UNIT 6 STORAGE OF MATERIAL

HANDLING OF HAZARDOUS
MATERIAL
Structure
6.1 Introduction
Objectives
6.2 General Hazardous
6.3 Safe Storing of Hazardous Materials
6.3.1 Fire and Explosion Risks
6.3.2 Emergency Action Plan
6.4 Material Handling
6.4.1 Material Handling Equipment
6.4.2 Bulk Handling Material Equipment
6.4.3 Engineered Systems
6.4.4 Industrial Trucks
6.4.5 Storage and Handling Equipment
6.4.6 Types of Storage and Handling Equipment
6.5 Manual and mechanical material handling
6.5.1 Precautions when Lifting and Carrying Long Objects as Team
6.5.2 Precautions when lifting and Moving Furniture as a Team.
6.5.3 The Legal Aspect
6.6 Electrical Handling
6.7 Principles of Material Handling
6.8 Safety in Material Handling
6.9 Let Us Sum Up
6.10 Key Words
6.11 Answers to SAQs
6.12 References and Further Readings

6.1 INTRODUCTION
We all know how important it is to take precautions when working with
hazardous materials. But we may not always recognize that it’s equally
important to maintain the same high level of safety when these materials are
in storage.
You will recall the Bhopal gas tragedy of 1984 when an estimated 15 to 20
thousand people died and about three to five lakh people were genetically
affected and the genetic mutations continued into their future generations as
well. It is to be noted that the plant was not in operation for quite a few
months and it was faulty storing of toxic material that caused this massive
tragedy. There have been similar incidents in history time and again which
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have proved to be eye openers on the importance of safely storing hazardous
Engineering materials.
Even when hazardous materials are out of sight and in containers, one should
be mindful of their storage.If they're stored properly, these substances
shouldn't cause problems. But unless we're all aware of what safe storage
means, and how to protect ourselves in a storage area, we run the risk of
accidents. And we can't afford to take that risk with hazardous materials. So
in this unit, we will discuss the basics of safe storage of hazardous materials
and the precautions we should follow when we're in those areas. We will also
discuss Emergency Action Plan if hazardous materials go out of containment.
We will also look more closely at some specific high-risk substances so that
you can better understand why we store these materials as we do.
The Occupational Safety and Health Administration has detailed rules for the
location and construction of rooms or buildings that contain these substances,
including explanations of what can't be stored with different types of
hazardous materials. As you realize that every aspect of storage room design
has a reason and purpose, you'll be better able to see to it that those storage
areas and the substances stored in them, are kept safe.
Objectives
After studying this unit you will be able to:
 describe the kinds of health hazards;
 appreciate the importance of safe storing of hazardous material;
 classify material handling equipment;
 explain manual and mechanical material handling; and
 describe electrical handling and electrical safety tips.

6.2 GENERAL HAZARDS

A hazard is broadly defined as an agent which has the potential to cause harm
to a vulnerable target. They may be natural or man made. As regards storage
of hazardous material, the substances we use and store can pose a number of
different hazards if they're not handled and used properly and safely.
Some of the hazards are physical hazards. These could include:
 Fire
 Explosion
 Sudden release of pressure (for instance, if a tank of compressed gas is
punctured)
 Reactivity (fire, explosion, or release of dangerous gases that can result
from contact between chemicals and certain other chemicals or air or
water)
There are also many potential health hazards that can result from over
exposure to hazardous substance(s) through a length of time. Working in a
rubber factory can be an example. Sometimes the hazard is minor, like a
headache or mild skin rash. But other health hazards are much more serious.
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For instance, skin burns from contact with corrosive chemicals. With some Handling of Hazardous
substances, too much exposure or prolonged exposure could cause organ Material
damage, allergic reactions, cancer or, in the worst cases, death.
Sometimes the risk isn't just to the individuals working with or near the
substance in question. A major spill of a chemical that is dangerous to health
can pose dangers to many people if it gets into the water supply. If there's a
fire or explosion that releases toxic gases, they could spread out to harm
people in the neighbourhood.
So there are a lot of potential risks including some very serious ones in any
hazardous material storage area. Fortunately, there are also excellent
safeguards against those risks becoming realities. Our storage areas are
designed for safety and maintained for safety. That's only good sense, and in
many instances, it's also the law.
Handling and storing materials involve diverse operations such as hoisting
tons of steel with a crane; driving a truck loaded with concrete blocks;
carrying bags or materials manually; and stacking palletized bricks or other
materials such as drums, barrels, kegs, and lumber.

The efficient handling and storing of materials are vital to industry. In

addition to raw materials, these operations provide a continuous flow of parts
and assemblies through the workplace and ensure that materials are available
when needed. Unfortunately, improper handling and storing of materials
often result in costly injuries.

SAQ 1
a) What are the general hazards in industries?
b) Describe some hazards in storing and handling of materials.

