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Preventing Crush Injuries During Material Handling

Caught In Between | OSHA Fatal Four

The Problem

Crush injuries are a serious risk in material handling and can occur in seconds, leading to severe injuries or even fatalities. Whether it’s from moving heavy equipment, improper stacking, or working too close to forklifts, these injuries are often preventable with the right precautions. Today, we’ll discuss how to recognize crush hazards and take steps to stay safe while handling materials.

Identify the Hazards

Common causes of crush injuries during material handling include:

  • Caught-Between Hazards: Getting trapped between heavy objects, walls, or machinery.
  • Falling Loads: Improperly secured or stacked materials can fall and crush workers.
  • Heavy Equipment: Forklifts, pallet jacks, and cranes can strike or trap workers if not operated safely.
  • Improper Material Storage: Overloading shelves or unsafe stacking can lead to collapse.‍
  • Pinch Points: Hands or fingers caught in machinery or between materials.

Safety Practices and Preventative Measures

To prevent crush injuries, always follow these safety guidelines:

  1. Plan Ahead:

    • Evaluate the materials to be moved and identify potential hazards.
    • Use equipment that is rated for the size and weight of the load.
  2. Use Proper PPE:

    • Wear steel-toed boots, gloves, and high-visibility vests.
    • Ensure all PPE fits properly and is in good condition.
  3. Safe Lifting and Handling:

    • Use team lifting or mechanical assistance (e.g., forklifts, hoists) for heavy or awkward items.
    • Keep your hands and feet clear of pinch points when placing or removing materials.
  4. Equipment Safety:

    • Inspect forklifts, cranes, and pallet jacks for defects before use.
    • Operate machinery at safe speeds and avoid sudden stops or turns.
    • Ensure operators are trained and certified to handle equipment.
  5. Material Storage:

    • Stack materials evenly and securely, ensuring heavier items are at the bottom.
    • Do not exceed load limits for shelving or racks.
    • Use barriers or guards to prevent stacked materials from tipping over.
  6. Safe Work Zones:

    • Stay clear of moving equipment and never stand between a vehicle and a fixed object.
    • Use spotters to guide operators in tight spaces.
    • Establish designated walkways to separate pedestrians from equipment.

Real-Life Case or Scenario

Where possible, use an actual incident that you have experienced or been involved in.

E.g. In a recent incident, a worker suffered a severe crush injury when a forklift operator lost control of an improperly secured pallet. The load tipped over, trapping the worker's leg. This accident could have been prevented with proper load inspection and clear communication between the worker and the operator.

Employee Responsibilities

  • Inspect all tools, equipment, and loads before use.
  • Follow safe handling procedures and wear the appropriate PPE.
  • Stay alert to your surroundings and maintain a safe distance from moving machinery.
  • Report hazards immediately to your supervisor.

Employer Responsibilities

  • Provide well-maintained equipment and ensure it is suitable for the task.
  • Offer regular training on material handling safety and equipment operation.
  • Clearly mark hazardous areas and establish traffic control measures.
  • Investigate and address any reported hazards promptly.

Discussion & Questions

  • "What are some crush hazards you’ve noticed during material handling on this job site?"
  • "Does anyone have a story of how a crush hazard was identified and resolved?"

Encourage employees to ask questions or share their experiences.

Commitment/Action Plan

Starting today, let’s commit to inspecting all materials and equipment before handling them. If you see a potential crush hazard, take immediate action or report it to your supervisor. By working together, we can create a safer work environment.

Wrap-Up

Crush injuries can be devastating, but they are also preventable. By staying aware of hazards, following safety protocols, and using the right equipment, we can keep ourselves and our coworkers safe. Thank you for your attention, and let’s prioritize safety in all our tasks.

Standards Overview

  • OSHA 1926.250 outlines the safe handling, storage, and stacking of materials.
  • OSHA mandates the use of proper personal protective equipment (PPE) and training to minimize risks during material handling.
  • Employers and employees share responsibility for ensuring safe practices when moving or storing heavy materials.
OSHA Occupational Safety and Health Administration

Legal Disclaimer

This toolbox talk is provided for informational and educational purposes only. It is not intended to be a substitute for professional legal, safety, or regulatory advice. The information presented is based on best practices and general industry standards but may not apply to all workplace situations.
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It is the responsibility of the employer, supervisors, and workers to ensure compliance with applicable federal, state, and local laws, regulations, and standards. The authors, presenters, and distributors of this toolbox talk assume no liability for the use or application of the information provided.
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Participants are encouraged to consult appropriate legal, safety, or regulatory professionals to address specific concerns or questions. Always follow your organization's policies and procedures for workplace safety and hazard mitigation.

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