
• Stand up by thrusting off with the back leg and
continuing in an upward and forward direction.
• Keep the load close to the body.
• Keep the rear arm straight.
• Move off without twisting the body.

When putting a load down…

• Take a wide stance with one foot in front of the
other.
• Keep the load close to the body.
• Keep the back straight.
• Bend the hips and knees.
• Set the load down onto the ground.
• Keep the load tilted to avoid bruising fingers.
• Remove fingers from under the load.
• Stand up smoothly, easing muscles.
• Avoid jerky releases.

b. Lifting a Compact Bag

The best way to handle a bag depends on its size, weight, stability, and how
far it is to be carried.

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When lifting, remember to:

 Straddle the end of the bag.

 Bend the hips and knees.
 Keep the back straight.
 Use a secure grip.
 Grasp the bag with both hands under the closer end. Keep elbows inside the
thighs.
 Lean forward, straightening the knees to set the bag upright.
 Readjust the straddle position moving feet closer to the bag.
 Readjust the grasp, with one hand clasping the bag against the body and the
other under it.
 Stand up by thrusting off with the back leg and continuing in an upward and
forward direction.
 Lift the bag up with the knee while straightening the body.
 Do not twist your body.
 Put the bag on the shoulder opposite the knee used to thrust the bag up.
 Stabilize the bag on the shoulder.
 Begin moving without bending sideways.

When lowering the bag…

Avoid unloading a bag from the shoulder directly to floor level. Use an intermediate
platform or get help from a co-worker.

 Stand close to the platform.

 Place one foot in front of the platform.
 Bend hips and knees.
 Keep the back straight.
 Ease the bag off the shoulder and put it upright on the platform.
 Pull the bag slightly over the edge of the platform.
 Stand close to the platform with the bag touching the chest.
 Clasp the bag against the body with one hand, the other hand holding bottom of
the bag.
 Step back.
 Bend hips and knees, keeping back straight.
 Ease the bag on the floor.

What are more tips?

 Avoid lifting from the floor whenever possible.

 Use mechanical assistive devices such as a hand truck, a scissor lift, load lifter or
pneumatic lifter to raise or lower the load.

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  Lift with the help of a co-worker (preferably of similar height, if possible).
 Raise or lower the work surface to suit the height of the worker.
 Wear gloves that are the proper size for the individual and that have a surface
that will increase grip stability.
 Pad the shoulder to provide a cushion.

Source:https://www.ccohs.ca/oshanswers/ergonomics/mmh/compactbags.html

c. Lifting sacks

c.1. Heavy and Large Sacks

Lift heavy and large sacks in two stages using an intermediate platform.
When lifting, remember to:

 Straddle the end of the sack.

 Bend the hips and knees.
 Keep the back straight.
 Don't stoop.
 Grasp the bag with both hands under the end closest to you. Keep elbows inside
the thighs.
 Lean forward and straighten the knees to set the bag upright.
 Move your feet closer to the sack.
 Squat with the sack between the thighs with one foot flat on the floor in front of
the other.
 Grasp the sack with your elbow inside the thighs. With one hand clasp the sack
against your body and use your other hand to hold the bottom of the sack.
 Stand up in one smooth motion.
 Place the sack upright on the platform.
 Place one foot in front of the other with the front foot along side of the platform.
 Bend the hips and knees and keep the back straight.
 Put one shoulder against the sack.
 Readjust your grasp.
 Lean the sack against your shoulder.
 Stand up and straighten the hips and knees.
 Make sure your hands and feet are clear when putting the load down.

c.2. Bulky Sacks

Bulkier sacks are easier to carry on your back. Lift the sack onto your back from a
platform as described below.

 Move the sack to the edge of the platform.

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  Put your back against the sack.
 Grasp the sack with both hands on the upper corners of the sack.
 Ease the sack onto your back, bending your hips and knees before taking the
weight.
 Keep your back straight.
 Stand up and straighten your hips and knees.
 Stabilize the sack.
 Move away without bending sideways.

c.3. Two person lift and stack

 Position one person on either side of the sack.

 Squat with one foot balancing behind the sack.
 Keep your back straight.
 Hold the bottom of the sack with your closer hand and grasp the upper corner
with your outer hand.
 On one person's command, both people:
o Stand up and straighten their hips and knees.
o Move towards the stack.
o Put the sack on the stack.

https://www.ccohs.ca/oshanswers/ergonomics/mmh/sacks.html

d. Lifting Drums and barrels

Handling drums and barrels can be dangerous. Do not handle drums and barrels
without training. Use lifting equipment or assistance devices whenever possible.
d.1 Raising drum from the ground
Use mechanical aids whenever possible. Do not attempt to raise a full drum alone.

