Dear Valued Customer,

In this issue of the “——————–“ we focus on pushing or pulling heavy objects.

Lifting heavy items is one of the leading causes of injury in the workplace. In fact, in a recent year, the Bureau of Labor Statistics reported that over 36 percent of injuries involving missed workdays were the result of shoulder and back injuries. Overexertion and cumulative trauma were the biggest factors in these injuries.

Read on to understand the potential hazards and possible solutions. Awkward postures to avoid when lifting. What to do if you are lifting a lot for long periods at a time, and more. Together we can help make lifting safer.

We appreciate your continued business and look forward to serving you.

Kind regards,

Lifting heavy items is one of the leading causes of injury in the workplace. In 2001, the Bureau of Labor Statistics reported that over 36 percent of injuries involving missed workdays were the result of shoulder and back injuries. Overexertion and cumulative trauma were the biggest factors in these injuries.

When employees use smart lifting practices and work in their “power zone,” they are less likely to suffer from back sprains, muscle pulls, wrist injuries, elbow injuries, spinal injuries, and other injuries caused by lifting heavy objects.

• Weight of Objects
• Awkward Postures
• High-Frequency and Long-Duration Lifting
• Inadequate Handholds
• Environmental Factors

Weight of Objects

Potential Hazards:

Some loads, such as large spools of wire (Figure 1), bundles of conduit, or heavy tools and machinery place great stress on muscles, discs, and vertebrae. Lifting loads heavier than about 50 pounds will increase the risk of injury. Possible Solutions: Use mechanical means such as forklifts (Figure 2) or duct lifts to lift heavy spools, transformers, switch gear, service sections, conduit, and machinery. Use pallet jacks and hand trucks to transport heavy items. Avoid rolling spools. Once they are in motion, it is difficult to stop them. Use suction devices (Figure 3) to lift junction boxes and other materials with smooth, flat surfaces. These tools place a temporary handle that makes lifting easier. Use ramps or lift gates to load machinery into trucks rather than lifting it. Materials that must be manually lifted should be placed at “power zone” height, about mid-thigh to mid-chest. Special care should be taken to ensure proper lifting principles are used. Maintain neutral and straight spine alignment whenever possible. Usually, bending at the knees, not the waist, helps maintain proper spine alignment. Place materials that are to be manually lifted at “power zone” height, about mid-thigh to mid-chest. Maintain neutral and straight spine alignment whenever possible. Usually, bending at the knees, not the waist, helps maintain proper spine alignment. Order supplies in smaller quantities and break down loads off-site. When possible, request that vendors and suppliers break down loads prior to delivery.

Figure 1. A spool holding 117 pounds of wire. Figure 2. Forklift. Figure 3. Suction tool. Figure 4. Two-man lift.

Prefabricate items in a central area where mechanical lifts can be used. Only transport smaller, finished products to the site. Limit weight you lift to no more than 50 pounds. When lifting loads heavier than 50 pounds, use two or more people to lift the load (Figure 4). Work with suppliers to make smaller, lighter containers.

Awkward Postures

Potential Hazards:

Bending while lifting (Figure 5) forces the back to support the weight of the upper body in addition to the weight you are lifting. Bending while lifting places strain on the back even when lifting something as light as a screwdriver. Bending moves the load away from the body and allows leverage to significantly increase the effective load on the back. This increases the stress on the lower spine and fatigues the muscles. Reaching moves the load away from the back, increases the effective load, and places considerable strain on the shoulders. Carrying loads on one shoulder, under an arm, or in one hand, creates uneven pressure on the spine. Poor housekeeping limits proper access to objects being lifted, and forces awkward postures.	Figure 5. Employee twisting in an awkward position.
Possible Solutions:
Move items close to your body and use your legs when lifting an item from a low location (Figure 6). Store and place materials that need to be manually lifted and transported at “power zone” height, about mid-thigh to mid-chest. Minimize bending and reaching by placing heavy objects on shelves, tables, or racks. For example, stack spools on pallets to raise them into the power zone. Avoid twisting, especially when bending forward while lifting. Turn by moving the feet rather than twisting the torso. Keep your elbows close to your body and keep the load as close to your body as possible. Keep the vertical distance of lifts between mid-thigh and shoulder height. Do not start a lift below mid-thigh height nor end the lift above shoulder height. Lifting from below waist height puts stress on legs, knees, and back. Lifting above shoulder height puts stress on the upper back, shoulders, and arms.	Figure 6. Different approaches to lifting. Figure 7. Aerial lift.
Use ladders or aerial lifts (Figure 7) to elevate employees and move them closer to the work area so overhead reaching is minimized. Break down loads into smaller units and carry one in each hand to equalize loads. Use buckets with handles, or similar devices, to carry loose items. Keep the load close to the body. When lifting large, bulky loads, it may be better to bend at the waist instead of at the knees in order to keep the load closer to your body. Optimize employee access to heavy items through good housekeeping and preplanning. Use roll-out decks installed in truck beds to bring materials closer to the employee and eliminate the need to crawl into the back of a truck. See the Vehicular Activities section for more information.

