Occupational Safety and Health

Administration
OSHA

Material Handling and Storage

Presented By:
Eastern Michigan University
UAW-Ford Visteon
Introduction
Proper material handling and storage is a primary factor in providing workplace
safety. Many injuries and deaths are caused by improper material handling and
storage.

In a review of the Global Preliminary Incident Reporting System (GPIRS) for the
year 2000, the following injuries and deaths were reported:

• 186 Total Reported Incidents

• 1 Fatality
• 39 Serious
• 163 Involved a PMHV
• 70 of the PMHV incidents involved pedestrian

It is encouraging that in PMHV-Trained facilities from 1989 to today,

there has only been... 1 fatality.

Types of PMHV Incidents

GPIRS Reported PMHV Incidents

FAO / Visteon - 2000

Other:
Other: 15
15
(9%)
(9%)
Fixed
Fixed Object:
Object: 35
35 Pedestrian:
Pedestrian: 70
70
(21%)
(21%) (43%)
(43%)

Lost
Lost Load
Load // Matl:
Matl: 20
20
(12%)
(12%) Other
Other PMHV:
PMHV: 23
23
(14%)
(14%)
Total: 163

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 Location of Pedestrian
in Incident
Pedestrian Location in PMHV Incidents
FAO / Visteon - 2000

Standing
Standing by
by In
In Workcell:
Workcell: 11
11
PMHV:
PMHV: 88 (16%)
(16%)
(11%)
(11%)
Other:
Other: 12
12
(17%)
(17%) Already
Already in
in
Aisleway:
Aisleway: 1414
(20%)
(20%)

Entering
Total: 70
Entering Aisleway:
Aisleway: 25
25
(36%)
(36%)

Type of PMHV in
Serious / Fatal Incidents
Equipment Involved in Serious/Fatal Pedestrian
Incidents - FAO / Visteon 2000

Prsn'l Other:
Other: 11
Prsn'l // Burden
Burden
(5%)
(5%)
Carrier:
Carrier: 11
(5%)
(5%) Fork
Fork Lift:
Lift: 15
15
(71%)
(71%)

Tow
Tow Motor:
Motor: 44
(19%)
(19%)
Serious: 20
20
Fatal:
Fatal: 11

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OSHA Subpart N
Materials Handling and Storage
OSHA Subpart N (Material Handling) Covers a wide variety of topics. In this
module we will focus on General requirements for Material Handling and
Industrial Powered Trucks.

1910.176 Handling Materials (General)

1910.176 1910.178 Powered Industrial Trucks

1910.176 Handling Materials (General)

(a) Use of Mechanical Equipment

(b) Secure Storage
(c) Housekeeping
(d) [Reserved]
(e) Clearance Limits
(f) Rolling Railroad Cars
(g) Guarding

Use of Mechanical Equipment

1910.176(a)

Sufficient Clearance For Aisles. “Where mechanical handling equipment is

used, sufficient safe clearances shall be allowed for aisles, at loading docks,
through doorways and wherever turns or passage must be made. Aisles and
passageways shall be kept clear and in good repair, with no obstruction across or
in aisles that could create a hazard. Permanent aisles and passageways shall be
appropriately marked.”

Ford/Visteon has determined that “sufficient clearance” for aisles shall

be:
FOR ONE WAY AISLE: Width of Widest Load + 3 feet
FOR TWO-WAY AISLE: 2 x Width of Widest Load + 3 feet

For clearance at loading docks and doorways, keep in mind that OSHA standards
are performance standards. Therefore, “sufficient clearance” must be large
enough to prevent injuries and accidents.

NOTE: Pedestrians are not allowed to use overhead doors

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 1910.176(a)
“Aisles and passageways shall be kept clear and in good
repair.” “Permanent aisles shall be appropriately marked”

Maintain The Physical Elements

• Lines, signs, signals

• Delete obsolete walkway markings
• Plan, do, check, adjust
• FOLLOW UP!

