MATERIALS HANDLING AND STORAGE

1. MATERIALS HANDLING AND STORAGE Handling Material (General) Servicing Multi-Piece and Single-Piece Rim Wheels Powered Industrial Trucks Overhead and Gantry Cranes Crawler, Locomotive, and Truck Cranes Derricks Helicopters.

2. Introduction • Most injuries in industry occur while employees move materials. In every day operations, workers handle, transport, and store materials. • They may do so by hand, manually operated equipment, or power operated equipment. • This module specifies the materials handling and storage procedures developed by the Occupational Safety and Health Administration (OSHA) to reduce injuries resulting from mishandling or improper storage. © 2003 Seton Identification Products

3. Objectives • At the end of this Materials Handling and Storage module, you should be able to: • Identify general requirements for handling materials • Identify servicing requirements for single-piece and multi-piece rim wheels • Identify operation and safety requirements for powered industrial trucks • Identify inspection, design, and operation requirements for overhead and gantry cranes • Identify inspection, design, and operation requirements for crawler, locomotive, and truck cranes • Identify design and operation requirements for derricks • Identify communication, load handling, and protective requirements for helicopters. © 2003 Seton Identification Products

4. Handling Materials (General) • The Handling Materials (General) section, based on 1910.176, describes basic requirements that apply to any situation where equipment must be stored. • Where mechanical handling equipment is used, sufficient safe clearance shall be allowed for aisles, at loading docks, through doorways, and whenever turns or passage must be made. • Permanent aisles and passageways shall be appropriately marked. © 2003 Seton Identification Products

5. General • Storage of material shall not create a hazard. • All stored materials stacked in tiers shall be stacked, blocked, interlocked, and limited in height so that they are secure against sliding or collapse. • Storage areas shall be kept free from accumulation of materials that constitute hazards from tripping, fire, explosion, or pest harborage. • Vegetation control will be exercised when necessary. © 2003 Seton Identification Products

6. Multi-Piece and Single-Piece Rim Wheels • This section is based on 29 CFR 1910.177. • The standard describes requirements for employees working with either multi-piece or single-piece rim wheel structures. • This section covers the topics listed to the left. • In 1984, OSHA amended the safety standard for the servicing of multi-piece rim wheels to include requirements for the safe servicing of single-piece rim wheels used on large trucks, trailers, buses, and off-road machines. © 2003 Seton Identification Products

7. Multi-Piece and Single-Piece Rim Wheels • Training for all tire servicing employees • Utilization of industry-accepted procedures that minimize the potential for employee injury • Use of proper equipment such as clip-on chucks, restraining devices or barriers to retain the wheel components in the event of an incident during the inflation of tires • Use of compatible components. © 2003 Seton Identification Products

8. Multi-Piece and Single-Piece Rim Wheels • A rim wheel is the component assembly of a wheel, tire, tube, and other components. There are two types of rim wheels: • Single-Piece Rim Wheels • Multi-Piece Rim Wheels. • A single-piece wheel is the component of the assembly used to hold the tire, form part of the air chamber (with tubeless tires), and provide the means of attachment of the assembly to the vehicle axle. • A multi-piece wheel is a vehicle wheel consisting of two or more parts, one of which is a side or locking ring that holds the tire and other components on the rim wheel by interlocking the components when the tire is inflated. • The standard does not apply to the servicing of rim wheels utilizing automobile tires or truck tires designated "light trucks (LT)." © 2003 Seton Identification Products

9. Hazards • Single-piece rim wheels react differently than multi-piece rim wheels in accidents involving a release of pressurized air. • In a multi-piece rim wheel accident, the wheel components separate and are released from the rim wheel with violent force. • The severity of the hazard is related not only to the air pressure but also to the air volume. • Single-piece rim wheel accidents occur when the pressurized air contained in the tire is released suddenly by a bead breaking or the bead slipping over the rim flange. © 2003 Seton Identification Products

10. Hazards • An employee in close proximity and within the rim wheel trajectory can be hurled across the room. • A release of pressurized air can also propel the rim wheel in any potential path that a rim wheel component may travel during an explosive separation, or the area into which the airblast may be released. • All employees working with rim wheels require training for these hazards. © 2003 Seton Identification Products