 Make sure that the drum is empty before raising it.

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  Stand at the end of the drum.
 Place one foot forward at the side of the drum, the other behind.
 Bend your hips and knees.
 Keep the back straight.
 Grasp the rim about 15 cm from the ground with the elbows inside thighs.
 Stand up by thrusting off with the back leg and continuing in an upward and
forward direction.
 Bring the back leg forward as if you are walking. Keep close to the drum.
 Stop at the balance point to change hand grip.
 Set the drum on its base by moving back leg forward. Use the body weight as a
counter balance.

d..2 Two person lift

 Use two people to lift a full drum.

 Use the same technique as with one person, but have two people squatting at
either side of the drum.

d..3 Moving a standing drum

 Stand close to the drum with feet apart. One foot at the front and the other
behind.
 Keep knees slightly flexed.
 Put your hands firmly against upper rim of the drum.
 Keep arms straight with the elbows "locked".
 Rock the drum gently to get the feel of its contents before you move it.
 Push the top of the drum away by extending the back leg and shifting your body
weight onto your front leg.
 Stop tilting the drum at the balance point. Use back leg as a counter balance.

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Should drums be lifted manually when they are stacked?
No. Always use cranes or lift trucks to stack drums.

Source: https://www.ccohs.ca/oshanswers/ergonomics/mmh/drums.html

e. Lifting Sheet Material

 Stand close to the pile of sheets in a walking stance.

 Grasp sheet firmly at the mid-point of its long side with the closer hand.
 Pull the sheet up and towards your body.
 Change your grip using your other hand and put your fingers on top of the sheet.
 Pull sheet up to a vertical position and to the side until one half is off the pile.
 Grasp the lower edge of the sheet with the free hand and support the hand by
placing it on your knee.
 Stand up without bending and twisting your body.

What should be done when carrying the load?

 Use drywall carts to carry sheet materials.

 Get help from another person where carts are not available.
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  Apply carrying handles for manual carrying.
 Grasp the carrying handles firmly when carrying the load.
 Always use gloves and carrying handle for glass and other materials with sharp
edges.
 Make sure the pathway is clear and has no obstructions.

Source: https://www.amazon.com/Sheetrock-Drywall-Handling-Service-Skroutz/dp/B0776F6XVH

Source: https://www.amazon.in/Carrier-Gripper-Drywall-Plywood-carrying/dp/B07P78YLLB

Source: https://www.ccohs.ca/oshanswers/ergonomics/mmh/sheetmaterials.html

C. Mechanical materials handling

As the name suggests, this pertains to use of rigid, manually or mechanically-powered

equipment mainly for handling bulky and heavy items.

1. Manually powered materials handling equipment reduce physical effort,

making materials handling easier and safer. Here are some tips when using
mechanical aids:

• Check for the availability of mechanical aids before lifting or moving

loads.
• Do not operate any equipment if you are not trained to use it.
• Keep the equipment in good operating condition. It saves effort
while transporting loads.
• Select the right equipment to complete the task.
• Specific tasks or objects require specialized equipment.
• Do not operate any equipment if you are not trained to use that
equipment.
• Keep the equipment in good operating condition. It saves effort
while transporting loads.
Here are some manually powered materials handling equipment:

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 • Use rolling platforms to assist in carrying and handling heavy
objects where limited space does not allow for comfortable body
position.

Source:https://www.rotomshop.co.uk/warehouse-transport/dollys-and-rolling-platforms/

Use a hand truck to move bulky objects

Source:https://www.storage-mart.com/tips/appliances/washing-machine

• Use a shelf truck to move a variety of objects.

 Use a platform truck to move heavy, irregularly shaped objects.

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Source:https://www.walmart.com/ip/Push-Cart-Dolly-Wellmax-Moving-Platform-Hand-Truck-Foldable-Easy-Storage-360-Degree-
Swivel-Wheels-330lb-Weight-Capacity-Yellow-Color/984

 Use a semi-live skid for temporary storage of work.

Source:https://www.tenaquip.com/product/rubbermaid-semi-live-skids-fg449400bla-ml597

 Select the rack or bin that suits the task and mount on semi-live skid or platform
truck.

