In one recent example, a construction worker in Pennsylvania was crushed to death by a section of a steel plate. The month before, a worker in Houston died when a pallet carrying a one-ton load struck him. In Maryland, two bar joists fell off a stack on a flatbed truck, killing a worker.
The U.S. Occupational Safety and Health Administration reports that material handling accidents account for hundreds of thousands of injuries each year on construction sites. Safe material handling practices can prevent much needless suffering and also save contractors and their insurance companies millions of dollars in medical and disability benefit costs.
Safe material handling covers three distinct areas: safe handling, safe storage and proper disposal of debris and scrap.
Safe handling of construction materials
- Properly secure all materials that are stored in tiers. Pipes, steel beams, poles and other heavy materials can slide or tilt if they are not stacked and blocked adequately, allowing them to potentially fall on workers.
- Keep combustible and flammable materials in fire-resistant containers.
- Determine and prominently post the maximum safe load limits of floors where materials are stored, and take care not to exceed those limits.
- Maintain clear and sound aisles and passageways for moving materials.
- Construct ramps or graded walkways between work areas on different levels to reduce the chances of accidents and spills.
Sound storage practices
- Stack bricks in piles no more than seven feet high, tapering every layer above four feet back two inches for every foot. While masonry blocks can be stacked taller, taper piles above six feet.
- Limit stacks of lumber to 20 feet high (16 feet if workers will handle lumber without machines) in stable piles on level sills that provide good support. Remove all used nails before stacking.
- Keep materials more than six feet from hoistways.
- Do not store materials in floor openings. Store materials more than 10 feet from an exterior wall that is shorter than the top of the pile.
- Do not store materials on scaffolds or runways unless they will be used there immediately.
Proper waste disposal
- Remove all scrap, especially combustible materials, as it accumulates instead of letting it pile up; however, do not remove it until workers above are finished tossing it to the ground.
- Use an enclosed chute to drop debris from higher points of the building when practical.
- Barricade areas where workers will drop debris without using a chute.
- Use separate containers for materials contaminated with oil or flammable liquids.
An insurance company's loss control department may have resources available to assist contractors with improving material handling. Contractors can review insurance options such as Construction Supply & Contractor Insurance to learn about risk-control services and coverage considerations.
Where heavy equipment and forklifts are used to move loads, it is important to consider coverage for that equipment; employers may want information on Construction and Mining Machinery Insurance to address machinery-related exposures.
Materials that protect the building envelope pose their own handling and storage risks; for those working with exterior materials, resources such as Roofing, Siding & Insulation Materials Insurance can be helpful.
Those who want assistance arranging a review should ask your agent to set up a meeting with loss control or risk-management professionals.
Frequently Asked Questions
What are the most common material handling hazards on construction sites?
Common hazards include falling or shifting stacked materials, improperly secured loads, unsafe use of lifting equipment, and debris dropped from heights.
How should lumber and bricks be stacked to reduce risk?
Lumber should be stacked on level sills and supported, with height limits observed; bricks should be tapered above specified heights to maintain stability.
When is it safe to remove scrap and debris from a jobsite?
Remove scrap as it accumulates, but only after confirming that workers overhead are finished dropping materials and proper controls are in place.
Who can help contractors develop better material handling practices?
Loss control departments at insurers, safety consultants, and site supervisors can provide guidance and help implement safer handling, storage, and disposal procedures.