11. Employee Training • Employers must provide a training program for all employees who service rim wheels. This training must include the hazards involved and the safety procedures to be followed when servicing rim wheels. • The employer must regularly evaluate each employee's performance and provide additional training, as necessary, to assure that each employee maintains proficiency. • At a minimum, the training program must include the contents of the OSHA standard and the information in the manufacturer's rim manuals, or the OSHA charts. Charts are available from OSHA national, regional, or area offices. • Employers must ensure that employees do not service any rim wheels unless the worker has been trained in and can demonstrates: • Demounting tires, including deflation • Inspecting and identifying rim wheel components • Installing, handling, and removing rim wheels • Inflating tires when single-piece rim wheels are mounted on a vehicle • Mounting tires, including inflating them with a restraining device or other safeguard • Understanding the necessity of standing outside the trajectory during inflation of the tires and of inspecting the rim wheels following inflation. © 2003 Seton Identification Products

12. Servicing Equipment • Two types of devices that can be used to protect an employee when a wheel is being inflated are listed below. • Restraining • Barrier • For multi-piece rim wheels, the employer must furnish a restraining device for inflating a tire. • For single-piece rim wheels, a restraining device or barrier is required unless the single-piece rim wheel is bolted onto a vehicle during inflation. © 2003 Seton Identification Products

13. Servicing Equipment • Restraining devices with any of the following defects must be removed from service immediately: • Cracks at welds • Cracked or broken components • Bent or sprung components caused by mishandling, abuse, tire explosion, or rim wheel separation • Pitted component due to corrosion or other structural damage that would decrease its effectiveness. • Restraining devices or barriers removed from service must not be returned to service until they are repaired and re-inspected. © 2003 Seton Identification Products

14. Servicing Equipment • Restraining devices or barriers requiring structural repair must not be returned to service until they are certified to meet strength requirements (force of 150 percent of the maximum tire specification pressure) by either the manufacturer or a registered professional. © 2003 Seton Identification Products

15. Servicing Equipment • Once protective equipment is checked for defects, multi-piece rim wheel components and single-piece rim wheels must be inspected prior to assembly. • Any wheel or wheel component that is bent out of shape, pitted from corrosion, broken, or cracked must be marked or tagged "unserviceable" and removed from the service area. • Damaged or leaky valves must be replaced. • Rim flanges, rim gutters, rings, and the bead-seating areas of wheels must be free of any dirt, surface rust, scale, or loose or flaked rubber buildup prior to tire mounting and inflation.. © 2003 Seton Identification Products

16. Servicing Equipment • The size and type of the tire and wheel must be checked for compatibility prior to assembly. • Mismatching of half sizes such as 16-inch and 16.5 inch tires and wheel must be avoided. • Multi-piece wheel components must not be interchanged except as indicated in the applicable charts or rim manuals. © 2003 Seton Identification Products

17. Servicing Equipment • In addition to specifying inspection and protective equipment procedures, 1910.177 also regulates reference material and special equipment that may be used when servicing wheels. • Current charts or rim manuals containing instructions for the types of wheels being serviced must be available in the service area, including a mobile service unit. • Only tools recommended in the rim manual may be used for the type of wheel being serviced. • The employer must supply air line equipment with a clip-on chuck with sufficient length of hose between the chuck and in-line valve or regulator to allow the employee to stand outside the trajectory. • The employer must also supply an in-line valve with a pressure gauge or a presettable regulator © 2003 Seton Identification Products

18. Multi-Piece Rim Wheel Safe Operating Procedures • Employers must instruct employees on safe operating procedures for multi-piece rim wheels including those listed here and on the next page: • The tire must be completely deflated by removing the valve core before a rim wheel is removed from the axle in the following situations: • When the tire has been driven underinflated at 80 percent or less of its recommended pressure • When there is obvious or suspected damage to the tire or wheel components. • The tire must be completely deflated by removing the valve core before demounting • A rubber lubricant must be applied to the bead and rim mating surfaces when assembling the wheel and inflating the tire unless the tire or wheel manufacturer recommends against its use © 2003 Seton Identification Products

19. Multi-Piece Rim Wheel Safe Operating Procedures • If a tire on a vehicle is under inflated but has more than 80 percent of the recommended pressure, the tire may be inflated while the rim wheel is on the vehicle, provided remote control inflation equipment is used, and no employee remains in the trajectory during inflation • The tire shall be inflated outside a restraining device only to a pressure sufficient to force the tire bead onto the rim ledge and create an airtight seal with the tire and bead. • Whenever a rim wheel is in a restraining device, the employee must not rest or lean any part of his/her body, or equipment, on or against the restraining device. © 2003 Seton Identification Products

