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MATERIAL HANDLING

TUTOR

12 February 2020

GROUND RULES
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SAFETY STEPS TO
FOLLOW INSIDE CLASSROOM
1. STAY IN YOUR PERSONAL SPACE.

2. SIT IN YOUR DESIGNATED AREA.

3. BE CAREFUL WHEN YOU SIT, MAKE SURE THE FURNITURES

ARE IN GOOD CONDITION.

4. DON’T TOUCH OR OPERATE COMPUTER/PROJECTOR AND ITS

PERIPHERALS.

5. 5. WEAR MASK IF ADVISED.

CLASSROOM SAFETY

6. USE YOUR OWN MATERIALS .

7. DON’T EAT INSIDE TRAINING ROOM.

8. DON’T CARRY TOOLS & EQUIPMENT

TO THE TRAINING ROOM.

9. KEEP THE AREA CLEAN & TIDY, DON’T LEAVE

WASTE MATERIALS BEHIND.

10. REPORT ANY DAMAGES TO THE CONCERNED

PERSON IMMEDIETLY.
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SAFETY MOMENT

1. SWITCH OFF/ SILENT YOUR MOBILE PHONES.

2. SMOKING IN DESIGNATED AREAS ONLY

3. REGARDLESS OF YOUR POSITION WE ALL PLAY

VITAL ROLE IN ENSURING WE DO THINGS SAFELY

SAFETY MOMENT

TWO SIDES OF SAFETY: VISIBLE & INVISIBLE.

1. THINGS WE CANNOT SEE BUT KNOW THEY EXIST

• 2. THINGS WE CAN OBSERVE & MEASURE

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Safety Moment

DID YOU KNOW

If Your Personal Protection Equipment isn't exactly
right, things can go seriously wrong

For many tasks, PPE is the only thing that stands between you and injury- or
worse. Whether we're talking respirators, safety glasses, helmets, steel toe
boots, fire resistant clothing or chemical suits.

Its not enough to just identify the correct PPE for the hazards at hand.

Your equipment should be proper fit and regularly maintained and inspected
before use.

For example, did you know that hard hats have expiration dates? And for good
reason, plastic gets brittle with age. After a while or once its sustained a
serious blow- a hard hat needs to be replaced.

MATERIAL HANDLING
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Introduction
Lesson objectives:
1. Identify types of hazardous materials and how
exposures can occur.
2. Identify hazards associated with hazardous
materials, including injuries that may occur.
3. Describe methods for eliminating physical
hazards of hazardous materials.
4. Describe methods for eliminating health hazards
of hazardous materials.

Types
• HAZARDOUS
• NON HAZARDOUS
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Hazardous Materials
What are hazardous materials?
• Group of products for which the storage, handling,
and use are regulated under the Hazardous
Materials standard
• Primarily associated with physical hazard
• May also pose health hazard

Exposure to Hazardous Materials

Examples of worksite exposure:

• Operations involving the storage, handling,
and/or use of:
• Compressed gases
• Liquefied gases – anhydrous ammonia, chlorine, propane,
nitrous oxide, and carbon dioxide
• Non-liquefied gases – oxygen, nitrogen, helium, and argon
• Dissolved gases - acetylene
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Exposure to Hazardous Materials

• Flammable liquids
• Category 1 – ethyl ether, isopentane, propylene oxide
• Category 2 – acetone, benzene, ethyl alcohol, gasoline
isopropyl alcohol, toluene
• Category 3 – naphtha, turpentine, xylene
• Category 4 – ethylene glycol, glycerine
• Cryogenics and refrigerated liquids – oxygen, nitrogen,
argon, hydrogen, helium LNG, Liquid methane, carbon monoxide
• Liquefied petroleum gases (LPGs) – propane, propylene,
butane, and butylene
• Explosives and blasting agents

Exposure to Hazardous Materials

• Spray finishing operations

• Dipping and coating operations
• Processing of highly hazardous
chemicals
• Clean-up and management of
hazardous waste operations
and emergency response

Source: FEMA; S. Shapira

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Exposure to Hazardous Materials

Additional precautions for hazard exposures:
• Hazardous (classified) locations
• Confined spaces

Source: OSHA

Exposure to Hazardous Materials

Routes of entry:
• Inhalation*
• Ingestion
• Absorption
• Injection

* Most Common

Source: Construction Safety Council, used with permission.

