In October 2010, 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 handling
Safe handling of construction materials involves several measures, including properly securing 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.
Key safe-handling measures
- Keeping combustible and flammable materials in fire-resistant containers.
- Determining and prominently posting the maximum safe load limits of floors where materials are stored, and taking care not to exceed those limits.
- Maintaining clear and sound aisles and passageways for moving materials.
- Constructing ramps or graded walkways between work areas on different levels to reduce accidents and spills.
- Avoiding improperly stored materials that can shift or topple over and cause serious injuries.
Sound storage practices
OSHA outlines specific storage practices to reduce collapse and falling hazards when materials are piled or stacked.
- Stack bricks in piles no more than seven feet high, tapering every layer above four feet back two inches for every foot. Masonry blocks may be stacked taller, but 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, and remove all used nails before stacking.
- Keep materials more than six feet from hoistways and 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, and avoid storing materials on scaffolds or runways unless about to use them.
For guidance related to the insurance and safety needs of suppliers and contractors, see Insurance for Construction and Building Supply Businesses.
When heavy equipment and machinery are involved in moving or lifting materials, consider protections and coverages specific to that equipment; more information can be found at Construction and Mining Machinery Insurance.
Disposal and waste removal
In the hurry to get the job done, workers sometimes dispose of construction debris in unsafe ways, such as tossing pieces of lumber off the side of a building. This risks injury to anyone standing below.
- Remove scrap and combustible materials as they accumulate instead of letting them pile up, but do not remove debris until workers overhead have finished dropping it to the ground.
- Use an enclosed chute to drop debris from higher points on the building whenever possible.
- 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 and reducing risk. Those who want this help should talk to an agent to arrange a meeting and review available services.
Sound material handling practices help prevent injuries, fines and penalties, and reduce workers' compensation costs. They also enhance an employer's reputation with potential employees. Putting these safeguards into place makes both moral and practical sense.
Frequently Asked Questions
What are the most common material handling hazards on construction sites?
Common hazards include falling or shifting stacked materials, unsecured loads during lifting, struck-by incidents from moving pallets or equipment, and debris dropped from heights.
How should heavy materials be stacked to reduce risk?
Stack on level sills with stable support, limit pile heights according to material type, taper higher layers as recommended, and block items to prevent sliding or tilting.
When is it appropriate to use a debris chute?
Use an enclosed chute whenever dropping material from elevated work areas to control the path of debris and protect workers below; barricade areas where chutes are not used.
Can an insurer help reduce material-handling risks at a jobsite?
Yes. Many insurers offer loss control consultations, training resources, and site assessments to help contractors improve handling practices and reduce claims.