20. Multi-Piece Rim Wheel Safe Operating Procedures • More safe operating procedures for multi-piece rim wheels are listed below: • After tire inflation, the tire and wheel must be inspected while still within the restraining device to make sure that they are properly seated and locked. • If further adjustment is necessary, the tire must be deflated by removing the valve core before the adjustment is made • An attempt must not be made to correct the seating of side and lock rings by hammering, striking, or forcing the components while the tire is pressurized © 2003 Seton Identification Products

21. Multi-Piece Rim Wheel Safe Operating Procedures • Cracked, broken, bent, or otherwise damaged wheel components must not be reworked, welded, brazed, or otherwise heated. • Heat must not be applied to a multi- piece wheel • Whenever multi-piece rim wheels are being handled, employees must stay out of the trajectory unless the employer can show that performance of the servicing makes the employee's presence in the trajectory necessary. © 2003 Seton Identification Products

22. Single-Piece Rim Wheel Safe Operating Procedures • Employees must be instructed in and follow the single-piece rim wheels’ safe operating procedures listed below and on the following page: • Mounting and demounting of the tire must be performed only from the narrow ledge side of the wheel. • Care must be taken to avoid damaging the tire beads. The tire also must be mounted only on a compatible wheel of mating bead diameter and width © 2003 Seton Identification Products

23. Single-Piece Rim Wheel Safe Operating Procedures • A nonflammable rubber lubricant must be applied to the bead and wheel mating surfaces before assembling the rim wheel, unless the tire or wheel manufacturer recommends against the use of any rubber lubricant • If a tire changing machine is used, the tire may be inflated only to the minimum pressure necessary to force the tire bead onto the rim ledge and create an airtight seal before removal from the tire changing machine • If a bead expander is used, it must be removed before the valve core is installed and as soon as the rim wheel becomes airtight (when the tire bead slips onto the bead seat). © 2003 Seton Identification Products

24. Single-Piece Rim Wheel Safe Operating Procedures • More safe operating procedures for single-piece rim wheels are listed below: • The tire must be completely deflated by removal of the valve core before demounting • The tire may be inflated only when contained within a restraining device, positioned behind a barrier, or bolted with the lug nuts fully tightened • The tire must not be inflated when any flat, solid surface is in the trajectory and within 1 foot of the sidewall © 2003 Seton Identification Products

25. Single-Piece Rim Wheel Safe Operating Procedures • The tire must not be inflated to more than the inflation pressure stamped in the sidewall unless a higher pressure is recommended by the manufacturer • Employees must stay out of the trajectory when a tire is being inflated • Heat must not be applied to a single-piece wheel • Cracked, broken, bent, or otherwise damaged wheels must not be reworked, welded, brazed, or otherwise © 2003 Seton Identification Products

26. Quiz Question: • The hazard associated with a release of pressure in a multi-piece rim wheel is that the wheel components could separate and fly across the room at high speeds. • True • False © 2003 Seton Identification Products

27. Quiz Question: • Damaged restraining devices and barriers must be permanently removed from service. • True • False © 2003 Seton Identification Products

28. Quiz Question: • Which of the following is NOT a proper safe operating procedure for multi-piece rim wheels? • Heat may only be applied to multi-piece wheels during repairs • Whenever a rim wheel is in a restraining device, the employee must not rest or lean against the restraining device • Employees must stay out of the wheel trajectory when it is being handled unless the employer shows that servicing requires it • The tire must be completely deflated by removing the valve core before demounting © 2003 Seton Identification Products

29. Introduction • The Powered Industrial Trucks section, based on 1910.178, contains safety requirements relating to fire protection; design; maintenance; and use of fork trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines. • This section does not apply to compressed air or nonflammable compressed gas-operated industrial trucks, nor to farm vehicles, nor to vehicles intended primarily for earth moving or over-the-road hauling. • In this section, the term "approved truck" or "approved industrial truck" means a truck that is fire safety listed or approved by a nationally recognized testing laboratory, using nationally recognized testing standards. • The topics covered are listed to the left. © 2003 Seton Identification Products

30. General Requirements • No employee, including supervisory personnel, is permitted to operate a powered industrial truck unless properly trained and authorized. Methods shall be devised by management to train operators in the safe operation of powered industrial trucks. • Approved powered industrial trucks shall bear a label or some other identifying mark indicating approval by the testing laboratory. • Trucks are assigned to one of 11 different designations defined by the truck’s protection and power supply. © 2003 Seton Identification Products

31. General Requirements • Atmospheres or locations throughout the plant must be classified hazardous or non-hazardous prior to considering the use of industrial trucks therein. • Refer to summary table N-1 of 1910.178(c)(2) on the use of industrial trucks in various locations. • Modifications and additions which affect capacity and safe operation of trucks shall not be performed by the user without the manufacturers' prior written approval, except as noted for overhead safety guards. © 2003 Seton Identification Products

