CHAPTER XIII

MATERIALS HANDLING AND STORAGE

OBJECTIVES:

After reading this chapter, you will be able to:

 Describe common materials handling problems and precautions on the job
 Explain safe manual handling methods for lifting and carrying loads
 Describe the hazards, safeguards, and operating guidelines for common materials
handling equipment
 Establish a training program for your workers to ensure that they follow sale
working practices while moving materials
 Establish a program of regular inspection, repair, and replacement of all materials
handling equipment and tools.
 Understand the principles and guidelines for safe storage of materials.

GENERAL:

Most workers at one time or another, have had to handle materials on the job.
Materials handling, whether done manually or with mechanical equipment, can be a major
source of occupational injuries. This course presents basic materials handling hazards
and safeguards to help prevent injuries and the destruction of property. The topics
covered include materials handling problems; manual handling methods; equipment used
for materials handling: inspection and storage of materials.

MATERIALS HANDLING PROBLEMS:

Manual handling of materials accounts for an estimated 25 percent of all

occupational injuries. These injuries are not limited to the shipping department or the
warehouse, but come from all operations, because it is impossible to run a business
without moving or handling materials. Common injuries workers suffer include strains and
sprains, fractures, and bruises. These are caused primarily by unsafe practices--improper
lifting, carrying too heavy a load, incorrect gripping, failing to observe proper foot or hand
clearances, and failing to use or wear proper equipment and/or personal protective
equipment and clothing. Another major cause of materials handling accidents can be
traced to poor job design. Take a look at your operations and ask the following questions
about your present operating practices:

1. Can the job be engineered to eliminate manual handling of materials?

2. How do materials such as chemicals, dusts, and rough and sharp objects injure
the people doing the handling?
3. Can employees be given handling aids-properly sized boxes, adequate trucks, or
hooks that will make their job safer?
4. Will protective clothing, or other personal equipment help to prevent injuries?
MANUAL HANDLING METHODS:

Since the largest number of injuries occurs to the fingers and hands, people need
to be taught how to pick up and put down heavy bulky or long objects. Some general
precautions are in order.

1. Inspect materials for slivers, jagged edges, burrs, rough or slippery surfaces.
2. Get a firm grip on the object.
3. Keep fingers away from pinch points, especially when putting materials down.
4. When handling lumber, pipe, or other long objects, keep hands away from the ends
to prevent them from being pinched.
5. Wipe off greasy, wet, slippery, or dirty objects before trying to handle them.
6. Keep hands free of oil and grease.

In most cases, gloves, hand leathers, or other hand protectors an be worn to

prevent hand injuries. In other cases, handles or holders can, be attached to the objects
themselves, for example, handles for moving auto batteries,tongs for feeding materials to
metal forming machinery, or wicker baskets for carrying laboratory samples.

A. Lifting and Carrying:

Obviously, the best means to reduce back injuries is to try to eliminate manual
lifting. If this cannot be done, another way is to reduce exposure. This can be achieved
by cutting weight loads using mechanical aids, and rearranging the workplace. Inspite of
all these efforts, manual lifting cannot be entirely eliminated: The basic rules and
instructions to be followed for manual lifting include:

1. Never let workers over exert themselves when lifting. If the load is thought to be
more than one person can handle, assign another person to the job.
2. Lift gradually, without jerking to minimize the effects of acceleration.
3. Keep the load close to the body.
4. Lift without twisting the body.
5. Follow the safe lifting procedures described below.

In reference to the safe lifting procedures, remember that some researchers working in
the area of safe lifting now feel that it is better to let workers choose the lifting position
most comfortable for them.

B. Training for Safe Lifting Procedures:

Numerous attempts have been made to train materials handlers to do their work
particularly lifting in a safe manner. Unfortunately, reduction of overexertion injuries
through the use of training have been generally disappointing. These are several reasons:
 1. If the job' requirements are stressful, “doctoring the system” through behavioral
modification will not eliminate the inherent risk. Designing a safe job is basically
better than training people to behave safely in an unsafe job.
2. People tend to revert to previous habits and customs if practices to replace
previous ones are not reinforced and refreshed periodically.
3. Emergency situations, the unusual case, the sudden quick movement, increased
body weight, or impaired physical well-being may overly strain the body, since
4. training does not include these conditions.

