Materials Handling and Storage

Materials handling injuries — including strains, sprains, and crush injuries — are among the most common injuries in construction. Manual lifting is the most frequent cause of back injuries. Proper technique: stand close to the load, feet shoulder-width apart, bend at the knees (not the waist), keep the back in its natural curve, grip the load firmly, lift by straightening the legs, keep the load close to the body, and never twist the spine while carrying. As a general guideline, loads exceeding 50 lbs should require either a two-person team lift or mechanical assistance. When team lifting, designate one person to coordinate — announce movements before making them and keep the load at the same height for all participants.

Mechanical materials handling is essential for heavy and bulk materials. Forklifts require operators to be trained and certified per OSHA 29 CFR 1910.178 — the operator's certification and training are required even in construction settings. Forklifts should: never exceed rated capacity (displayed on the data plate), travel with forks lowered to 6-8 inches, reduce speed for turns and ramps, yield to pedestrians, and operate in pedestrian areas only with proper traffic control. Crane pick operations for materials require pre-lift meetings, load chart review, and establishment of exclusion zones (no workers under suspended loads).

Storage principles protect workers from struck-by and caught-in hazards. Materials must be stacked and stored to prevent sliding, falling, or collapse. Stacks must be stable — heavy items on lower shelves, lighter items on top, and maximum stack heights based on material stability. Lumber must be stacked on level surfaces with stickers (spacers) for air circulation and stability. Flammable materials must be segregated in approved storage areas with proper ventilation. Compressed gas cylinders must be stored upright, chained or strapped to prevent falling, with valve caps on when not in use, and oxygen cylinders must be separated from fuel gas cylinders by at least 20 feet or a 5-foot non-combustible barrier.