Material Handling Safety

1. Material Handling Safety
johnanewquist@gmail.com
Draft 5 20
2015

2. January 2015
• Kevin Voyles was
killed in a GA factory
by falling marble
slabs.

3. Feb 2014
• Two men were killed in an
industrial accident at a granite
company facility in San
Francisco
• Two men were trapped after at
least one large slab of granite
fell on them as they unloaded
a container truck,

4. Dec 2013
• Todd L. Wolf, 51, was
operating the forklift
as it was being
unloaded from a
trailer.
• When the forklift
tipped, it crushed the
man beneath it.

5. Dec 2013
• $281 Million award
• Osorio was driving a
Heckmann tractor-trailer on FM
133 in TX and the drive shaft
broke off from under the truck.
• The part plowed through the
windshield of a pickup that
Aguilar was a passenger in
• The lawsuit alleged that the
drive shaft broke because the
defendants did not properly
maintain the tractor-trailer.

6. Nov 2013
Cont

7. Nov 2013 cont

8. May 2015
• Federal OSHA does not
specifically require employers
to equip forklifts with portable
fire extinguishers.
• However, if the manufacturer
equips its forklifts with fire
extinguishers, the employer
must maintain the
extinguishers
• Also, the Liquefied Petroleum
Gas standard 2006 edition
addresses their use in Chapter
9, which states that where
either the "authority having
jurisdiction" or the end user
requires an industrial truck to
be equipped with a portable
extinguisher
• The NFPA standard also says
that industrial trucks can only
be equipped with portable
extinguishers if operators have
been trained in their safe
operation and use.

9. July 2013
• Billy Johnston, 48, was killed in an industrial
accident in West Allis was lowering a 24,000
pound dust collector when a chain broke. He
was either hit in the head by the chain and
thrown 30 feet from the piece of equipment, or
he hit his head as a result of the fall

10. July 2013
• Rack on the right
• Slid forks in
• Tilted forks up
• Heard a pop
• Stuck hand in to see if
product damaged
• Rack back bar had
popped loose
trapping arm

11. July 2013
• $82,600
• An unapproved C-clamp
slid off a 2,600-pound
press brake ram as it was
lifted, causing the ram to
fall to the ground and pin
the worker pinning him to
the ground and resulting
in amputation at the knee.

12. May 2013
• Workers were lifting a bag of
processed powdered
chemicals.
• The bag, which weighed 3,675
pounds, was hoisted by
several straps designed to
bear the load.
• During the operation, one of
the straps failed, causing the
bag to drop.
• A worker’s arm and head were
wedged underneath the bag
while others worked to free
him.

13. Dekalb accident 1997
• Protect sling from sharp surfaces
• Employees were positioning a
22,000 pound generator with the
use of a truck-mounted crane and
four synthetic web slings.
• While the employees were moving
the generator, the slings contacted
a steel purlin and were cut.
• The generator fell and rolled onto
the employees.
• Employee #1 suffered fatal
internal injuries.
• Employee #2 suffered back
injuries and was hospitalized.
• Photo is an example

14. Struck By OSHA Reg 5

15. 2010 Accident Causation Factors
• 37 struck by falling object or load
• 34 struck by forklift
• 28 falls: includes 10 pallet, platform or forks, 8 forklift went off dock, 1 ejected
from forklift, 5 fall from load lifted, 1 fall through hole, 1 order picker platform, 2
mezzanine
• 27 crushed or caught in Forklift/load and an object
• 14 Forklift overturned
• 8 caught in amputation
• 5 burns / fire
• 3 CO, 1 Ammonia
• Type of forklift not included due many not identifying the type.

16. Falls
• Getting on a pallet
has lead to many
deaths and is not
acceptable.
• Employees use what
is available.

17. Struck-by
• What should be
done?
• Many foot crushing by
people too close.
• How close is too
close?’

18. Struck By
• Loads falling off kill
people.
• Loads improperly
stored kill people.
• What can be done?

19. Struck-by
• What should be done
when backing out?

20. May 2014

21. Overturned
• Curbs
• Seat belts
• Excessive weight
lifted

22. Certification
Initially
Every 3 years
Near Miss

23. Evaluation
Date of Certification
Operator’s name
Trainer’s Name

24. Training
• For classroom training
element, the employer may
demonstrate the employee's
successful completion by a
written or oral test or other
appropriate means, such as an
evaluation by the instructor.