C. Rules for Lifting:

There are no comprehensive and sure-fire rules for "safe” lifting. Manual materials
handling is a very complex combination of moving body segments, changing joint angles,
tightening muscles, and loading the spinal column. The following DOs and DO NOTs
apply,

DOs
1. Do design-out manual lifting and lowering task in the workplace.
2. Do be in good physical shape. If you are not accustomed to lifting and vigorous
exercise, do not attempt to do difficult lifting or lowering task.
3. Do think before acting. Place material conveniently with in reach. Make sure
sufficient space is cleared.
4. Do get a good grip on the load. Test the load before trying to move it.
5. Do get the load close to the body. Place the feet close to the load. Lift mostly by
straightening the legs.

DON'TS
1. Do Not twist the back or bend sideways.
2. Do Not lift or lower awkwardly.
3. Do Not hesitate to get mechanical help or help from another person.
4. Do Not lift or lower with the arms extended.
5. Do Not continue heaving when the load is too heavy.

MATERIALS NORMALLY HANDLED IN INDUSTRIAL PLANTS ARE:

1.Solids:
a. Bulk -crated large machineries and parts, crated materials, lumber etc.
b. Powders-Flour, phosphates, sugar, cement.
c. Granule and Gravel size -Copra meal pellets, silicates, brickets.
d. Odd sizes-copra

2. Liquids:
a. Light-solvents, oils, fuels
b. Viscous - molasses, asphalt, heavy oils, tar, paints
c. Paste- Detergent paste, adhesives
3.Gases:

Classified according to hazardous characteristics:

a. Flammable
b. Corrosive
c. Explosives
d. Emits hazardous fumes or gases
e. Toxic
f. Fragile

POINTERS ON SAFETY STORAGE OF MATERIALS:

1. Materials that can react with each other should be stored in separate areas.
2. Storage areas should be well ventilated and lighted.
3. In storage areas of flammable materials, explosion proof lighting fixtures and
switches are to be used.
4. Where flammable fumes are emitted by stored materials, battery operated forklifts
are to be used
5. Only non-spark type tools, are permitted to be used inside flammable storage area.
6. Storage areas should be provided with fire extinguishers located at strategic places
and are accessible.
7. If warehouse is provided with sprinkler system, no stock should be closer than 2
ft. from the sprinkler head.
8. Provide at least·4 feet of space between the stock pile and the wall. This is to
protect the pile against heat if there is fire at the other side of the wall. This too will
afford ventilation and serves as access way for firefighters in the event of fire.
9. Use screw nails in making or repair of wooden pallets.
10. No welding or open flame cutting should be permitted in storage of flammable
materials . Hot work permit is mandatory should welding is extremely necessary.
 CHAPTER XIV

ELECTRICAL SAFETY

GENERAL:

After reading this chapter, you will be able to:

1. Explain the action of electricity on the human body and how to use grounding to
prevent shocks and shock hazards,
2. Explain the uses and limitations of ground fault circuit interrupters.
3. Understand the classes and divisions of hazardous locations and the proper
equipment to use for each classified location.
4. Instruct workers in the proper safety standards and procedures to handle electrical
equipment safely on or off the job.
5. Understand how to test branch circuits and electrical equipment.
6. Describe how to use plug and cord connected equipment and extension cords
safely.

MYTHS AND MISCONCEPTIONS ABOUT ELECTRICITY:

Misconceptions about electricity among workers can lead to serious accidents and
property damage. The more common myths are:

1. Electricity takes the path of least resistance. This myth implies that current only
takes low resistance paths. Actually, current will take any path, high or low
resistance in order to return to the source that provides power.
2. A person is led to believe that electricity wants to go to ground and simply
disappear. In reality, current-uses the ground to get back to its grounded power
source.
3. When an electrical tool or appliance falls into water, it does not short out. If the
switch is ON, the item will continue to operate. If the switch is OFF. It will simply
get wet.
4. AC reverse polarity it not hazardous. The switch is supposed to be on the “hot”
conductor supplying power to the item.
5. It takes high voltage to kill;120 volts AC is not dangerous. Current is the culprit.
However, AC voltage as low as 60 volts can kill. At higher voltages the body can
be severely burned and yet the victim could live.
6. Double-insulated power tools are doubly safe and can be used in wet and damp
locations.

