Lecture 4-Material and Machine Safety

04/21/23Industrial Safety Lecture Four1

Safe Materials Handling and Safe Materials Handling and Machine SafetyMachine Safety

Joe Nail


Introduction Introduction

Handling Materials SafelyHandling Materials Safely

50 tons per one ton shipped.50 tons per one ton shipped. Some is moved by machine and some by hand.Some is moved by machine and some by hand. When handling material, technique is everything.When handling material, technique is everything.


Causes of InjuriesCauses of Injuries

25% of all injuries are related to material 25% of all injuries are related to material handling.handling.

80% are to the lower back.80% are to the lower back. Incorrect lifting causes most injuries.Incorrect lifting causes most injuries. Incorrect use of equipment.Incorrect use of equipment.


CarelessnessCarelessness Be aware of your environment.Be aware of your environment.

Hey Charlie! Did you see that game last night?


Avoiding Workplace Injuries Avoiding Workplace Injuries

Stay in shape.Stay in shape.

Consider where you will walk.Consider where you will walk. Don’t use your body if you don’t have to.Don’t use your body if you don’t have to.


Rules for LiftingRules for Lifting

Get close to the load.Get close to the load. Keep feet apart.Keep feet apart. Keep back straight.Keep back straight. Bend your knees.Bend your knees. Tuck your chin.Tuck your chin.

Grip the load with your palms.Grip the load with your palms.


Hazards Associated with Hazards Associated with Materials HandlingMaterials Handling

Check your environment for sufficient Check your environment for sufficient moving roommoving room

Check for projecting objects, wear gloves.Check for projecting objects, wear gloves. Are materials secure?Are materials secure? Are chemicals to be moved?Are chemicals to be moved?


Teamwork and Handling Teamwork and Handling Various Shapes and SizesVarious Shapes and Sizes

If an object seems to heavy to lift, it If an object seems to heavy to lift, it probably is.probably is.

When working with others, When working with others, communication is critical.communication is critical.

Your back should be kept straight when Your back should be kept straight when you carry objects.you carry objects.

Special lifting tools should be sought out Special lifting tools should be sought out and used for large objects.and used for large objects.

Protect yourself when handling things.Protect yourself when handling things.


Examples of Lifting EquipmentExamples of Lifting Equipment


Hand Tools and AccessoriesHand Tools and Accessories


Power Operated Hand TrucksPower Operated Hand Trucks

Examples of a “walkie” and a “rider” type powered hand trucks


Powered Industrial trucksPowered Industrial trucks

Trucks are usually classified by power Trucks are usually classified by power source.source.

Electric MotorsElectric Motors Internal Combustion EngineInternal Combustion Engine

– GasolineGasoline– DieselDiesel– LP Liquefied PetroleumLP Liquefied Petroleum


Standard Powered Industrial Standard Powered Industrial Lift TruckLift Truck


Straddle TruckStraddle Truck


Order Picker TruckOrder Picker Truck


Industrial Truck SafetyIndustrial Truck Safety Popular Misconceptions Popular Misconceptions“Anyone can drive a lift truck.”Anyone can drive a lift truck.” ““They handle just like a car.”They handle just like a car.” ““They are easier to drive than a car.”They are easier to drive than a car.” ““You don’t need any training to safely You don’t need any training to safely

drive a fork lift.”drive a fork lift.”


Industrial Truck SafetyIndustrial Truck SafetyFactsFacts The center of gravity of a lift truck The center of gravity of a lift truck

changes.changes. Most trucks are “rear steer.”Most trucks are “rear steer.” Most trucks have no suspension system.Most trucks have no suspension system. It is NOT safe to alter the lift truck’s It is NOT safe to alter the lift truck’s

counterweight!counterweight!


Industrial Truck SafetyIndustrial Truck Safety

What does OHSA say about powered What does OHSA say about powered industrial truck training?industrial truck training?

OSHA regulations state that “only OSHA regulations state that “only trained and authorized operators shall trained and authorized operators shall be permitted to operate a powered be permitted to operate a powered industrial truck.”industrial truck.”