6.3 SAFE STORING OF HAZARDOUS

MATERIALS
The Directorate General of Factory Advice Service and Labour Institutes under the
Ministry of Labour, GOI, has drafted a National Occupational Safety and
Health (OSH) Profile that industries are required to follow. One has to ensure
that chemicals and dangerous substances are stored and handled to minimise
risks and limit people's exposure to them.
One needs to assess the risks of storing and handling dangerous substances.
This includes the possibility of environmental damage caused by leaks and
spills.
Precautions needed to control risks must be taken. This includes:
 storing chemicals or other hazardous substances according to the
manufacturer's instructions on the safety data sheet.
 keeping the minimum quantity of hazardous substances needed.
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 storing incompatible substances separately.
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 taking steps to prevent release or leakage of dangerous substances.
 keeping a spill kit near the storage areas, and ensuring that staff are
trained in what to do in the event of a spill
 cleaning up any leaks or spills that occur
 using the right precautions when handling substances - for example,
wearing protective clothing or ensuring adequate ventilation.
 ensuring employees who store and handle dangerous substances are
properly trained
 checking that containers used for short-term storage are properly labelled.

6.3.1 Fire and Explosion Risks

There are certain safety measures to be taken in case of fire and explosion
related risks. These are discussed below:
1. If you store chemicals or dangerous substances that could create a fire or
explosion, you must also comply with the applicable Industrial Safety (IS)
specification. For example, IS 3594-1991 for General Storage &
warehouses and IS 3034-1993 for Electrical Generating & distribution in
industrial buildings.
2. Ensure that flammable substances are correctly stored in suitable
containers and are not stored near to a source of ignition such as a heater.
3. Some of the best practices are to:
 Place stores of liquid above the ground level where they are unlikely
to be damaged, eg. away from traffic routes
 Avoid overfilling containers
 Supervise deliveries
 Maintain gauges, valves and pipework
 Monitor oil use - unexpectedly high use may indicate a leak
 Have procedures for dealing with emergency leakages
 Use a secondary containment system such as a drip tray or bund (a
storage area designed to prevent liquids escaping)

6.3.2 Emergency Action Plan

In spite of taking all precautions disasters do happen. You will need to have
an Emergency Action Plan in place for such eventualities. The guidelines of
framing such a Policy is given for your understanding but the actual Policy of
any organisation will depend and have to be framed based on the type of
industry you are working in, its layout, the kind of possible hazards and other
individual characteristics of the organisation.
An emergency action plan (EAP) has to be a written document. The purpose
142 of an EAP is to facilitate and organize employer and employee actions during
 Storage of Material
workplace emergencies. Well-developed emergency plans and proper Handling of Hazardous
employee training (such that employees understand their roles and Material
responsibilities within the plan) will result in fewer and less severe employee
injuries and less structural damage to the facility during emergencies. A
poorly prepared plan, is likely to lead to a disorganized evacuation or
emergency response, resulting in confusion, injury, and property damage.

6.3.2.1 Minimum Requirements

Putting together a comprehensive emergency action plan that deals with those
issues specific to your worksite is not difficult. It involves taking what was
learned from your workplace evaluation and describing how employees will
respond to different types of emergencies, taking into account your specific
worksite layout, structural features, and emergency systems.

6.3.2.2 Develop and Implement an EAP

Drafting an emergency action plan (EAP) is not enough to ensure the safety
of your employees. When an evacuation is necessary, you will need
responsible, trained individuals who can supervise and coordinate activities
to ensure a safe and successful evacuation. A disorganized evacuation can
result in confusion, injury, and property damage.

6.3.2.3 Fight or Flee

A fire is the most common type of emergency for which small businesses too
must plan. Evacuation plans that designate or require some or all of the
employees to fight fires with portable fire extinguishers, increase the level of
complexity of the plan and the level of training that must be provided to the
employees.

6.3.2.4 Shelter-in-Place
Chemical, biological, or radiological contaminants may be released into the
environment in such quantity and/or proximity to a place of business that it
may be safer to remain indoors than to evacuate employees.

6.3.2.5 Fire, Rescue, Medical Services

Although most of us quickly move away from the hazardous environments
created during emergency situations, a group of dedicated and well-trained
professional emergency responders and medical service personnel should be
tasked with containing and mitigating these incidents, rescuing individuals at-
risk, and providing medical assistance to the injured.

6.3.2.6 Reporting Emergencies

Employees must know how to report emergencies. In times of crisis, there are
various means of internal communication like intercom, or public address
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systems to notify other employees. It is important for employees to further
Engineering notify the authorities such as fire, medical, or rescue services, if your
company relies on this type of assistance during an emergency.

SAQ 2
a) What are the best practices of storing hazardous materials?
b) What is EAP?

6.4 MATERIAL HANDLING

Material handling is the movement, protection, storage and control of
materials and products throughout manufacturing, warehousing, distribution,
consumption and disposal. As a process, material handling incorporates a
wide range of manual, semi-automated and automated equipment and
systems that support logistics and make the supply chain work.