Every piece of equipment is a potential source of electrical shock. Even an

electrical shock, small enough not to cause injury can trigger. An involuntary reaction that
results in physical harm. For example, after touching a live wire, a person may lose his or
her balance and fall off a ladder. Obviously design, layout, installation, and a preventive
maintenance program can minimize live or “hot” electrical equipment. An effective
electrical safety policy coupled with an employee training and hazard awareness program
can further prevent electrical shock. It is also recommended that an effective electrical
inspection program be implemented and conducted periodically as conditions warrant.

ELECTRICAL FUNDAMENTALS’REVIEW:

Ohm’s Law:

Ohm’s law simply states that one volt will cause a current of one ampere to flow
through a resistance of one ohm. As a formula, the relationship is represented by
E(volts)=I(amps) Times R (resistance). An easy way to remember this formula, and the
different ways it can be expressed is to put the symbols in a circle as shown below:

1. Put your finger on I: I = E/R

2. Put your finger on R: R = E/I

3. Put your finger on E: E = I x R

With this basic formula you can better understand and explain the effects that electrical
current has on the human body.

To demonstrate Ohm’s Law, try to solve this problem. Assume a person is working and
perspiring and has a hand-to-hand resistance of 1,000 ohms. This person contacts 100
volts with one hand and touches a ground surface with the other, completing a loop to the
voltage source. What would be the current going through the body. By direct substitution,
the equation would be:

I = E/R = 100/1.000 = 0.1 amp(100 ma)

Another important formula is the relationship of voltage, current, and power utilization
(watts). Power is measured in watts and is equal to E (volts), x I (current). In other words,
one watt would be equal to one ampere of current flowing through a resistor with one volt
of potential difference. Another way to put this relationship to practical use would be to
consider a 6-watt electric bulb (about the size of a night light). Determine the current flow
of filament of a 6-watt bulb that is being used in a 120 volt light socket.

I = P/E = 6/120 = 0.05 amp = 50 ma

This current is enough to affect the human heart and induce a fatal irregular heart beat,
which can result in a heart attack. These examples of current levels from 50 ma to 20000
ma are used to illustrate and clarify misconceptions about electricity and its effect on the
human body.

Factors Enhancing Electrical Shock:

The route that electrical currents take through the human body determines the
degree of injury and voltage determines how much current flows. In cases where
individuals come in contact with distribution lines, high voltage and high current can cause
the moisture in the body to heat so rapidly that body parts can literally explode. This
extreme expansion is the result of the body fluids changing to steam. This could result in
a person's being injured severely, but not electrocuted.

Other factors that enhance electrical shock potential are as follows:

1. Wet and / or damp locations

2. Ground/grounded objects
3. Current loop from power source back to power source
4. Path of current through body and duration of contact
5. Area of body contact and pressure of contact
6. Physical size, condition, age of person
7. Type and/or amount of voltage
8. Personal protective equipment, gloves, shoes
9. Metal object such as watches, necklace, rings
10. Miscellaneous
a) Poor workplace illumination
b) Color blindness
c) Lack of safety training and knowledge of electricity
d) No safe work procedures

Basic Rules of Electrical Action:

There are four basic rules of electrical action that everyone should know. They are as
follows:

1. Electricity isn’t “live” until current flows.

 2. Electrical current won’t flow until there is a complete loop, out from and back to the
power source.
3. Electrical current always returns to its source, that is, the transformer has created
it.
4. When current flows, work (measured in watts) is accomplished.

Rule 1. This rule explains why faulty power tools with live metal cases can be carried
around and used without causing a shock. Only when a person comes in contact with a
ground loop with low resistance will current flow through the body and produces a shock.

Rule 2. When a current loop is formed, the electric current now has a path to return
to its source. If the loop is broken, the current will stop flowing. To minimize electrical
shock hazards, look for ways .to prevent ground loops. Insulated mats, electrical gloves,
and insulated tools are some methods that can be used.

Rule 3. Current will find any available loop or path to return to its source. In a
grounded system the NEC requires that the power source be electrically attached to an
earth-driven ground rod as well as to the water piping. This creates many potential ground
loops for current to get back to its source.