But why?But why?


Get the picture?Get the picture?

Training helps to Prevent Accidents!Training helps to Prevent Accidents!


Data plate.

Powered Industrial Trucks -Powered Industrial Trucks -Operator TrainingOperator Training

1910.178 (l)1910.178 (l)1915.120 (a)1915.120 (a)1917.1 (a)(2)(xiv)1917.1 (a)(2)(xiv)1918.1 (b)(10)1918.1 (b)(10)1926.602 (d)1926.602 (d)

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DisclaimerDisclaimerThis presentation is intended as a resource for

providing training on OSHA’s revised powered industrial truck operator standards. It is not a substitute for any of the provisions of the Occupational Safety and Health Act of 1970, or for any standards issued by the U.S. Department of Labor’s Occupational Safety and Health Administration (OSHA). It is also not a substitute for a powered industrial truck operator training program.

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AcknowledgmentAcknowledgment OSHA’s Office of Training and Education wishes to

acknowledge the following for contributing some of the graphics used in this presentation:– Caterpillar Lift Trucks– Mason Contractors Association of America– Industrial Truck Association– State of Utah Labor Commission - Occupational Safety &

Health Division – Steamship Trade Association of Baltimore– Taylor Machine Works, Inc.– UAW - Ford National Joint Committee on Health and Safety

Appearance of products does not imply endorsement by the U.S. Department of Labor.

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Powered IndustrialPowered IndustrialTruck - DefinitionTruck - Definition

A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier materials. [American Society of Mechanical Engineers (ASME) definition]

Excluded are vehicles used for earth moving and over-the-road hauling.

Commonly known as forklifts, pallet trucks, rider trucks, forktrucks, or lifttrucks.

Can be powered through electric or combustion engines.

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Scope of StandardScope of Standard

The scope provisions of 1910.178(a), which are based on ANSI B56.1 - 1969, remain in effect and cover:– ... fork trucks, tractors, platform lift trucks,

motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines.

– It does not apply to compressed air or nonflammable compressed gas-operated industrial trucks, farm vehicles, nor vehicles intended primarily for earth moving or over-the-road hauling.

This scope covers general industry, construction and shipyards.

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Scope of Standard Scope of Standard (continued)(continued)

For marine terminal and longshoring industries, all powered industrial trucks are covered, no matter what specialized name they are given.

This includes, but is not limited to, straddle carriers, hustlers, toploaders, container reach stackers, and other vehicles that carry, push, pull, lift, or tier loads.

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Reasons for New StandardReasons for New Standard

Powered industrial truck accidents cause approximately 100 fatalities and 36,340 serious injuries in general industry and construction annually.

It is estimated that 20 - 25% of the accidents are, at least in part, caused by inadequate training.

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Additional Reasons for New Additional Reasons for New StandardStandard

Updated consensus standards have been published.

OSHA has been petitioned to improve the requirements for industrial truck training.

Advisory Committee on Construction Safety and Health has recommended improving the standard.

Resolutions have been introduced in the Senate and House urging OSHA to revise its outdated standard.

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Forklift Fatalities, 1992-1996Forklift Fatalities, 1992-1996

Source: Bureau of Labor Statistics, Job Related Fatalities Involving Forklifts

86 89

120

95

114

1992 1993 1994 1995 1996

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Forklift Fatalities by Age GroupForklift Fatalities by Age Group1992 -19961992 -1996

3%

10%

22%

21%

12%

5%

27%

Under 20

20 - 24

25 - 34

35 - 44

45 - 54

56 - 64

65 & over

Source: Bureau of Labor Statistics

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Industries Where Powered Industrial Industries Where Powered Industrial Truck Accidents OccurredTruck Accidents Occurred

Source: OSHA Fatality/Catastrophe Reports, complied by OSHA Office of Electrical/Electronic andMechanical Engineering Safety Standards.

32Source: Bureau of Labor Statistics, Job Related Fatalities by Selected Characteristics, 1996.