6.4.1 Material Handling Equipment

The term ‘material handling equipment’ is a broad one. There are plenty of
situations where it’s critical to move large and often heavy materials in a
production environment. Any piece of equipment that helps with this process
is called material handling equipment. Plenty of items fall under this
definition, from tools and storage units to vehicles and major appliances.
Anything that deals with the transportation, storage and control at any stage
of the processing of materials can also be classified as material handling
equipment.
6.4.1.1 Categories of Material Handling Euipment
There are 4 main categories of material handling equipment:
 Bulk material handling
 Engineered systems
 Industrial trucks
 Storage and handling equipment

6.4.2 Bulk Handling Material Equipment

The term ‘bulk handling equipment’ refers to the storage, control and
transportation of materials in bulk and in loose form. There are plenty of
examples of this applicationlike large scale handling of food, beverages,
liquids, metal items (such as screws and nails) and minerals to name a few.
In general terms, such equipment is used to handle these items when they are
loose. One example is a conveyor belt that is used to move items from one
part of the production process to another. Drums and hoppers may be used as
well, to ‘funnel’ these loose items into a stage where they can be more easily
processed, or packaged.
Conveyor belts are used for horizontal transportation. For vertical
144 transportation, elevators are most commonly used.
Types of bulk handling material equipment Storage of Material
Handling of Hazardous
Material
There are different type of Bulk Handling equipment which are as follows:
 Bucket and Grain Elevators (Figure 6.1)

Figure 6.1: Bucket and Grain Elevators

 Conveyor Belts (Figure 6.2)

Figure 6.2: Conveyor Belts

 Hoppers and Silos (Figure 6.3)

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Figure 6.3: Hoppers and Silos

 Reclaimers (Figure 6.4)

Figure 6.4: Reclaimers

 Stackers (Figure 6.5)

Figure 6.5: Stackers

6.4.3 Engineered Systems

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 Storage of Material
An engineered system is one that is typically automated. Such systems are Handling of Hazardous
usually created from a variety of units. When combined, they work to enable Material
both storage and transportation.
An Automated Storage and Retrieval System (or AS/RS in short) is one
example of a system that is engineered. This is a large, automated device that
comes complete with racks, shelves and aisles. These storage solutions are
accessed by a ‘shuttle’ – a mechanized device.
This type of devices can be used by the system operator to manually select
the items as needed, or the entire system can be computerized and automated.
An AS/RS can be integrated with a production facility’s existing computer
network to keep a tab on stock control and other logistical systems. It can
also be integrated with other stages of the production process, so that as much
automation can be offered as possible.
6.4.3.1 Types of Engineered Systems
 Automated Guided Vehicles (Figure 6.6)

Figure 6.6: Automated Guided Vehicles (AGVs)

 Conveyor Systems (Figure 6.7)

Figure 6.7: Conveyor Systems

 Robotic Delivery System (Figure 6.8)

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Figure 6.8: Robotic Delivery System

6.4.4 Industrial Trucks

Industrial trucks provide transportation and include different types of
equipment like small, hand-operated devices and large-scale motorized
vehicles. Some items can be driven, while others, such as pallet trucks,
simply add mobility to the materials being handled.
Industrial trucks have useful characteristics such as forks or a flat surface that
can be inserted under pallets or other types of storage platforms. Other trucks
need separate attachments to be used for lifting.
Trucks have the capability to lift and tilt via powered or manual means, and
can be ridden upon in a driver’s cab, or simply power-assisted when pushed.
Such tucks can also be steered by human intervention, or can be completely
automated, following a pre-defined track on the production floor, sunken or
raised tracks, or coloured strips that are laid out and sensed by optical sensors.
Such automated industrial trucks also have anti-collision technology that
senses when an employee or other obstacle is near.
Stacking trucks are used to stacks items, while a non-stacking truck is just
used for transportation, and not for product loading.
6.4.4.1 Types of Iindustrial Trucks:
Given below are the types of industrial trucks:
i) Automated guided vehicles (AGVs)
Automated guided vehicles has been shown in Figure 6.6.
ii) Hand, platform and pallet trucks
 Hand, platform (Figure 6.9)

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Handling of Hazardous
Material

Figure 6.9: Hand, Platform

 Pallet jacks (Figure 6.10)

Figure 6.10:Hand Operated Pallet Jacks

 Order pickers (Figure 6.11)

Figure 6.11: Order Pickers

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Introduction to  Side-loaders (Figure 6.12)
Industrial Safety
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Figure 6.12: Sid-loaders

 Walking stackers (Figure 6.13)

Figure 6.13: Walking Stackers

6.4.5 Storage and Handling Equipment

In the previous section, we learnt about engineered systems which are
automated storage and handling equipment. Equipment that is used for
storage usually consists of items that are not automated.
Storage equipment is equipment that is used to hold products and materials
when they are not being used, or when they are waiting to enter or leave the
production process. These periods could be long-term, or short-term in order
to allow a suitable build-up of stock or finished items.
Most items that can be described as storage and handling equipment are
refered to as pallets, racking or shelves. Materials are stored in a neat and
convenient manner to await transportation, or their entry into the production
process as necessary.
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Having suitable storage equipment will add to any company’s production Handling of Hazardous
efficiency. The efficiency of any production system is maximized by the ease Material
at which each stage of the entire system operates. Any inefficient section
creates a bottleneck that will have an effect on all other sections of the system
further down the production line.
Space is also at a premium if you run a production environment. The better
utilized the available space is, the more the items that canbe stored. This
means the workflow can be in operation for much longer without worrying
about re-stocking. This helps to further increase efficiency.