Maintaining the physical elements pedestrian and vehicle aisleways is all part of
the Pedestrian and Vehicle Safety Program

Secure Storage
Secure storage. Storage of material shall not create a hazard.

Bags, containers, bundles, etc., stored in tiers shall be stacked, blocked,

interlocked and limited in height so that they are stable and secure against
sliding or collapse.

No stock higher than 4’ within 8’ of corner

Pedestrian Safety Process

●
● Plant layout study
– Stock storage restrictions
• No stock higher than 4’
within
within 8’
8’ of corner

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Storage Containers

Rigid, generic steel containers

Rigid, unique steel containers

Non-Rigid Collapsible and Plastic Containers

Pallet Boxes Unique Plastic Trays Totes

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When determining proper stack heights for containers use the ANSI MH26.1-
1991 standard. Maximum stack height can be easily determined by multiplying
the load bearing width by six (6) and then dividing by the container height.

Once you calculate that number round down to the next whole number. That
number will be the maximum number of containers that can be stacked
vertically.

For plastic containers, and non-ridgid containers, the maximum stack height is
150 inches total.

ANSI Standard
MH26.1 – 1991 Example

z Total height
of stack cannot
50”
exceed 6 times
the load bearing
width ÷ the
container height
39.5”
LOAD-BEARING WIDTH

6 x 39.5” = 237” ÷ 50”

50” = 4.74 = 4 Containers

Always
Always round
round down
down

Refer to Ford Motor Company letters, “Container Stack Height Guidelines, dated
October 18, 2000 and September 7, 2000, for assistance in determining the
proper stacking height of containers. The September 7th letter covers Rigid,
Durable Containers and the October 18, 2000 covers Non-Rigid Collapsible and
Plastic Containers.

Also refer to handout for “Centrally Owned Durable Containers”

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Container Stacking
Exercise

Using the Ford Motor Company Letter dated October 18, 2000 (Container Stack
Height Guidelines, Non-Rigid), answer the following questions:

1. How many SB 89 pallet boxes can you stack on top of one another?

2. What is the maximum stack height (in inches) for SB 89 pallet

boxes?

3. You receive a shipment of non-standard pallet boxes measuring 64”

long X 48” wide X 50” high, how many can you stack on top of one
another?

Using the handout for centrally owned durable containers, and the Ford Motor
Company Letter dated September 7, 2000 (Container Stack Height Guidelines,
Rigid Durable Containers), answer the following questions:

4. You have to stack some ZE-4 BINs, How many can you stack on top
of one another?

5. When you finish stacking the maximum number of ZE-12 BINs, How
high (in inches) will the stack be?

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Housekeeping
1910.176 (c):
“Storage areas shall be kept free from accumulation of materials that constitute
hazards from…”:

• Tripping

• Fire

• Explosion

• Pest harborage

Clearance Limits
1910.176 (e):

“Clearance signs to warn of clearance limits shall be provided”

Rolling Railroad Cars

1910.176 (f):
“Derail or bumper blocks shall be provided on spur railroad tracks where…”:

• Rolling car could contact other cars being worked

• Enter a building

• Work or traffic area

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Guarding
1910.176 (g):
“Covers and/or guard-rails shall be provided to protect personnel from the
hazards of…”:

• Open Pits

• Tanks

• Vats

• Ditches, etc.

1910.178 Powered Industrial Trucks

This section contains safety requirements relating to fire protection, design,
maintenance, and use of fork trucks, tractors, platform lift trucks, motorized
hand trucks, and other specialized industrial trucks powered by electric motors or
internal combustion engines.

In this section we will review the requirements for 1910.178(k) Trucks and
Railroad Cars and 1910.178(l).

Trucks and Railroad Cars

(k)(1)
The brakes of highway trucks shall be set and wheel chocks placed under the
rear-most wheels to prevent the trucks from rolling while they are boarded with
powered industrial trucks.