Nonfatal Occupational Injuries and Nonfatal Occupational Injuries and Illnesses by Source, 1996Illnesses by Source, 1996

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BackgroundBackground

The previous OSHA standards, while requiring operator training, did not define the type of training or authorization required.

March 15, 1988 - Industrial Truck Association (ITA) petitioned OSHA for specific training requirements.

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Background Background (continued)(continued)

American National Standards Institute (ANSI), in cooperation with ASME, has revised its standard 4 times, including current lifttruck technology and specific training topics.

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Background Background (continued)(continued)

OSHA published a proposed ruling on March 14, 1995 for General Industry, Shipyard, Marine Terminals, and Longshoring regulations, adding specific training requirements.

On January 30, 1996, OSHA proposed a revision of the construction standards, mandating the development of an operator training program based on the prior knowledge and skills of the trainee and requiring a periodic evaluation.

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Final RuleFinal RuleOSHA published the final rule for Powered

Industrial Truck Operator Training on December 1, 1998.

The effective date is March 1, 1999. Start-up dates are included in paragraph (l)(7).

It applies to all industries except agricultural operations.

OSHA estimates that the new rule will prevent 11 deaths and 9,422 injuries per year.

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Fatalities/Injuries Potentially Averted Fatalities/Injuries Potentially Averted Annually by New StandardAnnually by New Standard

Source: U.S. Department of Labor, OSHA, Office of Regulatory Analysis, 1997

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Performance-Oriented Performance-Oriented RequirementsRequirementsThe powered industrial truck operator

training requirements are performance-oriented to permit employers to tailor a training program to the characteristics of their workplaces and the particular types of powered industrial trucks operated.

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Revised Operator Training Revised Operator Training RequirementsRequirements General Industry: 1910.178 is amended by

revising paragraph (l) and adding Appendix A. Shipyard Employment: New section 1915.120 and

Appendix A are added. Marine Terminals: Section 1917.1 is amended by

adding new paragraph (a)(2)(xiv) and Appendix A. Longshoring: Section 1918.1 is amended by

adding new paragraph (b)(10) and Appendix A. Construction: 1926.602 is amended by adding new

paragraph (d) and Appendix A.

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Operator TrainingOperator TrainingSafe operations

– The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by successful completion of the training and evaluation specified in the OSHA standard.

– 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 required training (or previously received appropriate training).

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Training Program Training Program ImplementationImplementationTrainees may operate a powered industrial

truck only:– Under direct supervision of a person who

has the knowledge, training, and experience to train operators and evaluate their competence; and,

– Where such operation does not endanger the trainee or other employees.

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Training Program Implementation (continued)

Training shall consist of a combination of:Training shall consist of a combination of: Formal instruction (e.g., lecture, discussion, Formal instruction (e.g., lecture, discussion,

interactive computer learning, written material), interactive computer learning, written material), Practical training (demonstrations and exercises Practical training (demonstrations and exercises

performed by the trainee), and performed by the trainee), and Evaluation of the operator’s performance in the Evaluation of the operator’s performance in the

workplaceworkplace

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Training Program Training Program Implementation Implementation (continued)(continued)

Training and evaluation shall be conducted by a person with the knowledge, training and experience to train powered industrial truck operators and evaluate their competence.

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Training Program ContentTraining Program ContentOperators shall receive initial training in

the following topics, except in topics which the employer can demonstrate are not applicable to safe operation in the employer’s workplace. – Truck-related topics– Workplace-related topics– The requirements of the standard

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Training Program Content Training Program Content (continued)(continued)

– Operating instructions, warnings and precautions

– Differences from automobile

– Controls and instrumentation

– Engine or motor operation– Steering and maneuvering– Visibility

Truck-related topics– Fork and attachment

adaptation, operation, use – Vehicle capacity and stability– Vehicle inspection and

maintenance that the operator will be required to perform

– Refueling/Charging/ Recharging batteries

– Operating limitations– Other instructions, etc.

