Safe Handling and Storage of Loads

Posted on Aug 5, 2024 in Technology

Storage and Handling of Loads

Introduction

30% of accidents in Spain occur during material handling operations, particularly during loading, unloading, and storage. These accidents often involve manual or mechanical work and can result in significant material damage, even if fatalities are rare. The movement of materials is essential for production in any industry. While mechanization has increased, reducing human intervention, it remains a crucial aspect of many material handling operations.

Storage

Proper storage of materials is crucial to prevent risks such as detachment and slippage. While there are no general regulations on storing materials (except for specific legislation), technical criteria guide all storage-related matters.

1 Indoor and Outdoor Storage

Internal Storage:
  • Lower floors are safer due to increased structural resistance. They facilitate loading and unloading tasks but can be more dangerous.
  • Precautions for upper floors:
    • Stack materials close to load-bearing walls and structural elements.
    • Place merchandise along the perimeter of the storage area.
Storage outside:
  • Ensure firm and level ground.
  • Protect materials from rain and wind.
  • Use appropriate support materials to safeguard merchandise.

2 General Storage Considerations

  • Provide sufficient space for loading and unloading tasks, whether manual or mechanical.
  • Display clear instructions and signage. Provide appropriate equipment for storage, protection, and handling of dangerous products (toxic, corrosive, etc.).
  • Consider material access routes, ventilation, and lighting.

3 Storage Considerations for Dangerous Substances

Substances such as flammable, combustible, explosive, compressed gases, toxic, or hazardous waste require storage facilities with more stringent structural characteristics.

Obligations:
  • Employer: Responsible for preventing accidents related to dangerous substances in storage.
  • Warehouse Manager: Establish and enforce work and operational rules, supervise the application of these rules, and provide information on stored materials and their associated dangers. They also supervise or provide emergency protective elements.
  • Workers: Perform tasks according to the warehouse manager’s instructions, report anomalies or accidents, and use appropriate PPE.

4 Storage of Unpackaged Material

• Linear Rigid Materials (Sections, Rods, Tubes)
  • Store materials on roof supports or structures that provide stability.
  • Ensure a firm and resilient floor.
  • Recommended maximum stacking height: 6 meters.
  • Restrict personnel access to higher levels and prevent circulation on stored materials.
  • Store light bars vertically in designated racks.
  • Store heavy and large profiles and sheet metal on shelves with roller bearings. Tilt the shelves inward to facilitate handling when mechanical means are not used.
• Bags
  • Stack bags in a cross-layer pattern, with openings facing inward.
  • For stacks higher than 1.5 meters, spread and stagger every 0.5 meters of thickness.
  • Use retractable plastic wrapping to enhance stack stability.
• Non-Linear Rigid Materials (Boxes, Cans, etc.)
  • Store boxes in a pyramid shape, not exceeding 7 levels or a staggered height of 5 meters.
  • Position all rows of boxes at the same level.
  • Ensure each box rests on a quarter of the one below for stability and ease of access during stacking and unstacking.
  • Store cardboard boxes containing heavy products on pallets to protect them from moisture and prevent collapse. Limit stacking height.
  • Store cylindrical containers and vessels on pallets and secure them with straps for vertical storage.
  • Always store small pieces in baskets or suitable containers.
• Palletized Storage
  • Do not exceed the pallet’s load capacity.
  • Ensure the platform does not extend beyond the pallet’s perimeter. Avoid stacking loaded pallets on top of each other.

Handling Loads

There are three phases to handling loads:

  • Surveying
  • Transportation
  • Unloading

1 Manual Handling

Workers perform all three stages of manual handling. Back injuries are the most frequent risk and pathology, often caused by poor posture during lifting and unloading.

• Risk Factors in Cargo Handling
  • Weight, volume, placement, weight distribution, and consistency of cargo
  • Insufficient space
  • Poor lighting
  • Worker’s physical fitness and age
  • Intensity of work
  • Awkward postures
  • Lack of training
  • History of back injury

* It is crucial to minimize manual handling of loads and utilize mechanical means whenever possible. Provide workers with adequate equipment.

Correct Manual Handling of Loads:
  • Position feet shoulder-width apart.
  • Bend at the knees to lift the load, keeping your back straight.
  • Maintain a straight back during transport, avoiding twisting or bending movements.
  • To set the load down, bend your knees while keeping your back straight.

2 Mechanical Handling

There are two types of load handling equipment: automatic and worker-controlled. While mechanical handling mitigates the risks associated with manual handling, it introduces new risks.

Frequently Used Mechanical Handling Equipment:
  • Lifting equipment for loads and/or people: hoists, elevators, platform lifts, etc.
  • Lifting and transport equipment: gantry cranes, cranes, pulley blocks, winches, etc.
  • Mobile lifting and transport equipment: forklifts, pallet trucks
  • Continuous handling equipment: conveyors, screw conveyors, etc.
  • Auxiliary elements: cables, chains, slings
Risks:
  • Falling materials
  • Collisions with moving objects
  • Impacts against stationary objects
  • Entrapment by or between objects
  • Electric shock

2.1 Auxiliary Elements

Lifting accessories must be chosen based on:

  • Load handling requirements
  • Grip points
  • Coupling devices
  • Weather conditions

* Consider the safety factor and store accessories properly to prevent deterioration.

Forklift Components:
  • Rigid chassis
  • Vertical mast for movement
  • Two clamping brackets
  • Fork carrier plate
  • Electric or combustion engine
• Safety Accessories
  • Safety cage
  • Fork carrier plate guard
  • Ergonomic seat
• Safety Regulations
Forklift operators must:
  • Receive specific training for safe operation.
  • Possess management approval from the company verifying training.
  • Reduce speed at intersections and areas with limited visibility.
  • Ascend and descend facing the seat.
  • Maintain a clear view of the direction of travel.
Forklift operators must not:
  • Operate outside designated areas.
  • Exit the forklift while in operation.
  • Drive erratically.
  • Overtake other forklifts.
  • Walk or allow others to walk beneath loaded forks.
  • Transport people on the forks, on loads, or on the forklift itself.

Risks Related to Safety Conditions

• Working with the Load
  1. Lift the load approximately 15cm above the ground.
  2. Tilt the mast backward for movement.
  3. Position the forklift in front of the unloading area.
  4. Raise the load to a height that allows for safe braking.
  5. Maneuver the forklift to the unloading location.
  6. Level the mast and carefully place the load onto the stack.
  7. Slowly back the forklift away from the load.
• Circulation
  • Maintain floors in optimal condition.
  • Provide adequate lighting.
  • Ensure corridor dimensions accommodate loads and forklifts.
  • Ramps should have a gradual incline.
  • Avoid turning on slopes or crossing them diagonally.
  • Exercise extreme caution when reversing.
  • Recommended maximum speed: 10 km/h