6.4.6 Types of Storage and Handling Equipment

 Drive-through or drive-in racks (Figure 6.14)

Figure 6.14: Drive in Racks

 Pallet racks (Figure 6.15)

Figure 6.15: Pallet Racks

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Figure 6.16:Push Back Racks

 Shelving (Figure 6.17)

Figure 6.17: Shelving

 Sliding Racks (Figure 6.18)

Figure 6.18: Sliding Racks

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 Storage of Material
Handling of Hazardous
 Stacking Frames (Figure 6.19) Material

Figure 6.19: Stacking Frames

SAQ 3
a) What are 4 main categories of material handling equipment?
b) Elaborate on ‘Engineered Material Handling Systems’.

6.5 MANUAL AND MECHANICAL MATERIAL

HANDLING
Manual material handling is the lifting, carrying or moving of materials,
articles or things by manual labour. Mechanical material handling is the
movement of materials, articles or things by such means as lift trucks,
conveyors, or cranes and hoists mostly through manual control.
One of the more frequent, higher risk outcomes of manual material handling
is musculo skeletal disorders (MSDs). MSDs are injuries or pain in the
human muscular and skeletal systems, including the joints, ligaments,
muscles, nerves, tendons and skeletal system that supports limbs, necks and
back. It is found that the most common MSD is caused due to obstructions on
floors interfering with safe movement of materials; unsafe material lifting,
carrying and moving; unsafe storage of material and lack of examination of
lifting devices.
MSDs have become an important workplace health and safety issue.
Commonly observed reasons for MSDs are:
 Improperly securing vehicles against accidental movement, tipping or
falling
 Unsafe loading and unloading procedures
 Not using wheel chocking
 Work surface hazards
 Pinch point hazards
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Material handling operations are carried out in most workplaces either with
Engineering the use of physical might only, or when heavier or awkward materials are to
be handled, by using either motorized or non-motorized lifting equipment.
Each handling task poses unique demands on the worker. However,
workplaces can help workers to perform these tasks safely and easily by
implementing and upholding proper policies and procedures.
Let us understand how purely manual handling of heavy loads can be
managed by the example of Team Lifting or Team Handling,.
"Team handling" occurs when more than one person are involved in lifting or
handling heavy loads. Here are a few steps that a team can take while
handling heavy loads:
 Use team lifting and carrying where other solutions are inappropriate.
 Remember that the combined strength of the team is less than the sum of
individual strength.
 Select team members of similar height and strength.
 Assign a leader to the team.
 Determine a set of commands to be used such as "lift", "walk", "stop",
 "down". Make sure that everyone knows what to do when they hear
the command.
 Follow the commands given by the team leader.
 Practice team lifting and carrying together before attempting the task.

6.5.1 Precautions When Lifting and Carrying Long Objects

as Team
Following are the pprecautions when lifting and ccarrying long oobjects as
team:
 Use a shoulder pad to reduce compression.
 Carry load on the same shoulder.
 Walk in step.
All above steps has been shown in Figure 6.20.

Figure 6.20: Lifting and Carrying Long Objects

6.5.2 Precautions When Lifting and Moving Furniture as a

Team
When lifting and moving furniture as a team, following precautions may be
adopted:

154  Use straps.

 Storage of Material
 Adjust the length of the straps according to your height. Handling of Hazardous
Material

Figure 6.21: Webbing to Secure Straps

 Use webbing (Figure 6.21) around straps to secure them from slipping
off.
 Obtain assistance while loading a heavy object on the truck.
 Use your body weight to tilt the object.
 Place the lip of the truck under the object (Figure 6.22).

Figure 6.22: Place the Lip of the Truck Under the Object

 Tip the truck back with assistance (Figure 6.23).

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Figure 6.23: Tip the Truck Back with Assistance

 Move off. The assisting person directs the movement (Figure 6.24).

Figure 6.24: Move off

6.5.3 The Legal Aspect

The Indian Government has several IS specifications for guidance on safe
material handling procedures to be followed. Eg.IS 8324-1988 applies to
Lifting chain & chain slings. Employers, supervisors, owners and
constructors, among others, have an obligation to know and comply with the
regulations that apply to their workplaces. For the specifics on the regulations
that cover your workplace, you will need to look up the applicable IS
specification/s.

SAQ 4
a) What is the major occupational health hazard on account of manual
material handling and what are its main causes?
b) Provide some guidelines on how heavy materials should be handled
when only manual labour is available.

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6.6 ELECTRICAL HANDLING
 Storage of Material
Handling live electrical lines and equipment have been known to be one of Handling of Hazardous
the major causes of occupational hazard in the industry. The main causes and Material
their corrective actions of these hazards are listed below:
 Improper earthing of electrical circuitry, building or plant has been
observed to be a major cause of accidents and fire. Make sure all
electrical circuits are properly earthed following the guiding IS
specifications.
 Inspect portable cord-and-plug connected equipment, extension cords,
power bars, and electrical fittings for damage or wear before each use.
Repair or replace damaged equipment immediately.
 Always tape extension cords to walls or floors when necessary. Nails and
staples can damage extension cords causing fire and shock hazards.
 Use extension cords or equipment that is rated for the level of amperage
or wattage that you are using.
 Always use the correct size fuse. Replacing a fuse with one of a larger
size can cause excessive currents in the wiring in case of overload and
possibly start a fire.
 Be aware that unusually warm or hot outlets may be a sign that unsafe
wiring conditions exist. Unplug any cords or extension cords to these
outlets and do not use until a qualified electrician has checked the wiring.
 Always use ladders made with non-conductive side rails (e.g., fibreglass)
when working with or near electricity or power lines.
 Place halogen lights away from combustible materials such as cloths or
curtains. Halogen lamps can become very hot and may be a fire hazard.
 Risk of electric shock is greater in areas that are wet or damp. Install
Ground Fault Circuit Interrupters (GFCIs) as they will interrupt the
electrical circuit before a current sufficient to cause death or serious
injury.
 Use a portable in-line Ground Fault Circuit Interrupter (GFCI) if you are
not certain that the receptacle you are plugging your extension cord into
is GFCI protected.
 Make sure that exposed receptacle boxes are made of non-conductive
materials.
 Know where the panel and circuit breakers are located in case of an
emergency.
 Label all circuit breakers and fuse boxes clearly. Each switch should be
positively identified as to which outlet or appliance it is for.
 Do not use outlets or cords that have exposed wiring.
 Do not use portable cord-and-plug connected power tools with the
guards removed.
 Do not block access to panels and circuit breakers or fuse boxes.
 Do not touch a person or electrical apparatus in the event of an electrical
accident. Always disconnect the power source first.