25. Refresher Training
• Observe the powered
industrial truck operator
during normal operations
to determine if the
operator is performing
safely, and
• Ask pertinent questions to
ensure that the operator
has the knowledge or
experience needed to
operate a truck safely.

26. Is a Forklift a Crane?
• Slings use
• Qualified rigger?
• What can go wrong?

27. Pushing Loads
• Operators were
allowed to
“bulldoze” double
high pallets
• Issues are
obstructed view

28. Accidents – Forklift Leaves Dock
• November 1, 2000
• An employee was driving
a forklift truck in reverse.
She backed off of the
receiving dock and was
pinned under the forklift.
Operator was not wearing
seatbelt and the forklift
didn't have a overhead
guard.

29. Caught in
• Several under rack
caught in fatalities
• Driving into fixed
object
• Body part outside
frame of forklift

30. Seatbelts
• Seatbelts prevent the
operator from being
pinned by the truck or
overhead guard.

31. Inspection
• Barrel lifter with no
capacity plate
• Don’t forget unapproved
attachments that overload
the attachment

32. Fire / Burns
• Event Date: 08/13/2010
• Employee was operating a forklift at the time of the accident.
• The employee positioned the forklift to remove a tote of scrap paper.
• The forklift struck an overhead pipe containing toluene. The employee and
the forklift were dowsed in toluene.
• The employee pulled the equipment forward and then reverse the lift
moving back under the stream of toluene.
• Once past the toluene stream, the employee stopped the equipment and
climbed to a mezzanine to cut off the supply of toluene.
• The employee then remounted the forklift and drove to the locker rooms to
access the shower.
• The toluene ignited from an unknown source prior to the employee leaving
the lift seat.
• Both the employee and the lift were badly burned.
• 61 M Fatality

33. Truck Unloading
• Is there a procedure?

34. Mar 2014
• Cedar Rapids IA
• Jacob B. "Jake"
Harper, 28, died
Friday after steel
pipes slipped off of
a trailer, struck him
and caused fatal
injuries

35. Lockout or Guarding?
• The person who works on the forklift must know
the OSHA lockout standards.
• Forks can come down unexpectedly during
servicing.
• Any body part can be cut or crushed if caught in
a scissor point.
• Forklift maintenance fatalities – employees get
caught underneath because a jack fails, or
crushed between mast and frame of truck
because they didn’t block it

36. Forklift Amputation Hazard
• The mast has open
gears and scissor
points.

37. Fork Lift Platforms
• 5(a)(1) under
ANSI/ASME B56.1-
2000
• No screen on right.

38. Forklift Platforms
• Good Platform must
be guardrails
• Secureable
• Screen at forklift side

39. Slabs
• Several death
happening when
lifting large flat
objects

40. Operation
• Reverse travel if
operator cannot see
in front
• Seat belts
• Traffic control if in
road

41. Maintenance
• When working on any
vehicle/forklift,
cribbing or blocking
needs to be
performed in case of
hydraulic failure.

42. Riding on Forks
• Not allowed

43. Sample Safety Rules
• Follow Manufacturer’s
instructions and
OSHA regulations.
• Use ANSI B56
standards on forklifts
if you cannot get the
manufacturer’s rules..

44. Safety Rules
• Follow Warning
Labels.
• Only trained
personnel can
operate the lifts.
• A trained person must
inspect the machine
before each shift.
• And many more!

45. Training
• Hands on training is
necessary. An forklift
lift is not a car.
• The worker should be
able to demonstrate
all predicted uses of
the lift and
compliance with
manufacturers
instructions.

46. Cautions
• Watch for any holes.
These will flip some
forklift.
• These should be
identified in advanced
and plans to prevent
a forklift from going
into one is necessary.

47. Electrical
• 1/12/1999
• An employee was operating a
side loader, loading and
unloading rail car containers in
a terminal yard.
• A 7200-volt overhead power
line ran nearby, about 8.8
meters above the ground.
• The mast on the loader
reached up to about 9.1
meters.
• The employee brought the
mast of the loader into contact
with the power line.
• Three employees at the site
were electrocuted

48. Emergency Response
• What is your plan?

49. Struck By
• How can this be
avoided?

50. Fire
• Cylinder gases ignited
by forklift.
• What can be done?

51. Inspections
Why is this inspection form weak?

52. Inspections
• Before daily use using manufacturer’s
guidelines
• Check all working components and safety
device.
• Address all leakage of fluids.
• Search for defective hydraulic/pneumatic
cables.
• Look for electrical tape as quickfix that is
not acceptable.