32. Safety Guards • All high lift rider trucks shall be fitted with overhead safety guards where overhead lifting is performed. • Safety guard may be removed or a powered industrial truck without a guard may be used if operations or the environment do not permit space for the overhead guarding. • If a powered industrial fork truck carries a load that presents a hazard of falling back onto the operator, it shall be equipped with a vertical load back rest extension. © 2003 Seton Identification Products

33. Loading and Unloading • In plant receiving and shipping areas, powered industrial trucks are often used to load and unload materials from trucks and railroad cars. The loading procedures identified below should be followed. • The brakes of highway trucks shall be set and wheel chocks placed under the rear wheels to prevent trucks from rolling while they are boarded with powered industrial trucks. Fixed jacks may be necessary to support a semitrailer and prevent upending during the loading or unloading when the trailer is not coupled to a tractor. • Wheel stops or other positive protection shall also be provided to prevent railroad cars from moving during loading or unloading operations. • Only stable and safely arranged loads within the capacity of the truck shall be handled. Caution shall be exercised when handling off-center loads which cannot be centered. © 2003 Seton Identification Products

34. Truck Operation • Proper operating procedures ensure worker and equipment safety. • Some of the requirements regarding industrial truck operations are listed below: • No person shall be allowed to stand or pass under the elevated portion of any truck, whether loaded or empty • Unattended powered industrial trucks shall have load engaging means fully lowered, controls neutralized, power shut off, and brakes set. • Wheels shall be blocked if the truck is parked on an incline. • A powered industrial truck is "unattended" when the operator is 25 feet or more away from the vehicle which remains in his view, or whenever the operator leaves the vehicle and it is not in his view • Fuel tanks shall not be filled while the engine is running. © 2003 Seton Identification Products

35. Truck Operation • Spillage shall be avoided. Any spillage of oil or fuel shall be carefully washed away or completely evaporated and the fuel tank cap replaced before restarting the engine • Open flames shall not be used for checking electrolyte levels in storage batteries or gasoline levels in fuel tanks • Unauthorized personnel are not permitted to ride on powered industrial trucks. A safe place to ride shall be provided when riding of trucks is authorized • Powered industrial trucks found to be in need of repair, defective, or in any way unsafe shall be removed from service until restored to safe operating condition. © 2003 Seton Identification Products

36. Traveling • Industrial truck traveling requirements, like operating requirements, are designed to ensure worker and equipment safety. • Traveling requirements are listed below: • All traffic regulations shall be observed, including authorized plant speed limits • The driver is required to slow down and sound the horn at cross aisles and other locations where vision is obstructed. If the load carried obstructs the forward view, the driver shall be required to travel with the load trailing • Railroad tracks shall be crossed diagonally whenever possible. Parking closer than 8 feet from the center of railroad tracks is prohibited © 2003 Seton Identification Products

37. Traveling • When ascending or descending grades in excess of 10 percent, loaded trucks shall be driven with the load upgrade • Dockboards or bridgeplates shall be properly secured, as shown to the left, and driving over slowly and carefully. • Their rated capacity should never be exceeded. © 2003 Seton Identification Products

38. Maintenance • Any power-operated industrial truck not in safe operating condition shall be removed from service. • All repairs shall be made by authorized personnel. • No repairs shall be made in Class I, Class II, or Class III locations. Those repairs to the fuel and ignition systems which involve fire hazards shall be conducted only in locations designated for such repairs. • Industrial trucks shall be inspected before being placed in service, and shall not be placed in service if the inspection shows any condition adversely affecting the safety of the vehicle. • Subsequent inspections shall be made at least daily. Where trucks are used on a round-the-clock basis, they shall be inspected after each shift. © 2003 Seton Identification Products

39. Changing and Charging Storage Batteries • Workplaces using electrically powered industrial trucks will have battery charging areas somewhere in the plant. • Depending on the number of electrically powered industrial trucks in a workplace, there may be more than one changing and charging area. • This topic only applies to storage battery changing and charging areas associated with powered industrial trucks. It does not apply to areas where other batteries are charged, although some of the same hazardous conditions may exist. • Some of the requirements specified in 1910.178 are listed below: • Battery charging installations shall be located in areas designated for that purpose • Facilities shall be provided for flushing and neutralizing spilled electrolyte, fire protection, protecting charging apparatus from damage by trucks, and adequate ventilation for dispersal of air contaminants from gassing batteries • A conveyor, overhead hoist, or equivalent material handling equipment shall be provided for handling batteries • Smoking shall be prohibited in the charging area • Precautions shall be taken to prevent open flames, sparks, or electric arcs in battery charging areas © 2003 Seton Identification Products