6.6.1 The characteristics and Hazards Associated with

Power Arcs and the Precautions that should be Taken
to Avoid Injury by an Arc Blast

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Electrical workers are frequently in close proximity to energized parts where
Engineering power arcs can occur. It is not necessary to touch an energized conductor to
receive an electrical shock. Anyone who has rubbed their feet across a
carpeted room and reached for a metal doorknob can attest to that. High
voltage may cause current flow through the air from one conductive surface
to another if the voltage is great enough and conditions are right. A lightning
strike, which might have an electrical potential of millions of volts, is an
electrical arc that could span miles. Similarly, in electrical work, when there
is a difference of potential between two points, an arc can occur under the
right set of conditions. Not only could an electrical arc jump from a
conductor to a person and give them a shock but arcing can result in serious
burns and explosive blasts.
Typically, arcing distances are rather small. Safe approach distances should
include a safety factor to the arcing distances in order to account for such
things as inadvertent movement and variable work conditions. Workers
should always be aware of the arcing hazard when handling tools and
equipment near energized electrical conductors. Personal Protective
Equipment (PPE) may be required in certain situations depending on the
amount of energy available at the source.
The power arc is a discharge of electricity through a combination of ionized
air and vaporized conductor material. The conductive material is vaporized
by temperatures in an arc which can be as high as 35,000 degrees Fahrenheit.
Burns associated with high energy arcs can be fatal even if the victim is
several feet from the arc, and severe burns at distances up to ten feet are
common. Clothing may also be ignited at distances of several feet. This may
also be fatal, because the clothing cannot be removed or extinguished quickly
enough to prevent serious burns over much of the body's skin. The following
Table1, gives several examples of the increased temperature of human skin
above normal when exposed to power arcs of varying lengths.
Table 6.1: Arc Temperature vs Distance

Arc Sphere Distance from Center

Diameter

In. Cm. 20” 24” 30” 36” 60” 120”

50.8 cm. 61 cm. 76.2 cm. 91.4 cm. 152 cm. 305 cm.

1 2.54 69 F 47 F 31 F 21 F 8F 2F

2 5.08 274F 191 F 122 F 85 F 30 F 8F

3 7.62 619 F 429 F 275 F 191 F 69 F 17 F

4 10.2 1100 F 764 F 489 F 339 F 122 F 31 F

6 15.2 2474 F 1718 F 1100 F 764 F 275 F 69 F

8 20.3 4398 F 3054 F 1955 F 1358 F 489 F 122 F

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10 25.4 6872 F 4772 F 3054 F 2121 F 764 F 191 F Handling of Hazardous
Material
12 30.5 9896 F 6872 F 4398 F 3054 F 1100 F 275 F

16 40.6 17593 F 12217 F 7819 F 5430 F 1954 F 489 F

6.6.2 Electrical Arc Blasts

In addition to an electrical shock and burns, another hazard to employees is
the blast effect that can result from arcing. If the current involved is great
enough, these arcs can cause injury and start fires. Extremely high-energy
arcs can damage equipment causing fragmented metal to fly in all directions.
Low-energy arcs can cause violent explosions or blasts in atmospheres
containing explosive gases, vapors or combustible dusts. The hot vaporized
metal from the arc blast will combine with oxygen and become an oxide of
the metal of the arc. These molten particles will stick to almost anything
actually melting into many surfaces. Clothing may ignite as a result of
contact with this molten material and a victim may receive serious burns.
Also, your body has an instinctive reaction when you are suddenly startled, to
breathe in heavy or gasp. Inhaling the hot vaporized particles will cause
serious damage to your respiratory system by burning the lungs, throat and
esophagus. There is no equipment available to completely protect electrical
workers from the effects of blast. However, safe practices, such as standing to
the hinged side of a cubicle door when operating a breaker and other
precautions listed below can be taken to minimize the effect of a blast. The
main protections against arc blasts are listed in Table 2.
Table 6.2: Protection against arc blasts
Electrical Hazards Awareness
Exoisure Limitation The amount of time you spend around high energy
equipment; don’t loiter.
Distance Always stay as far away as possible form high
energy equipment unless you have a need there.
Mass Try to keep some type of sturdy material between
you and a potential blast.
Protective Clothing Flash suits may offer some protection to minimize
burns resulting from blasts.