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Hazards of Hazardous Materials

Types of physical hazards associated
with hazardous materials:
• Oxidizer • Corrosive to metal
• Flammable • High-pressure
• Explosion systems

Source of pictograms: OSHA

Hazards of Hazardous Materials

Types of health hazards associated with
hazardous materials:
• Acute/chronic toxicity • Germ cell mutagenicity
• Skin corrosion or irritation • Carcinogenicity
• Aspiration hazard • Reproductive toxicity
• Serious eye damage • Specific target organ
or eye irritation toxicity
• Respiratory or
skin sensitization
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Hazards of Hazardous Materials

Compressed gases:
• Oxygen displacement
• Fires
• Explosion
• Toxic gas exposures
• Physical hazards associated
Source: OSHA

with high pressure systems

Hazards of Hazardous Materials

Cryogenic and refrigerated
liquids:
• Extreme cold
• Extreme pressure
• Asphyxiation
• Fire or explosion

Source: OSHA
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Hazards of Hazardous Materials

Flammable liquids:
• Fire
• Explosion
Source: OSHA

Criteria for Flammable Liquids

Category Criteria

1 Flashpoint < 73.4°F and initial boiling point ≤ 95°F

2 Flashpoint < 73.4°F and initial boiling point > 95°F

3 Flashpoint ≥ 73.4°F and ≤ 140°F

4 Flashpoint > 140°F and ≤ 199.4°F

Hazards of Hazardous Materials

Spray finishing:
• Flammable/combustible materials
• Health hazards
• Example: Isocyanates
• Powerful irritant to eyes and
gastrointestinal and
respiratory tracts
• Inflammation to skin
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Hazards of Hazardous Materials

Liquefied petroleum gases (LPG):
• Pictograms:
• Signal word: Danger
• Hazard statements:
• Extremely flammable gas.
• Contains gas under pressure;
may explode if heated.
• May cause frostbite.
• May form explosive mixtures in air.
• May displace oxygen and cause rapid suffocation.

Hazards of Hazardous Materials

Anhydrous ammonia:
• Pictograms:
• Signal word: Danger
• Hazard statements
• Flammable Gas
• Contains gas under pressure
• May explode if heated
• Toxic if inhaled
• Causes severe skin burns and eye damage
• Corrosive to respiratory tract
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Hazards of Hazardous Materials

Hazardous (classified) locations:
• Class I – flammable gases or vapors
• Division 1
• Division 2
• Class II – combustible dust
• Division 1
• Division 2
• Class III – ignitable fibers or flyings

Hazards of Hazardous Materials

Confined spaces:
• Limited or restricted means
for entry/exit; not designed
for continuous occupancy
• PRCS contains or has
potential to contain
hazardous atmospheres
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Controlling Physical Hazards

Source: NIOSH

Controlling Physical Hazards

Compressed gases:
• Compressed gas cylinders shall be in a safe
condition to the extent that this can be
determined by visual inspection.
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Controlling Physical Hazards

Safety can:
• Not more than
5 gallons capacity
• Spring-closing lid
• Designed to relieve internal
pressure when subjected to
fire.

Controlling Physical Hazards

Cabinets:
• Not more than 60 gallons
of Category 1, 2, or 3
flammable liquids, nor
more than 120 gallons of Category 4
flammable liquids.
• Suitable fire control devices shall be
available at locations where
flammable liquids are stored.
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Controlling Physical Hazards

Ventilation:
• Category 1 or 2 flammable liquids, or Category
3 flammable liquids with a flashpoint below
100 °F (37.8 °C), shall be ventilated at a rate of
not less than 1 cubic foot per minute per
square foot of solid floor area.