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– Surface conditions

– Composition and stability of loads

– Load manipulation, stacking, unstacking

– Pedestrian traffic

– Narrow aisles and restricted areas

– Operating in hazardous (classified) locations

– Operating on ramps and sloped surfaces

– Potentially hazardous environmental conditions

– Operating in closed environments or other areas where poor ventilation or maintenance could cause carbon monoxide or diesel exhaust buildup

Workplace-related topics

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The requirements of the OSHA standard on powered industrial trucks must also be included in the initial operator training program.

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Refresher Training and Refresher Training and EvaluationEvaluationRefresher 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 required when:– Unsafe operation – Accident or near-miss– Evaluation indicates need– Different type of equipment introduced – Workplace condition changes

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Refresher Training and Refresher Training and Evaluation Evaluation (continued)(continued)An evaluation of each powered industrial

truck operator’s performance must be conducted:– After initial training,– After refresher training, and– At least once every three years

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Avoidance of Duplicative Avoidance of Duplicative TrainingTrainingIf an operator has previously received

training in a topic specified in this section, and the training is appropriate to the truck and working conditions encountered, additional training in that topic is not required if the operator has been evaluated and found competent to operate the truck safely.

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CertificationCertification

The employer shall certify that each operator has been trained and evaluated as required by the standard.

Certification shall include:– Name of operator– Date of training– Date of evaluation– Identity of person(s) performing the training

or evaluation

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DatesDates The employer shall ensure that operators of

powered industrial trucks are trained, as appropriate, by the dates shown in the following table.

If the employee was hired:

The initial training and evaluation of that employee must be completed:

Before December 1, 1999

By December 1, 1999

After December 1, 1999Before the employee is assigned to operate a powered industrial truck.

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Appendix A - Stability of Powered Appendix A - Stability of Powered Industrial TrucksIndustrial Trucks

Appendix A provides non-mandatory guidance to assist employers in implementing the standard.

This appendix does not add to, alter, or reduce the requirements of this section.

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Appendix A - Stability of Powered Appendix A - Stability of Powered Industrial TrucksIndustrial Trucks

Definitions General Basic Principles Stability Triangle Longitudinal

Stability Lateral Stability Dynamic Stability

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A

B

C

Vehicle Center ofGravity (Unloaded)

Center of Gravityof Vehicle and Maximum Load(Theoretical)

Stability Triangle - Figure 1

Notes:1. When the vehicle is loaded, the combined center of gravity (CG) shifts toward line B-C.

Theoretically the maximum load will result in the CG at the line B-C. In actual practice, the combined CG should never be at line B-C.

2. The addition of additional counterweight will cause the truck CG to shift toward point A and result in a truck that is less stable laterally.

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Load CG

Vertical StabilityLine(Line of Action)

Combined CG

Truck CG

Load CG

Combined CG

Vertical StabilityLine(Line of Action)

Truck CG

The vehicle is stable This vehicle is unstable and will continue to tip over

Stability Triangle - Figure 2

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Effective Powered Industrial Effective Powered Industrial Truck Operator Training ProgramTruck Operator Training Program

Four major areas of concern must be addressed:– The general hazards that apply to the operation

of all or most powered industrial trucks;

– The hazards associated with the operation of particular types of trucks;

– The hazards of workplaces generally; and,

– The hazards of the particular workplace where the vehicle operates.

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Types of Powered Industrial Types of Powered Industrial TrucksTrucks There are many different types of powered industrial

trucks covered by the OSHA standard. Commonly used types include:

– High lift trucks, counterbalanced trucks, cantilever trucks, rider trucks, forklift trucks, high lift trucks, high lift platform trucks, low lift trucks, motorized hand trucks, pallet trucks, straddle trucks, reach rider trucks, high lift order picker trucks, motorized hand/rider trucks, and counterbalanced front/side loader lift trucks.

A single type of truck can only be described by calling it by all of its characteristics, (e.g., a high lift, counterbalanced, sit down rider truck).

