What are the most common safety hazards in material handling operations?

1 Manual handling injuries

Manual handling is one of the most frequent causes of injuries in material handling operations. It involves using human force to lift, carry, push, pull, or move objects, which can result in musculoskeletal disorders, such as sprains, strains, back pain, and hernias. To prevent manual handling injuries, you should assess the weight, size, shape, and condition of the objects before lifting or moving them. Utilize mechanical aids like forklifts, carts, or hoists whenever possible and appropriate. Additionally, proper lifting techniques must be applied such as keeping the load close to your body and bending your knees. Wear suitable personal protective equipment like gloves, boots, and helmets for extra safety. Lastly, take regular breaks and avoid repetitive or prolonged tasks.

2 Forklift accidents

Forklifts are vehicles used to transport, stack, or load materials and products, and can cause serious injuries or fatalities if not operated or maintained properly. Common causes of forklift accidents include lack of training or certification for operators, excessive speed or reckless driving, overloading or unbalanced loads, poor visibility or lighting, mechanical failures or defects, collisions with objects, people, or other vehicles, and tipping over or falling from heights. To prevent forklift accidents, operators should be trained and certified according to the relevant standards and regulations. Forklifts should also be inspected and serviced regularly and reported if any problems or malfunctions occur. Additionally, operators should drive at a safe speed and follow the traffic rules and signs. Load capacity and stability of the forklift and materials should be checked before lifting or moving them. Horns, lights, mirrors, and signals should be used to communicate with other workers and pedestrians. Lastly, seat belts and other protective equipment should be worn at all times and driving on uneven or slippery surfaces near edges or openings should be avoided.

3 Fire and explosion hazards

Fire and explosion are a third type of safety hazard in material handling operations, which can cause severe burns, injuries, or deaths to workers and damage to equipment and facilities. Improper storage or handling of flammable or combustible materials, ignition sources such as sparks, flames, or static electricity, lack of ventilation or fire suppression systems, spills or leaks of flammable or combustible liquids or gases, and accumulation or dispersion of flammable or combustible dusts are some of the common causes of fire and explosion hazards. To prevent these hazards, you should store and handle flammable or combustible materials according to safety data sheets and labels. You should also eliminate or control ignition sources by using non-sparking tools and equipment. Additionally, you should install and maintain adequate ventilation and fire suppression systems; clean up any spills or leaks of flammable or combustible liquids or gases promptly and safely; and implement dust control and collection systems while avoiding creating dust clouds or layers.

4 Electrical hazards

To prevent electrical hazards, one must take certain precautions. Damaged or worn-out wires, cords, plugs, or outlets should be inspected and repaired. Electrical equipment should be used and maintained according to the manufacturer's instructions and safety standards. Contact with overhead or underground power lines should be avoided and their locations should be marked. Electrical equipment and materials should be grounded or bonded to prevent static electricity. Finally, electrical equipment and materials should be kept away from water or moisture, while rubber gloves and mats should be used. Such precautions can help to protect workers from shocks, burns, electrocution, or fire, as well as damage to equipment and facilities.

5 Ergonomic hazards

Ergonomic hazards, which can affect the health and wellbeing of workers, can occur due to the design, layout, or arrangement of the work environment, equipment, or tasks. Some of these hazards are awkward postures or movements, repetitive or forceful tasks, excessive vibration or noise from equipment or machinery, inadequate lighting, temperature, or humidity, and lack of adjustability, flexibility, or variety in the work. To prevent these hazards, you should design and organize the work environment to suit the workers' needs and abilities; provide proper tools and furniture that are ergonomic and comfortable; implement work rotation, rest breaks, and task variation; provide training on ergonomic principles; and monitor the workers' health and performance.

6 Here’s what else to consider

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