53. Forklift Inspections
• Overhead guard
improperly welded

54. Inspection
• Labels

55. Inspection
• Load Extension
Backrest

56. Inspection
• How much wear is
acceptable?

57. Forklift Inspection
• Broken Fiberglass
Housing is a
laceration Hazard

58. Inspection
• Leaking Hydraulic
Fluid

59. Carbon Monoxide
0222 HCOOHC xx 
Perfect World:
Real World:
xxxxx HCNOCOOHCONOHC  2222

60. Acute Exposure
• Headache
• Nausea
• Weakness
• Irritability
• Unconsciousness
• Chest Pain

61. Chronic Exposure
• Headache
• Lassitude
• Dizziness
• Anorexia
• Ataxia

62. Best Practice and Required in MN
• General industry: Minnesota Rules § 5205.0116 Carbon Monoxide
Monitoring
• The employer shall monitor environmental exposure of employees to carbon
monoxide whenever internal combustion engine powered industrial trucks
are operated indoors to ensure that carbon monoxide levels do not exceed
those given in Code of Federal Regulations, Title 29, section 1910.1000,
Table Z-1-A.
• The air monitoring shall be done at least quarterly and represent exposures
during a day of highest usage in the areas where employee carbon
monoxide exposure is most likely.
• Subpart 2. Tailpipe exhaust gas analysis. The employer shall ensure that
powered industrial truck engine exhaust gases do not contain more than
one percent carbon monoxide for propane fueled trucks or two percent
carbon monoxide for gasoline fueled measured at idle and at three-fourths
throttle during final engine tuning in a regular maintenance program.

63. Exposure Limits
• OSHA 50 ppm 8-hour
Time Weighted Average
(TWA)
• NIOSH 35 ppm 8-hour
TWA
• 200 ppm Ceiling by
NIOSH
• ACGIH Threshold Limit
Value is 25 ppm 8-hour
TWA; 40-hour work week

64. PPM CO Time Symptoms
200 2-3 hours Headache, fatigue,
nausea
400 1-2 hours Symptoms intensify. Life
threatening after 3 hours.
800 45
minutes
Dizziness, nausea,
convulsions. Death after
2-3 hours.
1600 20
minutes
Dizziness, nausea,
convulsions. Death
within 1 hour.

65. ACGIH Recommendations
• Limit CO
concentration to 1%
or less for propane
fueled trucks
• Limit CO
concentration to 2%
or less for gasoline
fueled trucks.

66. Prevention of CO Poisoning
• Maintain equipment in good working
order
• Provide periodic tune-ups for forklifts to
ensure that they run “lean”
• Periodic CO analysis of exhaust gases
to determine emission concentrations
• Provide adequate ventilation
• Install CO monitors

67. Forklift Exhaust
• No Violation.
• This forklift emits low
level of CO.

68. Storage
• What is the problem
and solution?

69. Storage
• No Violation.
• Material stored
properly in racks.

70. Storage
• Cylinders must be
secured from
falling down.

71. Material Handling
• Rack was hit by
forklift and tagged out
and pallets removed.

72. Material Handling
• No Violation
• Aisle properly marked
• Clean lanes

73. Aisles Not Marked

74. Struck By
• No Violation.
• Corner marked so
forklift operation can
see around corner.

75. Raised Dump Truck Bed
• Event Date: 01/05/2010
• Employee # 1 was attempting
to lower the bed of a detached
dump trailer which had
become stuck in the upright
position.
• The employee was working in
between the trailer bed and
frame when the bed fell
crushing the employee.
• Employee # 2 who assisted
employee # 1 but was standing
outside the caught between
area was also struck by the
falling trailer bed but sustained
only minor injuries.
• 34 M Fatality
Use physical stops to hold up in case of failure.

76. Semi-trailers
• Two fatals getting
caught between truck
and object.
• Trailer often is not
level causing load to
roll off
• Load straps release
improperly stacked
loads.