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Unique Characteristics of Unique Characteristics of Powered Industrial TrucksPowered Industrial Trucks

Each type of powered industrial truck has its own unique characteristics and some inherent hazards.

To be effective, training must address the unique characteristics of the type of vehicle the employee is being trained to operate.

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Components of a Forklift Truck*Components of a Forklift Truck*

*One of the most common types of powered industrial trucks

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Classes of Commonly-Used Classes of Commonly-Used Powered Industrial Trucks*Powered Industrial Trucks*

The Industrial Truck Association has placed powered industrial trucks into 7 classes.– Class I - Electric motor rider trucks– Class II - Electric motor narrow aisle trucks– Class III - Electric motor hand trucks or hand/rider trucks– Class IV - Internal combustion engine trucks

(solid/cushion tires)– Class V - Internal combustion engine trucks (pneumatic

tires)– Class VI - Electric and internal combustion engine

tractors– Class VII - Rough terrain forklift trucks

* Note that this classification refers to commonly-used vehicles and does not include all powered industrial trucks covered by the OSHA standard.

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Class I - Electric Motor Rider Class I - Electric Motor Rider TrucksTrucksCounterbalanced rider type, stand upThree wheel electric trucks, sit-downCounterbalanced rider type, cushion tires,

sit-down (high and low platform)Counterbalanced rider, pneumatic tire, sit-

down (high and low platform)

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Class I - Electric Motor Rider Class I - Electric Motor Rider TrucksTrucks

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Class I - Electric Motor Rider Class I - Electric Motor Rider TrucksTrucks

Counterbalanced Rider Type, Stand-Up

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Class II - Electric Motor Narrow Class II - Electric Motor Narrow Aisle TrucksAisle Trucks

High lift straddleOrder pickerReach type outriggerSide loaders, turret trucks, swing mast and

convertible turret/stock pickersLow lift pallet and platform (rider)

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Class II - Electric Motor Narrow Aisle Class II - Electric Motor Narrow Aisle Trucks Trucks

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Class II - Narrow Aisle Trucks Class II - Narrow Aisle Trucks

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Class III - Electric Motor Hand or Class III - Electric Motor Hand or Hand/Rider TrucksHand/Rider Trucks

Low lift platformLow lift walkie palletReach type outriggerHigh lift straddleHigh lift counterbalancedLow lift walkie/rider pallet

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Class III - Electric Motor Hand Class III - Electric Motor Hand or Hand/Rider Trucksor Hand/Rider Trucks

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Class III - Hand & Hand/Rider Class III - Hand & Hand/Rider TrucksTrucks

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Class IV - Internal Combustion Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Engine Trucks - Cushion (Solid) TiresTires

Fork, counterbalanced (cushion/solid tires)

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Class IV - Internal Combustion Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Engine Trucks - Cushion (Solid) TiresTires

73

Class V - Internal Combustion Class V - Internal Combustion Engine Trucks - Pneumatic TiresEngine Trucks - Pneumatic Tires

Fork, counterbalanced (pneumatic tires)

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Class V - Internal Combustion Class V - Internal Combustion Engine Trucks (Pneumatic Tires)Engine Trucks (Pneumatic Tires)

75

Class VI - Electric & Internal Class VI - Electric & Internal Combustion Engine TractorsCombustion Engine Tractors

Sit-down rider

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Class VII - Rough Terrain Forklift Class VII - Rough Terrain Forklift TrucksTrucks

– Straight-mast forklift – Extended-reach forklift

All rough terrain forklift trucks

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Rough Terrain Straight Mast Rough Terrain Straight Mast ForkliftsForklifts

78

Rough Terrain Extended-Reach Rough Terrain Extended-Reach ForkliftsForklifts

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Some Types of Powered Industrial Some Types of Powered Industrial Trucks Used in MaritimeTrucks Used in Maritime

– Container top handlers

– Container reach stackers

– Straddle carriers

– Semi-tractors/ Utility vehicles

– Sidehandlers

– Combination vacuum lifts

– Yard tractors

The following types of vehicles are covered by the OSHA standard if the vehicles carry, push, pull, lift, or tier

loads.