High-frequency and Long-duration Lifting

Potential Hazards:

Holding items for a long period of time, such as when installing fixtures or j-boxes (Figure 8), even if loads are light, increases risk of back and shoulder injury, since muscles can be starved of nutrients and waste products can build up. Repeatedly exerting, such as when pulling wire, can fatigue muscles by limiting recuperation times. Inadequate rest periods do not allow the body to rest.	Figure 8. Employee reaching overhead.
Possible Solutions:
Use a template made of a lightweight material (Figure 9) such as cardboard to mark holes for drilling when mounting heavy items such as junction boxes and service panels. This ensures that the heavier item does not need to be held in place to level and measure for anchor mounts. Provide stands, jigs, or mechanical lifting devices such as duct lifts to hold large, awkward materials such as junction boxes and service panels in place for fastening. Rotate tasks so employees are not exposed to the same activity for too long. Work in teams; one employee lifts and holds items while the other assembles. Take regular breaks and break tasks into shorter segments. This will give muscles adequate time to rest. Working through breaks increases the risk of musculoskeletal disorders (MSDs), accidents, and reduces the quality of work because employees are overfatigued.	Figure 9. Cardboard template for lighting fixtures. Figure 10. A prefabricated electrical box.
Plan work activities so employees can limit the time they spend holding loads. Pre-assemble work items such as fixtures or boxes (Figure 10) to minimize the time employees spend handling them.

Inadequate Handholds

 

Potential Hazards:

Inadequate handholds (Figure 11) make lifting more difficult, move the load away from the body, lower lift heights, and increase the risk of contact stress and of dropping the load.	Figure 11. Boxes without handles.
Possible Solutions:
Utilize proper handholds, including handles, slots, or holes (Figure 12), with enough room to accommodate gloved hands. Ask suppliers to place their materials in containers with proper handholds. Move materials from containers with poor handholds or without handholds into containers with good handholds. Wear proper personal protective equipment (PPE) to avoid finger injuries and contact stress. Ensure that gloves fit properly and provide adequate grip to reduce the chance of dropping the load. Use suction devices (Figure 13) to lift junction boxes and other materials with smooth, flat surfaces. These tools place a temporary handle that makes lifting easier.	Figure 12. Slots in boxes help in lifting.Figure 13. Suction device.

Environmental Factors

 

Potential Hazards:

Cold temperatures can cause decreased muscle flexibility, which can result in muscle pulls. Excessively hot temperatures can lead to dehydration, fatigue, and increased metabolic load. Low visibility or poor lighting (Figure 14) increases the chance of trips and falls.	Figure 14. Work space with window as only light source.
Possible Solutions:
Adjust work schedules to minimize exposure to extreme temperatures. Wear warm clothing when exposed to cold temperatures. Drink lots of water to avoid dehydration in excessive heat. Provide proper lighting (Figure 15) for areas with low light and perform work during daylight hours.	Figure 15. Light stand illuminating the work area.

Source: United States Department of Labor, “Materials Handling: Heavy Lifting” https://www.osha.gov website. Accessed December 2, 2015. https://www.osha.gov/SLTC/etools/electricalcontractors/materials/heavy.html#weight

© Copyright 2016. All rights reserved. This content is strictly for informational purposes and although experts have prepared it, the reader should not substitute this information for professional insurance advice. If you have any questions, please consult your insurance professional before acting on any information presented. Read more.