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DOK LOKS

Trailer Restraint Devices or “Dok Loks” may be used instead of wheel

chocks...or used to supplement wheel chocks

(k)(2)
Wheel stops or other recognized positive protection shall be provided to prevent
railroad cars from moving during loading or unloading operations.

(k)(3)
Fixed jacks…necessary to support a semi-trailer and prevent upending during the
loading or unloading when the trailer is not coupled to a tractor.

Fixed jacks are necessary to support semi trailer when trailer is not attached to
tractor

(k)(4)
Positive protection shall be provided to prevent railroad cars from being moved
while dockboards or bridge plates are in position.

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Powered Industrial Trucks
OSHA divides PMHVs into eleven (11) different designations for use in different
locations.

Powered Industrial Trucks

(Designated Locations)
OSHA divides industrial trucks (PMHVs) into
eleven (11) different designations for use in
different locations:

z Diesel Powered
– D, DS, DY
z Gasoline Powered
– G, GS
z LPG Powered
– LP, LPS
z Electric Powered
– E, ES, EE, EX

EX Industrial Trucks

Only “EX” designated PMHVs may be used in:

– atmospheres containing flammable vapors
o acetylene
o acetone
o alcohol,etc.
– atmospheres containing flammable dusts
o aluminum
o magnesium
o coal dust, etc.

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Operator Training
1910.178(l)

“The employer shall ensure that each powered industrial truck operator is
competent to operate a powered industrial truck safely, as demonstrated by the
successful completion of the training and evaluation…”
“Prior to permitting an employee to operate a powered industrial truck (except
for training purposes), the employer shall ensure that each operator has
successfully completed the training required.”

Training Program

Training programs must be under the direct supervision of persons who have the
knowledge, training, and experience to train operators and evaluate their competence; and
(l)(2)(i)(B)
Where such operation does not endanger the trainee or other employees.
(l)(2)(ii)
Training shall consist of a combination of formal instruction (e.g., lecture, discussion,
interactive computer learning, video tape, written material), practical training
(demonstrations performed by the trainer and practical exercises performed by the
trainee), and evaluation of the operator's performance in the workplace.
(l)(2)(iii)
All operator training and evaluation shall be conducted by persons who have the
knowledge, training, and experience to train powered industrial truck operators and
evaluate their competence.
Under the direct supervision of persons who have the knowledge, training, and
experience to train operators and evaluate their competence
Where such operation does not endanger the trainee or other employees
Training shall consist of a combination of:

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 • Formal instruction

• Practical training

• and evaluation of the operator's performance in the workplace

Operator License and Physical

PMHV Operators must have:

• A Physical Examination
• A Ford/Visteon issued operator’s license

Refresher Training and Evaluation

“Refresher training, including an evaluation of the effectiveness of that training,
shall be conducted to ensure that the operator has the knowledge and skills
needed to operate the powered industrial truck safely”

Refresher Training Must Be Provided When:

• Operator has been observed operating in unsafe manner The operator has
been involved in an accident or near-miss incident
• The operator has received an evaluation that reveals that the operator is
not operating the truck safely
• The operator is assigned to drive a different type of truck; or
• A condition in the workplace changes in a manner that could affect the
safe operation of the truck

Operator Evaluation

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An evaluation of each powered industrial truck operator's performance shall be
conducted at least once every three years.

Two Foot Rule

Six incidents of feet run-over by PMHV in a one-month period. Letter to plants in
August 2000 describing Operator Responsibilities and Pedestrian Responsibilities.

Also a decal is available for placement on PMHV’s.

Safety
• Employees / visitors not using pedestrian aisles
• Do Not store dunnage pedestrian aisles
• Eliminate blind spots
• Require stops when entering aisles from stairs or blind spots

Summary
• Worker safety depends on good material handling and storage practices
• Aisles must be marked and kept clear
• PMHV operators must be trained, competent, and licensed
• Constant reassessment of pedestrian and vehicle safety

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