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Powered Industrial Trucks Used Powered Industrial Trucks Used in Maritimein Maritime

Container Handlers

81

Powered Industrial Trucks Used in Powered Industrial Trucks Used in MaritimeMaritime

Empty-Container Handler

82


Container Reach Stacker

83


Straddle Carriers

84


Yard Tractor


Dock SafetyDock Safety

Painting of area.Painting of area. Trailer brakes and securing.Trailer brakes and securing. People in the area.People in the area. Perform daily check of truck.Perform daily check of truck.



Portable Docking PlatePortable Docking Plate



Dock Restraint MechanismDock Restraint Mechanism


ConveyorsConveyors


ConveyorsConveyors

Powered type is most dangerous.Powered type is most dangerous. Most people get hurt while working on Most people get hurt while working on

them.them. Most injuries involve fingers, hands, Most injuries involve fingers, hands,

and arms.and arms. Accidents can be prevented if workers Accidents can be prevented if workers

are careful to turn off the power and are careful to turn off the power and lock it out.lock it out.


Hoists and Hoists and CranesCranes


Hoists and Hoists and CranesCranes


Hoists and CranesHoists and Cranes

Hoists and Cranes should be inspected Hoists and Cranes should be inspected before use, every time.before use, every time.

When cranes fail, it usually happens When cranes fail, it usually happens fastfast.

Tension on a sling is relative to total Tension on a sling is relative to total weight be lifted and angle of sling.weight be lifted and angle of sling.

Never stand under a suspended load.Never stand under a suspended load.


Receiving and Storing Receiving and Storing MaterialsMaterials

Does this look safe to you?Does this look safe to you?


When Storing MaterialsWhen Storing Materials

Place large, heavy packages on the bottom Place large, heavy packages on the bottom and lighter ones on top.and lighter ones on top.

Never place materials where they can be Never place materials where they can be tripped over or where someone could get hurt tripped over or where someone could get hurt attempting to retrieve them.attempting to retrieve them.

When materials are moved to where you are When materials are moved to where you are working, they should be secured so they can’t working, they should be secured so they can’t fall on anyone.fall on anyone.

Never block a traffic path or prop materials Never block a traffic path or prop materials up against a wall where they might slide over up against a wall where they might slide over and cause an accident.and cause an accident.


Corrosive and Flammable Corrosive and Flammable LiquidsLiquids Understand what it is that you are about Understand what it is that you are about

to move.to move. Examine the containers to make sure Examine the containers to make sure

they are sealed and properly labeled.they are sealed and properly labeled. Make sure you are wearing all required Make sure you are wearing all required

PPE.PPE.


Safety GuardsSafety Guards


Safety GuardsSafety Guards

Are required to prevent accidents.Are required to prevent accidents. Protect people, not the machine.Protect people, not the machine. Hazardous parts include point of Hazardous parts include point of

operation components, control operation components, control mechanisms, parts that transmit power, mechanisms, parts that transmit power, and parts that retain stored energyand parts that retain stored energy


Moving Parts Moving Parts Make Make Guards Guards NecessaryNecessary


Moving Parts Moving Parts Make Guards Make Guards NecessaryNecessary


Point of Operation GuardPoint of Operation Guard

OSHA 29 CFR 1910.217OSHA 29 CFR 1910.217


Fixed GuardsFixed Guards


Fixed GuardsFixed Guards

Prevent entry into the Prevent entry into the point of operationpoint of operation Do not move when the machine is in Do not move when the machine is in

operation.operation. Example: Barrier GuardExample: Barrier Guard Example: Enclosure GuardExample: Enclosure Guard


Interlocking GuardsInterlocking Guards

Used when a fixed guard cannot be Used when a fixed guard cannot be used.used.

Connected to machine controls or power Connected to machine controls or power source.source.

Can be mechanical, electrical, or Can be mechanical, electrical, or pneumatic.pneumatic.