POTENTIAL HAZARDS

Handling and storing materials involves diverse operations such as hoisting tons of steel with a crane, driving a truck loaded with concrete blocks, manually carrying bags and material, and stacking drums, barrels, kegs, lumber, or loose bricks.

The efficient handling and storing of materials is vital to industry. These operations provide a continuous flow of raw materials, parts, and assemblies through the workplace, and ensure that materials are available when needed. Yet, the improper handling and storing of materials can cause costly injuries.

Workers frequently cite the weight and bulkiness of objects being lifted as major contributing factors to their injuries. In 1990, back injuries resulted in 400,000 workplace accidents. The second factor frequently cited by workers as contributing to their injuries was body movement. Bending, followed by twisting and turning, were the more commonly cited movements that caused back injuries. Back injuries accounted for more than 20 percent of all occupational illnesses, according to data from the National Safety Council (1).

In addition, workers can be injured by falling objects, improperly stacked materials, or by various types of equipment. When manually moving materials, however, workers should be aware of potential injuries, including the following:

• Strains and sprains from improperly lifting loads, or from carrying loads that are either too large or too heavy.
• Fractures and bruises caused by being struck by materials, or by being caught in pinch points; and
• Cuts and bruises caused by falling materials that have been improperly stored, or by incorrectly cutting ties or other securing devices.

Since numerous injuries can result from improperly handling and storing materials, it is important to be aware of accidents that may occur from unsafe or improperly handled equipment and improper work practices, and to recognize the methods for eliminating, or at least minimizing, the occurrence of those accidents. Consequently, employers and employees can and should examine their workplaces to detect any unsafe or unhealthful conditions, practices, or equipment and take the necessary steps to correct them.

METHODS OF PREVENTION

General safety principles can help reduce workplace accidents. These include work practices, ergonomic principles, and training and education. Whether moving materials manually or mechanically, employees should be aware of the potential hazards associated with the task at hand and know how to exercise control over their workplaces to minimize the danger.

MOVING, HANDLING, AND STORING MATERIALS

When manually moving materials, employees should seek help when a load is so bulky it cannot be properly grasped or lifted, when they cannot see around or over it, or when a load cannot be safely handled.

When an employee is placing blocks under raised loads, the employee should ensure that the load is not released until his or her hands are clearly removed from the load. Blocking materials and timbers should be large and strong enough to support the load safely. Materials with evidence of cracks, rounded corners, splintered pieces, or dry rot should not be used for blocking.

Handles and holders should be attached to loads to reduce the chances of getting fingers pinched or smashed. Workers also should use appropriate protective equipment. For loads with sharp or rough edges, wear gloves or other hand and forearm protection. To avoid injuries to the hands and eyes, use gloves and eye protection. When the loads are heavy or bulky, the mover should also wear steel-toed safety shoes or boots to prevent foot injuries if the worker slips or accidentally drops a load.

When mechanically moving materials, avoid overloading the equipment by letting the weight, size, and shape of the material being moved dictate the type of equipment used for transporting it. All materials handling equipment has rated capacities that determine the maximum weight the equipment can safely handle and the conditions under which it can handle those weights. The equipment-rated capacities must be displayed on each piece of equipment and must not be exceeded except for load testing. When picking up items with a powered industrial truck, the load must be centered on the forks and as close to the mast as possible to minimize the potential for the truck tipping or the load falling. A lift truck must never be overloaded because it would be hard to control and could easily tip over. Extra weight must not be placed on the rear of a counterbalanced forklift to offset an overload. The load must be at the lowest position for traveling, and the truck manufacturer’s operational requirements must be followed. All stacked loads must be correctly piled and cross-tiered, where possible. Precautions also should be taken when stacking and storing material.

Stored materials must not create a hazard. Storage areas must be kept free from accumulated materials that may cause tripping, fires, or explosions, or that may contribute to the harboring of rats and other pests. When stacking and piling materials, it is important to be aware of such factors as the materials’ height and weight, how accessible the stored materials are to the user, and the condition of the containers where the materials are being stored.