Controlling Physical Hazards

Explosion-proof apparatus:
• Apparatus enclosed in a case that is capable of
withstanding an explosion of a specified gas or vapor
that may occur within it and of preventing the ignition
of a specified gas or vapor surrounding the enclosure
by sparks, flashes or explosion of the gas or vapor
within, and that operates at such an external
temperature that it will not ignite a surrounding
flammable atmosphere.
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Controlling Physical Hazards

Grounding:
• Category 1 or 2 flammable
liquids, or Category 3
flammable liquids with a
flashpoint below 100 °F (37.8
°C), shall not be dispensed into
containers unless the nozzle
and container are electrically
interconnected.

Controlling Physical Hazards

Intrinsically safe:
• An apparatus/equipment in which all the circuits in
which any spark or thermal effect is incapable of
causing ignition of a mixture of flammable or
combustible material in air.
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Controlling Health Hazards

Controlling Health Hazards

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Controlling Health Hazards

Controlling Health Hazards

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Controlling Health Hazards

Controlling Health Hazards

Process Safety Management (PSM) of highly
hazardous chemicals:
• Regulations designed to prevent the release of
toxic, reactive, flammable and/or explosive
chemicals.
• Contains a list and threshold limits for when
employers must comply.
• Anhydrous Ammonia - 10,000 lbs
• Chlorine - 1,500 lbs
Controlling Health Hazards
Hazardous Waste Operations and Emergency
Response (HAZWOPER):
• Applies to employers and their employees who
are exposed to hazardous substances and who
are engaged in several operations including
clean-up, treatment, storage and disposal of
hazardous waste.

Hazardous Materials Worksheet

Hazard Anticipation

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Hazardous Materials Worksheet
Hazards Identification

Hazardous Materials Worksheet

Hazards Evaluation
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Hazardous Materials Worksheet

Hazards Controls - Engineering

Hazardous Materials Worksheet

Hazards Controls - Administrative
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Hazardous Materials Worksheet

Hazards Controls - PPE

Knowledge Check
1. The most common route of entry by which
hazardous materials are introduced into the
body is ___.
a. inhalation
b. absorption
c. ingestion
d. injection

Answer: a. inhalation
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Knowledge Check
2. Flammability is which type of hazard?
a. Carcinogenic
b. Health
c. Physical
d. Mutagenic

Answer: c. Physical

Knowledge Check
3. Which of the following hazards is an example
of a physical hazard?
a. Oxidizer
b. Exposure to carcinogen
c. Chronic toxicity
d. Acute toxicity

Answer: a. Oxidizer
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Knowledge Check
4. Which of the following hazards is an example
of a health hazard?
a. Fire hazard
b. Acute toxicity
c. Explosive
d. High pressure

Answer: b. Acute toxicity

Knowledge Check
5. Which of the following is the preferred order of
controlling hazards, or “hierarchy of controls,” for
hazardous materials?
a. PPE, Administrative Controls, Engineering Controls,
Elimination
b. Administrative Controls, Engineering Controls,
Elimination, PPE
c. Engineering Controls, Elimination, PPE, Administrative
Controls
d. Elimination, Engineering Controls, Administrative
Controls, PPE

Answer: d. Elimination, Engineering Controls,

Administrative Controls, PPE
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Knowledge Check
6. When transferring a flammable liquid from one
container to another, the containers should be ___
to prevent static electricity from creating a fire
hazard.
a. ventilated or pressurized
b. ventilated and pressurized
c. bonded or grounded
d. bonded and grounded

Answer: d. bonded and grounded

MSDS
• Material safety data sheet- Always refer to a MSDS
before handling hazardous material.
• It has 16 sections
1. Chemical Product Name
2. Hazardous Contents
3. Hazard Identification
4. First Aid Measures
5. Fire Fighting Measures
6. Health and Safety
7. Accident Release Measures
8. handling and Storage
9. Physical and Chemical Properties
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MSDS
10. Stability and Reactivity
11. Toxicological Issues
12. Ecological
13. Disposal
14. Transportation
15. Regulatory Issues
16. Other
Show a Sample MSDS

Legal Responsibilities

Health & Safety At Work Etc Act

1974 (HASAWA)
“every employer must ensure, as far as is reasonably
practicable, the health, safety and welfare at work
of all employees”
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Health & Safety At Work Etc Act

1974 (HASAWA)
Employer must:
• provide and maintain safe equipment and systems of work
• provide safe systems of work
• provide information, instruction,
supervision and training
• provide a safe place of work
• provide a safe working environment
• consult employees
• have a health & safety policy (written
when there are 5 or more employees).