(Left) Source: http://storageracksguzuisa.blogspot.com/2016/03/electronic-component-storage-racks.html

(Right )Source :https://docplayer.net/61797118-Pick-rack-systems-bin-shelf-combinations-ready-to-ship-call-or-shop-

online-for-other-styles-of-bin-racks-carts.html

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https://www.ccohs.ca/oshanswers/ergonomics/mmh/mechanicalaids_transport1.html

What other mechanical aids can used?

Specific tasks or objects require specialized equipment.

 Select the right equipment to complete the task. Equipment is rated for different
capacities, which determine the maximum weight the equipment can safely
handle, and the conditions under which it can handle those weights.
 Do not operate any equipment if you are not trained to use that equipment.
 Keep the equipment in good and safe operating condition. It saves effort while
transporting loads.
 Visually inspect the equipment for any defects such as loose wheels or damaged
platforms before use.
 Be sure that the load is securely in place before moving.
 Always push the equipment rather than pull it.
 Select a stair climbing truck when moving a load on stairs.

Select a stair climbing truck when moving load on stairs.

Source: https://www.globalindustrial.com/g/material-handling/hand-trucks-dollies/hand-trucks-
steel/steel-stair-climbing-hand-truck

 Choose a sturdy frame hand truck with larger wheels to move materials in rough
terrain. Additional set of handles allows for assistance.

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 Source: https://www.screwfix.com/p/heavy-duty-hand-truck-300kg/3602p

• Use a pump truck to move materials stored on pallets.

Source: https://www.liftruck.co.uk/shop/pallet-trucks-general-range/euro-chep-pump-truck.html

• Move and dump waste materials with dump trucks.

Source: https://www.amazon.com/Trash-Cart-Wheels/s?k=Trash+Cart+with+Wheels

 Use a tilting drum stand and drum dollies to move emptied barrels and drums.

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 Source:https://presto-lift.com/m/Vestil/Drum-Handling-Equipment

• Handle sheet materials with an "A" frame hand truck or dolly.

Source:https://www.homedepot.com/p/Vestil-2-000-lb-Capacity-30-in-x-60-in-A-Frame-Cart-AF-3060/303210098

https://www.ccohs.ca/oshanswers/ergonomics/mmh/mechanicalaids_transport2.html

2. Mechanically-powered materials handling equipment

Are classified into two: lifting equipment and transport equipment. Lifting
equipment includes a variety of items for lifting heavy and bulky items with minimal
human intervention such as hoists and cranes. Transport equipment, on the other
hand, consists of forklifts, dump trucks, trailers and conveyors among others.

Lifting Equipment

Wire rope hoist Mini crane hoist

(left) Source:https://www.indiamart.com/proddetail/electric-wire-rope-hoists-8820437562.html
(right) Source:https://www.pinterest.ph/pin/399624166928563768/

Transport Equipment

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Forklift Conveyor Dump truck
(left) Source: https://www.pmhsi.com/
(center) Source: https://mujiacn.en.made-in-china.com/product/vjHnJDVoAbWM/China-Hairise-Custonerized-Types-Conveyors-for-
Transfering-Material.html
(right) Source: https://www.pngegg.com/en/png-mezpw

To ensure safe operation of mechanically-powered handling equipment, the

following precautions must be observed:
• A worker must not operate an equipment if he is not trained to use
it;
• Operators must be certified and authorized;
• Operators must be trained in safety and health involving handling
equipment operation; and,
• Equipment must be properly maintained and regularly inspected.

In both manually-powered and mechanically-powered materials handling equipment,

you can use accessories such as ropes, chains or steel/plastic straps to secure loads
and prevent them from sliding or falling from the equipment.

Ropes
• You should know what particular rope can handle particular
tasks/loads.
• Keep rope in good condition all the time.

Chains
• Do not let chains get kinked, knotted or twisted.

Steel and plastic straps

• Make sure straps are not too loose or tight.
• Do not lift by the strap unless the same is designed for that purpose.

References :
https://www.labtrain.noaa.gov/osha600/mod12/1201----.htm
http://www.osha.mddsz.gov.si/resources/files/pdf/E-fact_14_-
_Hazards_and_risks_associated_with_manual_handling_in_the_workplace.pdf
https://www.hse.gov.uk/toolbox/manual.htm

https://www.pennyhydraulics.com/help-guides/manual-handling-guidelines-safe-manual-lifting-at-
work/
Source: http://www.ccohs.ca/oshanswers/ergonomics/push1.html

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