Automatic GuardsAutomatic Guards Push, pull, or sweep the operator’s Push, pull, or sweep the operator’s

hands out of the danger zone.hands out of the danger zone. Example: Automatic Pull BacksExample: Automatic Pull Backs


Presence-sensing GuardsPresence-sensing Guards

No physical barrier.Create a sensing No physical barrier.Create a sensing area around the danger zone.area around the danger zone.

May use magnetic fields, radio waves, or May use magnetic fields, radio waves, or light waves.light waves.

Machinery must be able to stop Machinery must be able to stop instantaneouslyinstantaneously.


Power Transmission GuardsPower Transmission Guards Prevent pieces from flying out.Prevent pieces from flying out. Should be kept in place at all times while the Should be kept in place at all times while the

machine is running.machine is running. Should only be removed for repair work.Should only be removed for repair work.


Other Safety DevicesOther Safety Devices

Machine controls.Feeding and extracting tools.Ejectors.


OSHA Lock Out/Tag Out OSHA Lock Out/Tag Out Procedures Procedures 29 CFR 1910.14729 CFR 1910.147 Locking out has to do with the removal or Locking out has to do with the removal or

prevention of hazardous energy.prevention of hazardous energy. Tag out is a communication technique that Tag out is a communication technique that

warns others of the machines repair work.warns others of the machines repair work.

109

Control of Hazardous EnergyControl of Hazardous Energy

29 CFR 1910.147 The standard covers the servicing and

maintenance of machines and equipment in which the unexpected energization or start up of the machines or equipment , or release of stored energy could cause injury to employees.

110

Provisions Of The StandardProvisions Of The Standard

Requires employers to establish procedures for isolating machines or equipment from their source of energy and affixing appropriate locks or tags to energy isolating devices

111

Employer ResponsibilitiesEmployer Responsibilities

Establish energy control programEstablish energy control procedures for

machines and equipmentProvide employee trainingConduct periodic inspections of the energy

control program

112

Application Of The StandardApplication Of The Standard

An employee is required to remove or bypass a guard or other safety device

An employee is required to place any part of their body in contact with the point of operation of the operational machine or piece of equipment

An employee is required to place any part of their body into a danger zone associated with a machine operating cycle

113

Work on cord and plug connected electric equipment controlled by unplugging of the equipment - the plug is under exclusive control of the employee performing maintenance

Exceptions To The StandardExceptions To The Standard

114

Hot tap operations involving transmission and distribution systems for substances such as gas, steam, water, or petroleum products

Exceptions To The StandardExceptions To The Standard

115

Minor Servicing TasksMinor Servicing Tasks

Employees performing minor tool changes and adjustments that are routine, repetitive, and integral to the use of the equipment and that occur during normal operations are not covered by the lockout/tagout standard, provided the work is performed using alternative measures that provide effective protection.

116

DefinitionsDefinitions

Authorized employee: A person who locks out or tags out machines or equipment in order to perform servicing or maintenance

Affected employee: A person whose job requires him to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout

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Energy isolating device: The mechanism that prevents the transmission or release of energy and to which locks or tags are attached

Includes manually operated circuit breakers, disconnect switches, line valves, blocks, and others

118

Lockout: The placement of a lockout device on an energy isolating device to ensure that the equipment being controlled cannot be operated until the lockout device is removed


119

Tagout: The placement of a tagout device on an energy isolating device to indicate the equipment being controlled may not be operated until the tagout device is removed


120

Shut down the machine or equipment Isolate the machine or equipment from the

energy sources Apply the lockout or tagout device(s) to the

energy isolating device(s) Safely release all potentially hazardous

stored or residual energy Verify the isolation of the machine or

equipment prior to the start of servicing work

De-energizing EquipmentDe-energizing Equipment

121

Stored EnergyStored Energy

If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation shall be continued until the possibility of such accumulation no longer exists

122

Re-energizing EquipmentRe-energizing Equipment

Ensure that machine or equipment components are operationally intact

Ensure that all employees are safely positioned or removed from equipment

Ensure that lockout or tagout devices are removed from each energy isolation device by the employee who applied the device