If an arcing fault occurs while a worker is in close proximity, the

survivability of the worker is mostly dependent upon system design aspects,
such as characteristics of the over-current protective device and precautions
the worker has taken prior to the event, such as wearing personal protective
equipment appropriate for the hazard. The effects of an arcing fault, as seen
in Figure 2 (below) can be devastating to a person. The intense thermal
energy released in a fraction of a second can cause severe burns. Molten
metal is blown out and can burn skin or ignite flammable clothing. One of the
major causes of serious burns and deaths to workers is ignition of flammable
clothing due to an arcing fault. The tremendous pressure blast from the

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vaporization of conducting materials and superheating of air can fracture ribs,
Engineering collapse lungs and knock workers off ladders or blow them across a room.

Figure 6.25: Electric Arc Model

6.6.3 Electrical Safety Tips

When working with any of the following, it is of utmost importance to
remember the Safety Tips which are also listed below:
 Power Tools
 Extension Cords
 Molded Case Circuit Breakers
 Downed Power Lines
 Ladders
Safety tips:
 Use the tool only for its designed purpose.
 Read the Owner’s Manual and follow manufacturer’s safety instructions.
 Remember electric-powered tools must have a three-wire plug with
ground or be double insulated.
 Use of electric-powered tools with a Ground Fault Circuit Interrupters
(GFCI) breakers will drastically reduce the possibility of electric shock
or electrocution.
 Don’t appropriate Personal Protective Equipment (PPE).
 If an extension cord is required, make sure it is for the correct wattage
and has the proper plugs. Verify condition of the cord and plugs and
check for rated use: indoor or outdoor.
 Ensure the power switch is “OFF” before plugging or unplugging tools.
 When working with the power line switched off, put a ‘DO NOT PUT
ON’ tag on the Main Switch to prevent others from inadvertently putting
it ON for their requirement.
 Never disconnect power by pulling on the cord – use the PLUG.
160  Never carry a tool by the cord.
 Storage of Material
 Unplug the cord before adjusting, changing/replacing parts/accessories. Handling of Hazardous
 Inspect tool before each use. Replace tool if parts are worn or damaged Material
as seen in figure 3. Remove from service and tag “Danger, Do Not
Operate.”
 When using a ladder preferably use one made of non-conductive material
or at least one with thick rubber pads at the resting points.
Hospital Emergency Rooms provide life-saving measures to tens of
thousands of individuals injured/maimed/impaired as a direct/indirect
result of the effects of electric current passing through their bodies
usually through a careless act. Over a thousand individuals are
electrocuted annually. Fires in the home and on-the-job are initiated as a
result of improper use and care of electrical equipment, extension cords,
and plugs. Causes for these events include inattention through repetition,
unexpected events and inexperience and overconfidence. We can
eliminate a large percentage of these injuries and death through the
application/use of safe tool/electrical practices. Contact with current
from machines, tools, appliances and light fixtures accounted for an
alarming number of electrocution deaths in construction. With the
myriad of extension cords and portable power tools used on a job site,
there is a real danger of shocks from damaged cords, lights and tools.
Dampness increases the risk.

Figure 6.26: Damaged Insulation and Plug

SAQ 5
a) What are some general safety tips for working with or near
electricity?
b) Describe the effects of a power arc blast and precautions needed
to avoid it.

6.7 PRINCIPLES OF MATERIAL HANDLING

Following are the principles of material handling:
1. Planning: All handling activities should be planned.
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2. Systems integration: As many handling activities should be integrated as
Engineering possible and the full scope of operations (receiving, storage, production,
inspection, packing, warehousing, supply and transportation) should be
well coordinated.
3. Space utilization: Make optimum use of cubic space.
4. Unit load principle: It implies athat materials should be handled in most
efficient, maximum size unit, mechanical means to reduce the number of
moves needed for a given amount of material..
5. Gravity: Utilize gravity to move a material wherever practicable.
6. Material flow: Plan an operation sequence and equipment arrangement to
optimize material flow.
7. Simplification: Reduce, combine or eliminate unnecessary movement
and/or equipment.
8. Safety: Provide for safe handling methods and equipment.
9. Mechanization: Use mechanical or automated material handling
equipment.
10. Standardization: Standardize method, types and size of material handling
equipment.
11. Flexibility: Use methods and equipment that can perform a variety of
tasks and applications.
12. Equipment selection: Consider all aspects of material, movement and
method to be utilized.
13. Dead weight principle: Reduce the ratio of dead weight and pay load in
mobile equipment.
14. Motion: Equipment designed to transport material should not lie idle.
15. Idle time principle: Reduce idle time/unproductive time of both MH
equipment and manpower.
16. Maintenance principle: Plan for preventive maintenance or scheduled
repair of all handling equipment.
17. Obsolescence principle: Replace obsolete handling methods/equipment
when more efficient method/equipment will improve operation.
18. Capacity principle: Use handling equipment to help achieve its full
capacity.
19. Control principle: Use material handling equipment to improve
production control, inventory control and other material handling.
20. Performance principle: Determine efficiency of handling performance in
terms of cost per unit handled which is the primary criterion of
performance.