Rule 4. If current flows through the body, it can do harm depending on the amount of
current available. The effect on the human body can be anything from a mild shock to
irreversible damage.

These rules should help you analyze how and why someone received an electrical shock.
Use the loop concept and Ohm’s Law to investigate actual or potential electrical shock
hazards in the workplace and to design proper safeguards.

GROUND-FAULT CIRCUIT INTERRUPTERS:

Operational Theory:

The ground fault circuit interrupter(GFCI)is a fast acting device that monitors the
current flow to a protected load. It can sense any leakage current returning to the power
supply by any electrical loop other than through the white (hot) and the black (grounded)
conductors. When any leakage current 5 ma or over is sensed, the GFCI, in a fraction of
a second, shuts off the current on both the hot and grounded conductors thereby
interrupting the fault current to the appliance and the fault loop.

Another type of ground fault can occur when a person contacts a hot conductor directly
or touches an appliance with no grounding conductor. In this case, I (current) represents
the current loop back to the transformer. This ground fault is generally the type that
personnel are exposed to. The GFCI is intended to provide workers protection by de-
energizing a circuit or portion of a circuit in approximately 1/40th of a second when the
ground fault current exceeds 5 ma. The GFCI should not be confused with ground fault
protection (GlFP) devices that protect equipment from damaging line-to-line fault currents.
Protection provided by GFCIs is independent of the condition of the equipment grounding
conductor.

HAZARDOUS LOCATIONS:

Overview of Classes and Divisions:

Hazardous locations are areas where flammable liquids, gases, vapors,

combustibles dusts, or other easily ignitable materials exist or can exist accidentally in
sufficient quantities to produce an explosion or fire. Hazardous locations are classified as
Class I, Class ll or Class III depending on what type of hazardous substance is or may be
present. In general, Class I locations are those in, which flammable vapors and gases
may be present. Class Il locations are those which combustible dusts may be found. Class
III locations are those in which there are ignitable fibers suspended in the atmosphere.
Each of these classes is divided into two hazard categories, Division 1 and Division 2,
depending on the likelihood of flammable or ignitable concentration of a substance.
Division 1 locations are designated as such because a flammable gas, vapor, dust, or
easily ignitable material is normally present in hazardous quantities. In Division 2
locations, the existence of hazardous, quantities of these materials is not normal but they
occasionally exist either accidentally or when material in storage is handled.

Equipment Requirements:

Hazardous areas require special electrical equipment designed for the specific
hazard involved. This includes explosion proof equipment for flammable vapor, liquid and
gas hazards and dust-ignition proof equipment for combustible dust.

1. Intrinsically Safe:

Intrinsically safe equipment cannot release sufficient electrical or thermal energy under
normal or abnormal conditions to ignite specific flammable or combustible materials
present in that location.

2. Explosion Proof:

Equipment installed in Class I locations must be approved as explosion proof. This

minimizes the risk of explosion that occurs when a flammable gas enters the enclosure
and is ignited by the arcs.

3. Dust-ignition Proof:

In Class II locations, dust-ignition proof is designed to keep ignitable amount of dust from
entering the enclosure.
SAFETY PROGRAM, POLICY AND PROCEDURE:

The policy should cover the responsibilities of supervisors, workers, and the specialist
who inspect, install and maintain the electrical equipment.

1. Supervisory Responsibilities:

a. Training and Education

b. Hazardous condition reporting
c. Work practices
d. Housekeeping

2. Employee Responsibilities:

a. Training and Education

b. Hazardous condition reporting
c. Work practices
d. Housekeeping

3. Electrical Safety Policy:

a. Plug power equipment into wall receptacles with power switches in the OFF
position.
b. Unplug electrical equipment by grasping the plug and pulling. Do not pull or
jerk the cord to unplug the equipment.
c. Checked for frayed, cracked, or exposed wiring on equipment cords.
d. Personnel should know the location of electrical Circuit breaker panels that
control equipment and lighting in their respective areas. Circuits and
equipment disconnects must be identified.
e. Temporary or permanent storage of any materials must not be allowed
within 3 ft. of any electrical panel or electrical equipment.
f. When defective electrical equipment is identified by personnel, it should be
tagged immediately and removed from service for repair or replacement.
g. Any electrical equipment causing shocks or with high leakage potential must
be tagged with a DANGER-DO NOT USE label.