All bound material should be stacked, placed on racks, blocked, interlocked, or otherwise secured to prevent it from sliding, falling, or collapsing. A load greater than that approved by a building official may not be placed on any floor of a building or other structure. Where applicable, load limits approved by the building inspector should be conspicuously posted in all storage areas.

When stacking materials, height limitations should be observed. For example, lumber must be stacked no more than 16 feet high if it is handled manually; 20 feet is the maximum stacking height if a forklift is used. For quick reference, walls or posts may be painted with stripes to indicate maximum stacking heights.

Used lumber must have all nails removed before stacking. Lumber must be stacked and leveled on solidly supported bracing. The stacks must be stable and self-supporting. Stacks of loose bricks should not be more than 7 feet in height. When these stacks reach a height of 4 feet, they should be tapered back 2 inches for every foot of height above the 4-foot level. When masonry blocks are stacked higher than 6 feet, the stacks should be tapered back one-half block for each tier above the 6-foot level.

Bags and bundles must be stacked in interlocking rows to remain secure. Bagged material must be stacked by stepping back the layers and cross-keying the bags at least every ten layers. To remove bags from the stack, start from the top row first. Baled paper and rags stored inside a building must not be closer than 18 inches to the walls, partitions, or sprinkler heads. Boxed materials must be banded or held in place using cross-ties or shrink plastic fiber.

Drums, barrels, and kegs must be stacked symmetrically. If stored on their sides, the bottom tiers must be blocked to keep them from rolling. When stacked on end, put planks, sheets of plywood dunnage, or pallets between each tier to make a firm, flat, stacking surface. When stacking materials two or more tiers high, the bottom tier must be chocked on each side to prevent shifting in either direction.

When stacking, consider the need for availability of the material. Material that cannot be stacked due to size, shape, or fragility can be safety stored on shelves or in bins. Structural steel, bar stock, poles, and other cylindrical materials, unless in racks, must be stacked and blocked to prevent spreading or tilting. Pipes and bars should not be stored in racks that face main aisles; this could create a hazard to passers-by when supplies are being removed.

USING MATERIALS HANDLING EQUIPMENT

To reduce potential accidents associated with workplace equipment, employees need to be trained in the proper use and limitations of the equipment they operate. This includes knowing how to effectively use equipment such as conveyors, cranes, and slings.

Conveyors

When using conveyors, workers’ hands may be caught in nip points where the conveyor runs over support members or rollers; workers may be struck by material falling off the conveyor; or they may become caught on or in the conveyor, thereby being drawn into the conveyor path.

To reduce the severity of an injury, an emergency button or pull cord designed to stop the conveyor must be installed at the employee’s work station. Continuously accessible conveyor belts should have an emergency stop cable that extends the entire length of the conveyor belt so that the cable can be accessed from any location along the belt. The emergency stop switch must be designed to be reset before the conveyor can be restarted. Before restarting a conveyor that has stopped due to an overload, appropriate personnel must inspect the conveyor and clear the stoppage before restarting. Employees must never ride on a materials handling conveyor. Where a conveyor passes over work areas or aisles, guards must be provided to keep employees from being struck by falling material. If the crossover is low enough for workers to run into, it must be guarded to protect employees and either marked with a warning sign or painted a bright color.

Screw conveyors must be completely covered except at loading and discharging points. At those points, guards must protect employees against contacting the moving screw; the guards are movable, and they must be interlocked to prevent conveyor movement when not in place.

Cranes

Only thoroughly trained and competent persons are permitted to operate cranes. Operators should know what they are lifting and what it weighs. The rated capacity of mobile cranes varies with the length of the boom and the boom radius. When a crane has a telescoping boom, a load may be safe to lift at a short boom length and/or a short boom radius, but may overload the crane when the boom is extended and the radius increases.

All movable cranes must be equipped with a boom angle indicator; those cranes with telescoping booms must be equipped with some means to determine the boom length, unless the load rating is independent of the boom length. Load rating charts must be posted in the cab of cab-operated cranes. All mobile cranes do not have uniform capacities for the same boom length and radius in all directions around the chassis of the vehicle.

Always check the crane’s load chart to ensure that the crane is not going to be overloaded for the conditions under which it will operate. Plan lifts before starting them to ensure that they are safe. Take additional precautions and exercise extra care when operating around power lines.