6.8 SAFETY IN MATERIAL HANDLING

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 Storage of Material
The National Safety Council suggests employers relay the following Handling of Hazardous
information to employees to help reduce workplace incidents when handling Material
and moving materials:
 Avoid lifting materials from the floor while seated.
 Make use of available handling aids.
 Refrain from using sudden or jerky movements.
 Never lift a load over an obstacle.
 Perform lifts in areas with adequate footing, space and lighting.
 Modify objects and redesign jobs to make moving easier.
 Seek assistance from co-workers.
 Stay in good physical shape.
 Begin lifts close to the body.
 Use containers made of lighter materials.
 Reduce load sizes when possible.
 Do not twist or bend while lifting objects.
 Ensure that repetitive, heavy and bulky lifts are not performed.
 Keep lifts between shoulder and knuckle height.
 Use conveyors, slides or chutes to eliminate pushing or pulling.

SAQ 6
a) Write down any five important principles of material handling.
b) Name a few important safety aspects in material handling.

6.9 LET US SUM UP

In this unit, we learnt how material handling equipment allows for the safe
and efficient transportation, movement, storage and protection of people and
products during the manufacturing and distribution process which in turn
helps to increase productivity.
We also learnt about the four types of material handling equipment .The four
main categories of material handling equipment include: storage, engineered
systems, industrial trucks and bulk material handling. This unit also threw
light on safety tips and precautions and principles of safety that one must take
into consideration while performing any heavy load material handling.

6.10 KEY WORDS

Potential Health Hazards : that can result from over exposure to hazardous
substance(s) through a length of time
Hazards: A hazard is broadly defined as an agent which has the potential to
cause harm to a vulnerable target
Emergency Action Plan (EAP) : The purpose of an EAP is to facilitate and
organize employer and employee actions during workplace emergencies.

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Introduction to Material Handling: Material handling is the movement, protection, storage
Industrial Safety
Engineering and control of materials and products throughout manufacturing,
warehousing, distribution, consumption and siposal
Bulk handling equipment: Refers to the storage, control and transportation
of materials in bulk and in loose form
Enginered system: Automated and created from a variety of units to enbable
both storage and transportation
Automated Storage and Retrieval System (AS/RS): Large computerised
and automated device that comes complete with racks, shelves and aisles
Automated guided vehicles (AGV): Portable robot that follows along
marked long lines or wires ont he floor, or uses radio wves, vision cameras,
magnets, or lasers for navigation
Storage equipment: Equipment atha tis sued to hold products and materials
when whty are not being used, or when they are waiting to enter or leave the
production process
Team Lifting or Team Handling: When more than one person is involved
in lifting or handling heavy loads
Electrical handling: Handling live electrical lines and equipment
Ground Fault Circuit Interrrupters (GFCIs): Interrupt the electrical
circuit before a current sufficient to cause death or serious injury
Electrical Arc Blast: Electrical shock and burns, blast effect that can result
from arcing

6.11 ANSWER TO SAQs

SAQ 1
a) Some of the hazards in industries are physical in nature. These could
include:
 Fire
 Explosion
 Sudden release of pressure (for instance, if a tank of compressed gas
is punctured)
 Reactivity (fire, explosion, or release of dangerous gases that can
result from contact between chemicals and certain other chemicals
or air or water)
Other type of hazards may come from using or handling hazardous
chemicals like Sulphuric acid, for example. Sudden leakage of toxic
substances or overexposure to a hazardous substance through a
length of time can be other types of hazards.
b) Handling and storing materials involve diverse operations such as
hoisting tons of steel with a crane; driving a truck loaded with concrete
blocks; carrying bags or materials manually; and stacking palletized
bricks or other materials such as drums, barrels, kegs, and lumber. All
these activities are potential physical hazards.

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 Storage of Material
Handling and storing of hazardous chemicals or toxic substances can be Handling of Hazardous
a source of major disaster not only to the workmen of the factory Material
concerned but to the much bigger area adjacent to it. Bhopal Gas
Tragedy is an unfortunate example.
SAQ 2
a) While storing hazardous materials the best practices are:
 place stores of liquid above ground where they're unlikely to be
damaged, eg. away from traffic routes
 avoid overfilling containers
 supervise deliveries
 maintain gauges, valves and pipework
 monitor oil use - unexpectedly high use may indicate a leak
 have procedures for dealing with emergency leakages
 use a secondary containment system such as a drip tray or bund (a
storage area designed to prevent liquids escaping)
b) EAP stands for emergency action plan. It has to be a written document.
The purpose of an EAP is to facilitate and organize employer and
employee actions during workplace emergencies. Well-developed
emergency plans and proper employee training (such that employees
understand their roles and responsibilities within the plan) will result in
fewer and less severe employee injuries and less structural damage to the
facility during emergencies.
SAQ 3
a) There are 4 main categories of material handling equipment:
 Bulk material handling
 Engineered systems
 Industrial trucks
 Storage and handling equipment
b) An engineered material handling system is one that is typically
automated. Such systems are usually created by combining a variety of
units to enable both storage and transportation.
An Automated Storage and Retrieval System’ ( AS/RS ) is one example
of an engineered material handling system. An AS/RS can be integrated
with a production facility’s existing computer network to keep a tab on
stock control, plus other logistical systems.
Other examples of engineered systems are Automated guided vehicles
(AGVs), Conveyor systems, Robotic delivery systems etc.
SAQ 4
a) One of the more frequent, higher risk outcomes of manual material
handling is musculoskeletal disorders (MSDs). It is found that the most
common MSD were due to obstructions on floors interfering with safe