77. Skid Steer
• Two fatals from being
struck by moving
Skidsteer
• One death from caught in
frame and bucket arm
• Aug 2013 Matthew
Mallett was riding in the
skid loader driven by his
great-aunt, Gail
Henderson, 49, when he
fell out.

78. Jan 2014
• 43-year-old Ronald L.
Meier, of Maria Stein,
Ohio, was working on
a skid loader when
the bucket fell,
pinning him between
the loader and the
bucket

79.  Lock-Out Tag-Out Considerations:
1. Review requirements for the individual crane.
2. Integrate lock out and maintenance requirements.
3. Ensure training in adequate for level of maintenance.
4. Ensure written programs are established and reviewed.
5. Carefully select lockout devices, ask the manufacturer for
recommendations.
6. Do not necessarily assume devices are interchangeable
between different types of cranes.
REVIEW THE MANUFACTURERS SPECIFIC INSPECTION REQUIREMENTS!
LOCKED
OUT
This Lock/Tag may
only be removed by
NAME: __________
DEPT : __________
COMPLETION
DATE: ___________
TIME: ____________
DON’T OPERATE
DANGER

80. 2
TON
ACME
CRANE
ALWAYS CHECK LOAD RATING
10
TON
10
TON CAP.
10 TON CAPACITY
KNOW THE RATED LOAD OF THE CRANE
BASICS OF CRANE SAFETYBASICS OF CRANE SAFETY

81. BASICS OF CRANE SAFETY
5 TON
ALWAYS ENSURE
THE LIFTING
DEVICE AND ALL
SUPPORTING
COMPONENTS ARE
RATED FOR THE
LOAD TO BE
LIFTED!
2
TON
10 TON LOAD
KNOW THE RATED LOAD OF THE CRANE
BASICS OF CRANE SAFETY

82. BASICS OF CRANE SAFETY
NEVER ALLOW A COWORKER
BETWEEN A FIXED OBJECT AND
A LOAD!
ACME
CRANE
2
TON
DANGER
WORKING
CRANES
BASICS OF CRANE SAFETY

83. BASICS OF CRANE SAFETY
2
TON
ACME
CRANE ALWAYS POSITION
LIFTING DEVICE
DIRECTLY OVER
LOAD BEFORE
LIFTING!
THINK BEFORE YOU LIFT
BASICS OF CRANE SAFETY

84. BASICS OF CRANE SAFETY
DISSIPATE ALL HAZARDOUS ENERGY
DANGER
HIGH
VOLTAGE
Always Ensure Energy
Sources Are Dissipated
Before Initiating Any
Maintenance Activity.
2
TON
ACME
CRANE
BASICS OF CRANE SAFETY

85. Accident
• 5/6/08
• No bridge stops
for pendant
controlled crane
• Crane ran off rails
and the lifting
device and crane
hit employee
•

86. Accident
• 03/19/2008
• Bridge Crane
employee was
servicing bridge
crane and fell
approximately 58 feet.

87. Accident
• 12/20/2007
• One of the four man
ground crew working
with a mobile
underhung bridge
crane got too close to
the wheel of the
crane and was ran
over.

88. Accident
• March 14, 2008
• A 1,868 pound plate fell
from the C-clamp and
onto the employee.
• These devices must be
designed and rated for
lifting steel plates.

89. Accident
• Tuscaloosa AL
• “Where passageways or
walkways were provided,
obstructions were so placed
that the safety of personnel
was jeopardized by
movements of cranes,”
• “employee was using a crane
to move a sheet of steel to the
hot bed when one of the
wheels of the crane's floor rail
system ran over Korey Ryan's
foot.”
Typical rail gantry crane

90. Quiz
• How often does a forklift driver have to be re-
evaluated/certified? __________
• OSHA’s limit for Carbon Monoxide in an 8 hour
shift is ____ ppm.

91. Summary
• Training
• Job Hazard Analysis
• Written procedures
• Manufacturer rules
• Inspections

92. Questions?

93. Further
• This ppt was prepared by John Newquist as a
preliminary aid for people required to evaluate
aerial lifts.
• Thanks to Misette Kobler, Janet S., for
corrections and suggestions.
• This is not an official OSHA publication. Those
will be on the OSHA.gov website.
• Newquist.john@dol.gov is my email if you see
any errors. This is just a draft as of the cover
date.
• 312-353-5977