6 Free Materials Handling Safety Articles
Materials handling and storage is the safe movement, lifting, stacking, and storing of materials at work, whether by hand or with equipment such as hand trucks, pallet jacks, and cranes. Nearly every workplace moves materials, and this work drives a large share of injuries, from strained backs during manual lifting to crush and struck-by incidents when loads shift, stacks topple, or equipment is used the wrong way.
The materials handling safety articles on this page cover both the manual and mechanical sides of the job. They explain safe material stacking, how to prevent common material storage hazards, and the precautions for using hand trucks and pallet jacks to move heavy loads without injury. Crane lift zone planning is also reviewed so the crew working below and around a suspended load stays protected.
Warehouse supervisors and safety managers can use these articles to plan a lift, lay out a storage area, or train a worker before they move heavy material by hand or machine. These materials handling articles are written for warehouse and distribution staff, laborers, equipment operators, and the supervisors and safety managers responsible for keeping a crew safe day to day.
Why it matters
Overexertion is a leading cause of workplace injuries.
Materials Handling Safety Articles
Materials Handling FAQs
What is materials handling and storage?
Materials handling and storage is the movement, lifting, and stacking of materials, plus the way they are stored between uses. It covers manual handling, such as carrying and lifting by hand, and mechanical handling with hand trucks, pallet jacks, forklifts, and cranes. Doing it safely protects workers from overexertion, struck-by, and caught-in or crushed-by injuries.
What OSHA standards apply to materials handling and storage?
Two main OSHA standards apply to materials handling and storage and they are the general industry materials handling and storage rule (OSHA 1910.176) and the construction materials storage rule (OSHA 1926.250). The general industry standard addresses secure storage, clear aisles and passageways, and housekeeping, while the construction standard covers how materials are stacked and kept clear of openings and edges. Powered equipment such as forklifts falls under a separate standard for powered industrial trucks (OSHA 1910.178).
What is the safe way to lift materials by hand?
To lift safely by hand, plan the lift first by sizing up the load, clearing the path, and getting help or a mechanical aid for anything too heavy or awkward. Keep a stable stance, hold the load close to your body, lift with your legs rather than your back, and avoid twisting as you carry. When a load is too heavy to handle safely, use a hand truck, pallet jack, or other equipment instead.
How should materials be stacked and stored safely?
Stack and store materials so they cannot slide, fall, or collapse. Stack loads evenly and squarely, keep them stable by blocking, interlocking, or racking, and limit stack height so the pile stays secure. Keep aisles, passageways, and exits clear, follow the posted load limits for floors and racks, and store heavier items low. On construction sites, OSHA also requires stored materials to be kept a set distance from floor openings and exterior walls.
What are the most common material storage hazards?
The most common material storage hazards are unstable stacks that collapse, materials falling from height, and loads that shift or roll. Blocked aisles and exits, overloaded racks or floors, and poor housekeeping add tripping, fire, and struck-by risks, and storing incompatible materials together can create chemical dangers. Most are controlled by secure stacking, posted load limits, clear walkways, and routine inspection of racks and shelving.
Do workers need training to use a hand truck, pallet jack, or crane?
Manual hand trucks and pallet jacks carry no formal OSHA certification requirement, but workers still need instruction on safe loading, pushing instead of pulling, and keeping loads stable. Powered pallet jacks and forklifts are powered industrial trucks, so operators must be trained and evaluated before use (OSHA 1910.178). Crane operation requires a qualified, and often certified, operator under OSHA's crane standards.
