Preventing Crush Injuries During Material Handling
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 recognise crush hazards and take steps to stay safe while handling materials.
Identify the Hazards
- 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
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.
Use Proper PPE:
- Wear steel-capped boots, gloves, and high-visibility vests.
- Ensure all PPE fits properly and is in good condition.
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.
Equipment Safety:
- Inspect forklifts, cranes, and pallet jacks for defects before use.
- Operate machinery at safe speeds and avoid sudden stops or sharp turns.
- Ensure all operators are trained, competent, and authorized.
Material Storage:
- Stack materials evenly and securely, ensuring heavier items are placed at the bottom.
- Do not exceed the load limits for shelving or racking systems.
- Use barriers or guards to prevent stacked materials from falling or tipping.
Safe Work Zones:
- Stay clear of moving equipment and never stand between a vehicle and a fixed object.
- Use spotters to guide equipment operators in tight or congested areas.
- Establish clearly marked pedestrian walkways, separate from mobile plant operating zones.
Real-Life Case or Scenario
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 keep a safe distance from moving machinery.
- Report hazards immediately to your supervisor.
Employer Responsibilities
- Provide well-maintained equipment suitable for the task.
- Offer regular training on safe material handling and equipment use.
- Clearly mark hazardous areas and implement 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 co-workers safe. Thank you for your attention, and let’s prioritise safety in all our tasks.
Standards Overview
Under Canadian workplace health and safety legislation, employers and organizations must identify and manage the risks associated with manual and mechanical material handling. Key expectations include:
- Providing suitable equipment and tools for moving and storing materials.
- Ensuring workers wear appropriate PPE and receive adequate training.
- Conducting regular inspections and maintenance of handling equipment.
- Managing workplace layout to reduce crush risks, including separating pedestrian and equipment routes.
Disclaimer
“The information provided in this toolbox talk is intended for informational and educational purposes only. It is not a substitute for professional legal, safety, or regulatory advice. The content reflects general best practices and industry standards but may not be applicable to all workplace environments or jurisdictions.
It is the responsibility of employers, supervisors, and workers to ensure compliance with applicable federal, provincial, and territorial laws, regulations, and standards, including but not limited to those set by the Canadian Centre for Occupational Health and Safety (CCOHS) and relevant provincial occupational health and safety authorities. Site App Pro, its affiliates, agents, or representatives—as well as the authors, presenters, and distributors of this toolbox talk—assume no liability for the use or application of the information provided.
Participants are strongly encouraged to consult appropriate legal, safety, or regulatory professionals regarding specific workplace concerns or questions. Always adhere to your organisation’s policies and procedures for health and safety and hazard management.
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