123

Lockout/Tagout RequirementsLockout/Tagout Requirements

If an energy isolating device is not capable of being locked out, the employer’s energy control program shall utilize a tagout system

124

Lockout RequirementsLockout Requirements

After January 1990, whenever replacement, major repair, or modification of a machine is performed, or whenever new machines or equipment are installed, they must be designed to accept a lockout device

125

Device RequirementsDevice Requirements

Durable: Lockout and tagout devices must withstand the environment to which they are exposed for the maximum duration

Standardized: Both lockout and tagout devices must be standardized according to either color, shape, or size

Tagout devices must also be standardized according to print and format

126

Substantial: Lockout and tagout devices must be substantial enough to minimize early or accidental removal

Identifiable: Locks and tags must clearly identify the employee who applies them.

Device RequirementsDevice Requirements

127

Tags must also include a legend such as:– Do not start– Do not open– Do not close– Do not energize– Do not operate

Tag RequirementsTag Requirements

128

Periodic InspectionsPeriodic Inspections

The employer shall conduct a periodic inspection of the energy control procedure at least annually

Shall be performed by an authorized employee other than the person(s) utilizing the energy control procedure being inspected

129

Shall be conducted to correct any deviations or inadequacies identified

Where lockout is used, the inspection shall include a review between the inspector and each authorized employee


130

Where tagout is used, the inspection shall include a review between the inspector and each authorized and affected employees


131

The employer shall:– Certify that the periodic inspections have been

performed– Identify the machine or equipment on which

energy control procedures were used The employer shall also note:

– The date of the inspection– The employees included in the inspection– The person performing the inspection


132

Training and CommunicationTraining and Communication

Each authorized employee shall receive training in:– Recognition of applicable hazardous

energy sources– Type and magnitude of the energy

available in the workplace– Methods and means necessary for energy

isolation and control

133

Each affected employee shall be instructed in the purpose and use of the energy control procedure

All other employees shall be instructed about the prohibition relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out


134

The employer shall certify that employee training has been accomplished and is being kept up to date

Certification shall contain employee names and dates of training


135

Group Lockout or TagoutGroup Lockout or Tagout

Primary responsibility is vested in an authorized employee for a set number of employees working under the protection of a group lockout or tagout device

Each authorized employee shall affix a personal lockout or tagout device to the group lockout device

136

Outside PersonnelOutside Personnel

Whenever outside servicing personnel are engaged in activities covered by lockout/tagout, the on-site employer and the outside employer shall inform each other of their respective lockout or tagout procedures

137

Tagout TagsTagout Tags

138

Lockout DeviceLockout Device

139

Group LockoutGroup Lockout

140

Tagout TagTagout Tag

141

Lockout SignageLockout Signage


ReviewReview 1. What is the best way to avoid hurting yourself when moving material? 2. What is most dangerous when wearing gloves around rotating equipment? 3. Describe the best method for lifting. 4. What is the best way to carry a small box or carton? 5. What equipment can you use to move a barrel alone? 6. Describe how to handle moving a loaded hand truck down a ramp. 7. When is it permissible to ride on the platform of a moving truck? 8. What must be checked before entering a trailer on a shipping dock? 9. What is the best way to prevent accidents while working on conveyors? 10. What does the angle of a lifting sling have to do with the stress placed on it? 11. What is a pinch point? 12. What is meant by the term “point of operation”? 13. What word is used to mean a back and forth motion? 14. What is the correct spacing for a grinder wheel from the work rest? 15. What type of machine guard limits the operator’s access to the danger zone? 16. Which type of machine guard prevents access to the danger zone altogether? 17. What type of guard cannot be moved while the machine is running? 18. What type of guard, when removed, prevents the machine from running? 19. What type of guard physically pulls the operator out of the danger zone? 20. How fast should a machine stop when it is equipped with a presence sensing

guard?

Documents

Lecture 4-Material and Machine Safety