Some mobile cranes cannot operate with outriggers in the traveling position. When used, the outriggers must rest on firm ground, on timbers, or be sufficiently cribbed to spread the weight of the crane and the load over a large enough area. This will prevent the crane from tipping during use. Hoisting chains and ropes must always be free of kinks or twists and must never be wrapped around a load. Loads should be attached to the load hook by slings, fixtures, or other devices that have the capacity to support the load on the hook. Sharp edges of loads should be padded to prevent cutting slings. Proper sling angles shall be maintained so that slings are not loaded in excess of their capacity.

All cranes must be inspected frequently by persons thoroughly familiar with the crane, the methods of inspecting the crane, and what can make the crane unserviceable. Crane activity, the severity of use, and environmental conditions should determine inspection schedules. Critical parts, such as crane operating mechanisms, hooks, air or hydraulic system components and other load-carrying components, should be inspected daily for any maladjustment, deterioration, leakage, deformation, or other damage.

Slings

When working with slings, employers must ensure that they are visually inspected before use and during operation, especially if used under heavy stress. Riggers or other knowledgeable employees should conduct or assist in the inspection because they are aware of how the sling is used and what makes a sling unserviceable. A damaged or defective sling must be removed from service.

Slings must not be shortened with knots or bolts or other makeshift devices, sling legs that have been kinked must not be used. Slings must not be loaded beyond their rated capacity, according to the manufacturer’s instructions. Suspended loads must be kept clear of all obstructions, and crane operators should avoid sudden starts and stops when moving suspended loads. Employees also must remain clear of loads about to be lifted and suspended. All shock loading is prohibited.

Powered Industrial Trucks

The OSHA standard for Powered Industrial Truck Operator Training was revised March 1, 1999. Training information which follows relates to the previous standard, and while it still has practical applications, the reader should refer to the current standard for compliance.

See Powered Industrial Trucks (Forklifts) Safety and Health Topics Page.

Workers who must handle and store materials often use fork trucks, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electrical motors or internal combustion engines. Affected workers, therefore, should be aware of the safety requirements pertaining to fire protection, and the design, maintenance, and use of these trucks.

All new powered industrial trucks, except vehicles intended primarily for earth moving or over-the-road hauling, shall meet the design and construction requirements for powered industrial trucks established in the American National Standard for Powered Industrial Trucks, Part ll, ANSI B56.1-1969. Approved trucks shall also bear a label or some other identifying mark indicating acceptance by a nationally recognized testing laboratory.

Modifications and additions that affect capacity and safe operation of the trucks shall not be performed by an owner or user without the manufacturer’s prior written approval. In these cases, capacity, operation, and maintenance instruction plates and tags or decals must be changed to reflect the new information. If the truck is equipped with front-end attachments that are not factory installed, the user should request that the truck be marked to identify these attachments and show the truck’s approximate weight, including the installed attachment, when it is at maximum elevation with its load laterally centered.

There are 11 different types of industrial trucks or tractors, some having greater safeguards than others. There are also designated conditions and locations under which the vast range of industrial-powered trucks can be used. In some instances, powered industrial trucks cannot be used, and in others, they can only be used if approved by a nationally recognized testing laboratory for fire safety. For example, powered industrial trucks must not be used in atmospheres containing hazardous concentrations of the following substances:

• Acetylene
• Butadiene
• Ethylene oxide
• Hydrogen (or gases or vapors equivalent in hazard to hydrogen, such as manufactured gas)
• Propylene oxide
• Acetaldehyde
• Cyclopropane
• Dimethyl ether
• Ethylene
• Isoprene, and
• Unsymmetrical dimethyl hydrazine

These trucks are not to be used in atmospheres containing hazardous concentrations of metal dust, including aluminum, magnesium, and other metals of similarly hazardous characteristics or in atmospheres containing carbon black, coal, or coke dust. Where dust of magnesium, aluminum, or aluminum bronze dusts may be present, the fuses, switches, motor controllers, and circuit breakers of trucks must be enclosed with enclosures approved for these substances.