40. Quiz Question: • An "approved truck" is a truck that has been fire safety approved by a nationally recognized testing laboratory. • True • False © 2003 Seton Identification Products

41. Quiz Question: • Industrial truck operation procedures require that: • Unauthorized personnel are not allowed to ride on trucks • Unattended trucks must have wheels blocked if the power is left on • A truck is defined as unattended when an operator leaves the controls • Only authorized persons may stand under elevated truck parts during loading © 2003 Seton Identification Products

42. Quiz Question: • Approved power industrial trucks must bear a label showing: • Lifting capacity • Indication of approval by the testing laboratory • Electrical and mechanical ratings • The manufacturer © 2003 Seton Identification Products

43. Quiz Question: • Standard 1910.178 requires that battery charging areas must: • Only be accessed by qualified employees • Provide a conveyor, overhead hoist, or equivalent material handling equipment to handle batteries • Provide flushing and neutralizing facilities for spilled electrolytes • Not allow smoking • Be part of maintenance areas © 2003 Seton Identification Products

44. Overhead & Gantry Cranes • Certain modifications, inspections, testing, and maintenance are required on cranes to protect workers and equipment. • The Overhead and Gantry Cranes section, based on 1910.179, describes these procedures. • The section applies to overhead and gantry cranes, including semi-gantry, cantilever gantry, wall cranes, storage bridge cranes, and others having the same fundamental characteristics.The topics covered in this section are listed below. © 2003 Seton Identification Products

45. General Requirements • Overhead and/or gantry cranes may not be modified and re-rated unless the modifications and the supporting structure are checked thoroughly for the new rated load by a qualified engineer or the equipment manufacturer. • The rated loads of the crane shall be plainly marked on each side of the crane. • If the crane has more than one hoisting unit, each hoist shall have its rated load marked on it or on its load block. © 2003 Seton Identification Products

46. General Requirements • The potential for overloading the crane increases if the hook-up person and/or the operator does not know the rated capacity. • Only employees selected by the employer or the employer's representative as being qualified to operate a crane shall be permitted to operate the crane. • A preventive maintenance program based on the crane manufacturer's recommendations shall be established. © 2003 Seton Identification Products

47. Cabs • A cab-operated crane is an overhead or gantry crane controlled by an operator in a cab located on the bridge or trolley. • The general arrangement of the cab and the location of control and protective equipment shall be such that all operating handles are within convenient reach of the operator when facing the area to be served by the load hook, or while facing the direction of travel of the cab. • The arrangement shall allow a full view of the load hook in all positions. The access to all cab-operated cranes shall be checked thoroughly. © 2003 Seton Identification Products

48. Cabs • Serious injuries have occurred as a result of the following conditions: • Conveniently placed fixed ladders, stairs, or platforms provided to reach the cab or bridge footwalk were not in place. • It is unacceptable and poses a significant hazard to allow employees to board a crane via climbing over guardrails, over, under, and around building structures, energized hot rails, portable ladders, or movable platforms • A gap exceeding 12 inches existed between a fixed ladder, stairs or platform, and access to the cab or bridge footwalk • The fixed ladder used as access to the crane did not meet the American National Standard Safety Code for Fixed Ladders, ANSI A14.3-1956. © 2003 Seton Identification Products

49. Footwalks and Ladders • Where sufficient headroom is available on cab-operated cranes, a footwalk shall be provided on the drive side along the entire length of the bridge of all cranes having the trolley running on the top of the girders. • Bridge footwalks shall be constructed rigidly and designed to sustain a distributed load of at least 50 pounds per square foot. • A standard railing and toeboards must be provided on all open sides of the bridge footwalk. • The standard railing provisions apply to all sides of the bridge footwalk including the inside edge next to the bridge girders if a fall potential exists. © 2003 Seton Identification Products

50. Footwalks and Ladders • Only certain structures may be used for boarding a crane. • All gantry cranes shall be provided with a ladder or a stairway that extends from the ground to the footwalk or the cab platform. • Any ladder or stairway to the crane shall be permanently and securely fastened in place and also shall be in compliance with standard 1910.27. • It is not permitted to board a gantry crane via portable ladders, crane structure, or any other method. • Footwalk Hazards © 2003 Seton Identification Products