Employees responsibilities
Health & Safety At Work Etc Act 1974 (HASAWA)
Management of Health & Safety at Work Regulations 1999
Manual Handling Operations Regulations 1992

• Cooperate with the employer

• Take reasonable care of themselves
and others
• Do not alter equipment provided
and use as instructed
• Report any faults or defects
• Inform the employer if they identify
hazardous handling activities.
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Management of Health & Safety at

Work Regulations 1999
COMPETENT PERSONS

• Every employer must appoint one or more competent

persons to assist with compliance
What is a ‘Competent Person’?

‘person with sufficient training and

experience or knowledge and other
qualities to enable proper assistance’.

Management of Health & Safety at Work

Regulations 1999
INFORMATION FOR EMPLOYEES

• Employer must provide comprehensible

and relevant information on:
• risks to their employees’ health & safety
• control measures
• emergency procedures
• competent persons in a language
they understand.
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Management of Health & Safety at Work

Regulations 1999
CAPABILITY OF EMPLOYEES

• Employers must take into account the capability of

any
employee before giving them a task to complete.

Management of Health & Safety at Work

Regulations 1999
TRAINING OF EMPLOYEES

• Employers must ensure that employees are

provided with adequate health & safety training
• on recruitment
• on being exposed to increased risk
• on a change of job or equipment
• from time to time (refresher training).
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Enforcement

• Local Authority Environmental Health Officers:

• Shops, offices, residential homes,
warehousing, entertainment

• Health and Safety Executive:

• Factories, hospitals, nursing homes,
mines, schools, construction etc.

Penalties

• Powers of the court:

• Fines
• Up to £20,000 for
breach of health
and safety legislation
• Unlimited on indictment

• Prison
• Up to six months in Magistrates’ Court
• Up to two years on indictment.
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Material handling equipment types

Powered
Conveyors Industrial Trucks

Source: OSHA Source: TEEX-Harwood

Material handling equipment types

Cranes Slings

Source: TEEX Source: OSHA

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Hazards Associated with Materials Handling

Factors contributing to injuries:
• Weight and bulkiness of objects
• Bending, twisting, turning movements

Source of photos: OSHA

Hazards Associated with Materials Handling

Hazards:
• Improper operation of equipment
• Accumulated materials or clutter
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Hazards Associated with Materials Handling

• Unsafe conditions of materials or containers

• Flammability or toxicity of some materials

Hazards Associated with Materials Handling

• Weight of materials
• Binding ties or other devices
that secure bundles or
bound materials
Source: OSHA
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Hazards Associated with Materials Handling

• Falling objects
• Lifting, pushing, pulling, or otherwise manually
moving large, heavy items

Hazards Associated with Materials Handling

• Improperly stacked materials
• Struck-by or caught-in/-between hazards
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Hazards Associated with

Materials Handling
Types of injuries commonly reported:
• Sprains, strains, tears
• Soreness and pain
• Bruises and contusions
• Cuts, lacerations, punctures,
crushing, and amputations

Hazards Associated with

Materials Handling
Examples of events or exposures
leading to injuries:
• Contact with objects
and equipment
• Transportation incidents
• Exposure to harmful substances
or environments
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Hazards Associated with

Materials Handling
• Falls, slips, trips, or loss of
balance
• Repetitive motion Source: OSHA

• Overexertion

Preventing Hazards
Moving materials manually:
• Use devices to assist with holding
loads
• Wear PPE
• Use proper lifting technique
• Seek help for oversized loads
• Use blocking materials
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Preventing Hazards
Overhead and gantry cranes:
• Never move a load over co-workers or allow co-
workers to walk underneath
• Return the load block to its designated location
after use
• Do not leave the load
block low enough for
someone to run into
• Never leave a suspended
load unattended