There also are powered industrial trucks or tractors that are designed, constructed, and assembled for use in atmospheres containing flammable vapors or dusts. These include industrial-powered trucks equipped with additional safeguards to their exhaust, fuel, and electrical systems; with no electrical equipment, including the ignition; with temperature limitation features; and with electric motors and all other electrical equipment completely enclosed.

These specially designed powered industrial trucks may be used in locations where volatile flammable liquids or flammable gases are handled, processed, or used. The liquids, vapors, or gases should, among other things, be confined within closed containers or. closed systems from which they cannot escape.

Some other conditions and/or locations in which specifically designed powered industrial trucks may be used include the following:

• Only powered industrial trucks that do not have any electrical equipment, including the ignition, and have their electrical motors or other electrical equipment completely enclosed should be used in atmospheres containing flammable vapors or dust.
• Powered industrial trucks that are either powered electrically by liquified petroleum gas or by a gasoline or diesel engine are used on piers and wharves that handle general cargo.

Safety precautions the user can observe when operating or maintaining powered industrial trucks include:

• That high lift rider trucks be fitted with an overhead guard, unless operating conditions do not permit.
• That fork trucks be equipped with a vertical load backrest extension according to manufacturers’ specifications, if the load presents a hazard.
• That battery charging installations be located in areas designated for that purpose.
• That facilities be provided for flushing and neutralizing spilled electrolytes when changing or recharging a battery to prevent fires, to protect the charging apparatus from being damaged by the trucks, and to adequately ventilate fumes in the charging area from gassing batteries.
• That conveyor, overhead hoist, or equivalent materials handling equipment be provided for handling batteries.
• That auxiliary directional lighting be provided on the truck where general lighting is less than 2 lumens per square foot.
• That arms and legs not be placed between the uprights of the mast or outside the running lines of the truck.
• That brakes be set and wheel blocks or other adequate protection be in place to prevent movement of trucks, trailers, or railroad cars when using trucks to load or unload materials onto train boxcars.
• That sufficient headroom be provided under overhead installations, lights, pipes, and sprinkler systems.
• That personnel on the loading platform have the means to shut off power to the truck.
• That dockboards or bridgeplates be properly secured, so they won’t move when equipment moves over them.
• That only stable or safely arranged loads be handled, and caution be exercised when handling loads.
• That trucks whose electrical systems are in need of repair have the battery disconnected prior to such repairs.
• That replacement parts of any industrial truck be equivalent in safety to the original ones.

ERGONOMIC SAFETY AND HEALTH PRINCIPLES

Ergonomics is defined as the study of work and is based on the principle that the job should be adapted to fit the person, rather than forcing the person to fit the job. Ergonomics focuses on the work environment and items such as design and function of workstations, controls, displays, safety devices, tools, and lighting to fit the employees’ physical requirements and to ensure their health and well being.

Ergonomics includes restructuring or changing workplace conditions to make the job easier and reducing/stressors that cause cumulative trauma disorders and repetitive motion injuries. In the area of materials handling and storing, ergonomic principles may require controls such as reducing the size or weight of the objects lifted, installing a mechanical lifting aid, or changing the height of a pallet or shelf.

Although no approach has been found for totally eliminating back injuries resulting from lifting materials, a substantial number of lifting injuries can be prevented by implementing an effective ergonomics program and by training employees in appropriate lifting techniques.

In addition to using ergonomic controls, there are some basic safety principles that can be employed to reduce injuries resulting from handling and storing materials. These include taking general fire safety precautions and keeping aisles and passageways clear.

In adhering to fire safety precautions, employees should note that flammable and combustible materials must be stored according to their fire characteristics. Flammable liquids, for example, must be separated from other material by a fire wall. Also, other combustibles must be stored in an area where smoking and using an open flame or a spark-producing device is prohibited. Dissimilar materials that are dangerous when they come into contact with each other must be stored apart.

When using aisles and passageways to move materials mechanically, sufficient clearance must be allowed for aisles at loading docks, through doorways, wherever turns must be made, and in other parts of the workplace. Providing sufficient clearance for mechanically moved materials will prevent workers from being pinned between the equipment and fixtures in the workplace, such as walls, racks, posts, or other machines. Sufficient clearance also will prevent the load from striking an obstruction and falling on an employee.

