Chapter 12. Materials Handling and Storage

I. General materials handling and storage.

A. Plan the logical movement of materials from when they are brought into the workplace until they exit the workplace.

B. Keep movement of materials to the minimum, both in distance and number of times moved.

C. Use mechanical equipment whenever possible for movement of large, bulky loads.

D. Workers should be aware of the potential hazards associated with the task and know how to minimize the danger.

E. Workers should be trained in safe and proper lifting methods to prevent back injuries.

F. Engineering controls such as reducing the size or weight of the object lifted, changing the height of a pallet or shelf, or installing a mechanical lifting aid should be used whenever possible.

G. When moving materials by hand:

1. use gloves and forearm protection for sharp or rough edged materials;

2. wear steel-toed safety shoes if loads are heavy or bulky; and

3. wear proper personal protective equipment including eye protection if wire or metal bound bales or boxes must be opened.

H. All materials handling equipment such as cranes, trucks, hoists, and forklifts, have rated-load capacities, the maximum weight the equipment can safely lift, which must be observed. Equipment rated-load capacity must be conspicuously displayed on the machine.

I. When moving materials by machine:

1. the load carried by a powered industrial forklift must be squarely centered on the forks and as close to the mast as possible;

2. do not overload the machine;

3. do not add extra weight to the rear of a forklift to offset an overload;

4. the load must be at the lowest position for traveling and the manufacturer's operating requirements must be followed; and

5. all stacked loads must be correctly piled and cross-tiered where possible.

J. When blocking a load:

1. the worker should ensure that the load is not released until all hands are out from under the load; and

2. blocking materials and timbers should be large and strong enough to support the load safely. Materials that are cracked, splintered, have rounded corners, or evidence of dry rot should not be used for blocking.

K. Building load limits must be conspicuously posted in all storage areas.

L. Stacking and piling.

1. When stacking materials, height and weight limitations, accessibility, and the stability of the material and its container should be considered.

2. Containers of flammable or combustible liquid when piled one upon the other must be separated by dunnage of sufficient stability to prevent stress on container walls. Flammables stored in 55 gallon drums should not be stacked greater than two high.

3. Storage and handling of liquefied petroleum gas fuel must be in accordance with the National Fire Protection Association.

4. Explosives or blasting agents must not be stored, handled or transported when they constitute an undue hazard to life.

5. All materials stored in tiers should be stacked, placed on racks, blocked, interlocked, or otherwise secured to prevent sliding, falling or collapse.

6. Separate containers and materials according their physical characteristics so that they will not slip, slide or roll.

7. Stack bagged materials in interlocking tiers.

8. Store chemical materials by their hazard class, i.e., separate combustibles and flammables, toxic materials, and dissimilar materials.

9. Flammable and combustible materials should be stored according to their fire characteristics, i.e., flammable liquids should be separated from other materials by a fire wall. Smoking, the use of an open flame, or spark producing devices should be prohibited from flammable or combustible storage areas.

10. Drums, barrels, and kegs should be stacked symmetrically. If stored on their sides, bottom rows should be blocked to keep them from rolling. For stacking on end, place planks, sheets of plywood dunnage, or pallets between each row to make a firm, flat stacking surface.

11. Do not climb on shelves or use shelving as a ladder.

M. Aisles and passageways must remain clear of obstructions and other trip hazards with sufficient space to maneuver materials and/or equipment. Materials should not be stored on scaffolds or runways. Permanent aisles and passageways should be appropriately marked.

N. All passageways, storerooms, and service rooms must be kept clean and orderly, and the floor of every workroom kept reasonably clean and, as far as is practicable, dry. The storage of materials should not create a hazard. Storage areas should be kept free from accumulation of materials that cause tripping, fire, explosion, or the harboring of rats rodents and other pests.

II. Grain handling.

A. Preventive maintenance is necessary for controlling fuel and ignition sources and for keeping equipment functioning properly and safely.

1. All mechanical and safety control equipment associated with dryers, grain stream processing equipment, dust collection, equipment, including filter collectors and bucket elevators should be inspected annually.

2. Equipment should be kept lubricated and maintained according to the manufacturer's recommendations. Equipment that malfunctions or operates below designed efficiency should be promptly repaired or removed from service.

3. Inspected or repaired equipment should show the date of inspection.

B. Housekeeping.

1. A written, standard operating procedure (SOP) on housekeeping should be maintained.

2. The SOP should include instructions for reducing dust accumulations on ledges, floors, equipment, and other exposed surfaces, and must identify "priority" areas in grain elevators that are know to be potential sources of ignition. Including:

a. floor areas within 35 feet of inside bucket elevator legs;

b. enclosed areas containing grinding equipment; and

c. enclosed areas containing grain dryers located inside the facility.

3. The SOP should include methods for removing grain spills from work areas. The use of compressed air is permitted only when all machinery that presents a source of ignition in the area is shutdown, and all other known potential ignition sources are removed or controlled.

4. A maximum accumulation (action level) of not more than 1/8-inch of grain dust is allowed in priority housekeeping areas.

a. Methods must be initiated immediately to remove such accumulations that exceed the action level.

b. These guidelines permit the use of an alternative means to the 1/8-inch action level where the alternative can be demonstrated to provide equivalent protection from explosions. This involves additional treatment of the dust and/or the area of accumulation such as spraying with oil or water.

c. The use of oil additives such as white mineral oil in the grain flow, and changes in materials handling processes can help reduce the accumulation of dust.

C. A written emergency action plan should be developed and implemented in units with ten or more workers.

1. The plan must include a distinguishable and distinct alarm system, evacuation procedures, and include emergency procedures training.

2. Workers should know where the nearest escape routes are and be familiar with workplace maps that clearly show these routes.

3. At least two means of egress from galleries (bin decks) are required in grain elevators.

4. A safe area outside the facility should be designated where workers can congregate after evacuation.

D. Training.

1. Workers should be trained in general safety precautions associated with the grain facility, as well as the recognition of and preventive measures for the hazards related to dust accumulations and common ignition sources such as smoking, and

2. Specific procedures and safety practices applicable to the job tasks including, but not limited to, clearing choked legs, performing housekeeping, hot work, preventive maintenance, and lockout/tagout.

E. Hot work includes electric or gas welding, cutting, brazing or similar flame producing operations. A permit system should be used to ensure the unit Director is aware of the hot work being performed in the grain facility and that appropriate safety precautions are taken prior to beginning the work. Workers in this case includes contractors.

F. Entry into bins, silos and tanks is especially hazardous and is considered confined space entry. See Confined Space Entry for details.

G. Inside bucket elevator legs.

1. Inside bucket elevators are potential ignition sources for primary explosions. To reduce this hazard, the surface electrical resistance of the belts must not exceed 300 megohms.

2. Bucket elevators must have an opening to the head pulley section and boot section to allow for inspection, maintenance, and cleaning.

3. Bearings must be mounted externally to the leg casing or monitoring for vibration, temperature, or other condition of the bearings mounted inside or partially inside the leg casing.

4. Elevator legs must be equipped with a motion detection device that will shut down the leg when the belt speed is reduced by 20 percent or more of the normal operating speed.

5. A belt alignment monitoring device is required to alert workers when the belt is not tracking properly. Alternately, a means to keep the belt tracking properly is required.

6. Bearing monitors, motion detection devices, and belt alignment devices are not needed if the bucket elevator is equipped with a fire and explosion suppression system that is capable of protecting the head and boot sections of the leg, or with a pneumatic dust control system that will keep the dust concentrations inside the leg casing 25% below the lower explosive limit during operation.