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Industrial Safety
movement of materials; unsafe material lifting, carrying and moving;
Engineering unsafe storage of material and lack of examination of lifting devices.
b) When heavy loads are required to be handled with purely manual labour,
one has to use Team Lifting or Team Handling.
Following are the basic criteria to be followed when using "Team Lifting
/ Handling".
 Use team lifting and carrying where other solutions are inappropriate.
 Remember that the combined strength of the team is less than the
sum of individual strength.
 Select team members of similar height and strength.
 Assign a leader to the team.
 Determine a set of commands to be used such as "lift", "walk",
"stop",
 "down". Make sure that everyone knows what to do when they hear
the command.
 Follow the commands given by the team leader.
 Practice team lifting and carrying together before attempting the task.
SAQ 5
a) Some general safety tips while working on live electrical lines are listed
below:
 Make sure all electrical circuits are properly earthed following the
guiding IS specifications.
 Repair or replace damaged or worn out portable cord-and-plug
connected equipment, extension cords, power bars, and electrical
fittings before each use.
 Always tape extension cords to walls or floors when necessary.
 Use extension cords or equipment that is rated for the level of
amperage or wattage that you are using.
 Always use the correct size fuse.
 Be aware that unusually warm or hot outlets may be a sign that
unsafe wiring conditions exists.
 Always use ladders made with non-conductive side rails (e.g.,
fibreglass) when working with or near electricity or power lines.
 Place halogen lights away from combustible materials such as cloths
or curtains.
 Risk of electric shock is greater in areas that are wet or damp. Install
Ground Fault Circuit Interrupters (GFCIs) as a safety measure.
 Make sure that exposed receptacle boxes are made of non-
conductive materials.
 Know where the panel and circuit breakers are located in case of an
emergency.
 Label all circuit breakers and fuse boxes clearly.
 Do not use outlets or cords that have exposed wiring.
 Do not use portable cord-and-plug connected power tools with the
guards removed.
 Do not block access to panels and circuit breakers or fuse boxes.
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 Storage of Material
 Do not touch a person or electrical apparatus in the event of an Handling of Hazardous
electrical accident. Always disconnect the power source first. Material

b) The effects of an arcing fault can be devastating to a person. The intense

thermal energy released in a fraction of a second can cause severe burns.
Molten metal blown out can burn the skin or ignite flammable clothing.
The tremendous pressure blast from the vaporization of conducting
materials and superheating of air can fracture ribs, collapse lungs and
knock workers off ladders or blow them across a room.
Following precautions can be taken to avoid arc blasts:
 Electrical systems should be worked on in a de-energized state.
Discuss with the site manager whether the required work could be
performed de-energized. This can often be accomplished through
pre-planning and scheduling.
 Isolate and lockout energy sources.
 Ensure that stored energy does not exist and apply appropriate
grounding if necessary.
 Use properly rated voltage testers to verify the absence of voltage at
each energy point. This should only be done by a qualified person.
 Plan and review the job carefully. Review all possible energy
sources and identify potential hazards and prevention methods
before starting the job.
 Wear appropriate personal protective equipment rated for the job,
including flame-resistant clothing. Never wear clothing made of
nylon, acetate, polyester, or rayon.
 Electrical apprentices and other electricians are the only people who
should assist an electrician in the field.
SAQ 6
a) Five important principles of material handling are listed below:
1. Planning principle: All handling activities should be planned.
2. Systems principle: Plan a system integrating as many handling
activities as possible and coordinating the full scope of operations
(receiving, storage, production, inspection, packing, warehousing,
supply and transportation).
3. Space utilization principle: Make optimum use of cubic space.
4. Gravity principle: Utilize gravity to move a material wherever
practicable.
5. Safety principle: Provide for safe handling methods and equipment.
b) Some of the important aspects of safety that should be followed during
material handling are listed below:
 Avoid lifting materials from the floor or while seated.
 Make use of available handling aids.
 Refrain from using sudden or jerky movements.
 Never lift a load over an obstacle.
 Perform lifts in areas with adequate footing, space and lighting.
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Introduction to
Industrial Safety
 Modify objects and redesign jobs to make moving easier.
Engineering  Seek assistance from co-workers.
 Stay in good physical shape.
 Begin lifts close to the body.
 Use containers made of lighter materials.
 Reduce load sizes when possible.
 Do not twist or bend while lifting objects.
 Ensure repetitive, heavy and bulky lifts are not performed.
 Keep lifts between shoulder and knuckle height.
 Use conveyors, slides or chutes to eliminate pushing or pulling.

6.12 REFERENCES AND FURTHER READINGS

[1] https://www.mtu.edu/ehs/documents/safety-manual/ch6.html
[2] Storage and Handling of Hazardous Materials, Createspace Independent
Pub (26 April 2013), ISBN-10: 1484816226.
[3] https://www.asecos.com/dokumente/M062_Code-of-Practice_Storage-of-
Hazardous-Substances.pdf

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