All passageways used by employees should be kept clear of obstructions and tripping hazards. Materials in excess of supplies needed for immediate operations should not be stored in aisles or passageways, and permanent aisles and passageways must be marked appropriately.

TRAINING AND EDUCATION

OSHA recommends using a formal training program to reduce materials handling hazards. Instructors should be well-versed in matters that pertain to safety engineering and materials handling and storing. The content of the training should emphasize those factors that will contribute to reducing workplace hazards including the following:

• Alerting the employee to the dangers of lifting without proper training.
• Showing the employee how to avoid unnecessary physical stress and strain.
• Teaching workers to become aware of what they can comfortably handle without undue strain.
• Instructing workers on the proper use of equipment.
• Teaching workers to recognize potential hazards and how to prevent or correct them.

Because of the high incidence of back injuries, safe lifting techniques for manual lifting should be demonstrated and practiced at the work site by supervisors as well as by employees.

A training program to teach proper lifting techniques should cover the following topics:

• Awareness of the health risks to improper lifting—citing organizational case histories.
• Knowledge of the basic anatomy of the spine, the muscles, and the joints of the trunk, and the contributions of intra-abdominal pressure while lifting.
• Awareness of individual body strengths and weaknesses—determining one’s own lifting capacity.
• Recognition of the physical factors that might contribute to an accident, and how to avoid the unexpected.
• Use of safe lifting postures and timing for smooth, easy lifting and the ability to minimize the load-moment effects.
• Use of handling aids such as stages, platforms, or steps, trestles, shoulder pads, handles, and wheels.
• Knowledge of body responses—warning signals—to be aware of when lifting.

A campaign using posters to draw attention to the need to do something about potential accidents, including lifting and back injuries, is one way to increase awareness of safe work practices and techniques. The plant medical staff and a team of instructors should conduct regular tours of the site to look for potential hazards and allow input from workers.

SAFETY AND HEALTH PROGRAM MANAGEMENT GUIDELINES

To have an effective materials handling and storing safety and health program, managers must take an active role in its development. First-line supervisors must be convinced of the importance of controlling hazards associated with materials handling and storing and must be held accountable for employee training. An on-going safety and health program should be used to motivate employees to continue to use necessary protective gear and to observe proper job procedures.

OSHA’s recommended “Safety and Health Program Management Guidelines” issued in 1989 can provide a blueprint for employers who are seeking guidance on how to effectively manage and protect worker safety and health. The four main elements of an effective occupational safety and health program are (a) management commitment and employee involvement, (b) worksite analysis, (c) hazard prevention and control, and (d) safety and health training. These elements encompass principles such as establishing and communicating clear goals of a safety and health management program; conducting worksite examinations to identify existing hazards and the conditions under which changes might occur; effectively designing the job site or job to prevent hazards; and providing essential training to address the safety and health responsibilities of both management and employees.

Instituting these practices, along with providing the correct materials handling equipment, can add a large measure of worker safety and health in the area of materials handling and storing.

---

¹ National Safety Council. Accident Facts, 1989 and 1991 Editions, Chicago, IL.

Source: United States Department of Labor, “Materials Handling and Storage” https://www.osha.gov website. Accessed December 2, 2015. https://www.osha.gov/doc/outreachtraining/htmlfiles/mathan.html

© Copyright 2016. All rights reserved. This content is strictly for informational purposes and although experts have prepared it, the reader should not substitute this information for professional insurance advice. If you have any questions, please consult your insurance professional before acting on any information presented. Read more.

Installation and Repair: Pulling and Feeding Wire

Electrical employees run or pull wire throughout a worksite. This involves pulling at one end of the run and feeding at the other. Wire is pulled through chases, conduit, or knockouts to get from the electrical supply to the final destination. This path is usually under the floor or in the ceiling, which forces employees to reach up or bend down. When these tasks are performed manually, they often require employees to exert significant force, assume awkward postures, perform repetitive motions, and be exposed to vibration and contact stress.

• Pulling Force
• Frequency of Pulling and Feeding
• Overhead Reaching

Pulling Force

Potential Hazards:

Figure 1 Heavy spools.

Figure 2 Large mechanical wire puller.

Figure 3 Portable pulley in an open ceiling panel.