Preventing Hazards
• Do not leave unused slings suspended on a
crane hook
• Store wall-mounted cranes against the wall
• Continuously observe equipment for any sign
of problems during operation.
• Don’t allow yourself to become distracted.
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Preventing Hazards
• Operated only by thoroughly trained
and qualified workers

Preventing Hazards
Eliminate/reduce crane
hazards by:
• Knowing
• Load
• Capacity of the crane
• When the load is safe to lift
• Always checking crane
load chart and never
exceed load limits
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Preventing Hazards
• Inspection of crane by a qualified person
• Modified, repaired, or adjusted
• Post-assembly
• At least every 12 months
• Equipment not in regular use
• Visual inspection by a
competent person
• Prior to each shift
• Monthly

Preventing Hazards
• Slings
• Connects a crane hook to a load
• Proper selection
• Inspection
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Preventing Hazards
• Reduce sling hazards by:
• Lubricating
• Not shortening with knots, bolts, or other devices, or kink
legs
• Keeping clear of loads
• Avoiding sudden movement

Preventing Hazards
Forklifts
• Main causes of injuries
• Forklift overturns
• Forklift striking workers
on foot
• Persons crushed by forklifts
• Persons falling from forklifts
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Preventing Hazards
• Illegal forklift operators
• Anyone under 18
• Anyone not properly trained

Preventing Hazards
• Driving the forklift
• Obstructed vision
• Travel path
• Approaching people
• Elevated platform
• Seat belts and ROPS
• Raising/lowering forks
• Safe distance
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Preventing Hazards
• Elevating workers with forklift
• Standing on forks
• Lifting personnel
• Approved lift platform
• Restraining means

Preventing Hazards
• Driving forklift on grades/ramps
• Use extreme caution
• No turns
• Tilting and raising load
• Point load up the incline
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Preventing Hazards
• Forklift operating speed
• Tip-overs
• Turning
• Avoiding collisions
• Wet and slippery floors
• Ascending/descending
• Obstructed vision

Preventing Hazards
• Avoiding excess weight
• Do not exceed weight capacity of
forklift.
• Center loads and secure to keep
from shifting to maintain balance of
weight
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Preventing Hazards
• Use of dock boards for
loading/uploading
• Bridging space
• Securing portable dock boards
• Handholds for dock boards

Preventing Hazards
• Exiting the forklift
• Set brake, lower forks/lifting carriage,
neutralize controls
• Stand-up type forklift

• Riding the forklift

• No passengers allowed
• Exception – seat is provided
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Preventing Hazards
• Avoiding struck-by/crushed-by
• Don’t jump from an overturning, sit-down type forklift.
• Stay with the truck, hold on firmly, and
lean in the opposite direction of the overturn.

Preventing Hazards
• Forklift training – do not operate a forklift without
proper training
• Reporting damage – any damage or problems that
occur to a forklift during a shift should be reported to
the supervisor.
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Recognizing Hazards
Identify potential hazards and possible solutions:

Source: OSHA

Recognizing Hazards
Identify potential hazards and possible solutions:
 .

Recognizing Hazards
Identify potential hazards and possible solutions:

Knowledge Check
1. What is the minimum age requirement for
the operation of a forklift, regardless of
training?
a. 16
b. 18
c. 21
d. 25

Answer: b. You must be at least

18 years old to operate a forklift.
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Knowledge Check
2. A way to prevent materials handling hazards is
to ___.
a. refuse to allow personnel to ride equipment without
a seat and seatbelt
b. report all damaged equipment immediately
c. operate within manufacturer’s specifications
d. All of these

Answer: d. All of these are good ways

to prevent materials handling hazards.

Knowledge Check
3. Which of the following is a method for
eliminating or reducing crane operation
hazards?
a. A competent person should visually inspect the crane
once a year
b. Never exceed the load limit by more than 10%
c. Never move a load over co-workers
d. All of these

Answer: c. Never move a load over co-workers

or allow co-workers to walk underneath.
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Knowledge Check
4. Employers must comply with OSHA standards
related to materials handling, including
training and _____.
a. equipment
b. operations
c. inspection
d. all of these

Answer: c. Employers must comply with OSHA

standards for training and inspection.

Thank you

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