• Due to increased weight and stiffness, pulling larger gauge wire requires greater effort than pulling smaller gauge. This increased effort can stress the hands, arms, shoulders, and back.
• Running wire through small diameter conduit increases the contact points between the conduit and wire. This increases the resistance, requiring employees to exert more force while pulling.
• Unwinding wire from spools may be strenuous when wire spools are large and heavy (Figure 1).
• Pulling wire through bends in conduit creates restriction points, which increases the force required to perform the task.
• Running wire while standing on ladders results in twisting torso and awkward posture of the upper extremities.

Possible Solutions:

• Use a mechanical wire puller (Figure 2). Pullers provide the force of several employees, eliminating the manual effort needed to pull therefore increasing productivity and reducing risk of overexertion.
• Appropriately positioned portable pulleys(Figure 3) allow employees to exert larger forces when in proper postures. Employees standing on the ground or other stable surfaces and working with the elbows close to the body and the torso upright can increase effectiveness of the task.
• Use spool rollers (Figure 4) that allow spools to rotate in place and release wire smoothly without twisting.
• Install inspection boxes at appropriate intervals so that employees do not have to pull wire through repeated bends or long lengths of conduit.
• Employees should be provided with platforms, scaffolds, or lifts so that they can raise themselves to do pulling tasks within easy reach and minimize overhead or low-location pulls. Pulling should be done in the power zone.
• When manual pulling is required:
  • take regular breaks from manual pulling, allowing muscles to rest.
  • rotate employees between pulling and feeding, installation and repair tasks.
  • use gloves that improve coupling and protect the hands from contact stress and cuts.
• Lubricate wire as it enters chases, conduits or knockouts to reduce friction and force requirement of pulling task.
• Use platform ladders which provide a work surface where employees may stand and turn to face the direction of work when pulling. This allows employees to exert force in ergonomically correct postures improving efficiency and reduces fatigue. A regular ladder is generally not as desirable since it restricts repositioning, forcing employees to reach and twist the torso when performing pulling tasks.

Frequency of Pulling & Feeding

Potential Hazards:

Figure 4 Spool roller.

Figure 5 Mechanical wire puller.

• Manually pulling or feeding wire through long runs of conduit may take a great deal of time, requiring highly repetitive forceful exertions involving muscles of the hands, arms and back.

Possible Solutions:

• Use spool rollers (Figure 4) that allow spools to rotate in place, releasing wire smoothly with less effort thus reducing force requirement of the task.
• Use a mechanical wire puller (Figure 5). This can reduce force requirements of the task, thereby reducing the risk  and preventing cumulative trauma disorders in the workplace.
• When manual pulling is required:
  • rotate employees between pulling and feeding and installation and repair tasks.
  • use gloves that improve coupling and protect the hands from contact stress and cuts.

Overhead Reaching

Potential Hazards:

Figure 6 Overhead reaching.

Figure 7 Pulling in the power zone.

Figure 8 Using a pulley in the ceiling overhead allows employees to pull or guide wire without overhead arm positions.

• Working on overhead tasks in awkward posture with the hands raised above the shoulder may restrict blood flow and result in nerve compression that affects the upper extremities and shoulders causing numbness, tingling, discomfort and fatigue when these postures are maintained for long periods of time. Common overhead tasks may include attaching parts, completing circuits, and pulling or feeding wire. (Figure 6)
• Awkward postures while pulling with the hands above the shoulder cause an increased load imposed on the shoulders, neck and back. When performed repeatedly, these tasks may result in overexertion of the back and upper extremities.

Possible Solutions:

• Conduct pre-planning to ensure that employees are provided with appropriate height ladders.
• Use platform ladders, lifts or other devices to get closer to the work area. Remove impediments such as work tables, bins or power equipment to improve access.
• Adjust height of the work pieces to allow elbows to stay close to the body within thepower zone (Figure 7).
• Use of a portable pulley (Figure 8) combined with mechanical pullers may significantly reduce overhead reaches and force requirements of the task.

 

Source: United States Department of Labor, “Solutions for Electrical Contractors: Installation and Repair” https://www.osha.gov website. Accessed December 2, 2015. https://www.osha.gov/SLTC/etools/electricalcontractors/installation/index.html

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