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 authorised.
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 the Health and Safety at Work Act 2015 (HSWA), WorkSafe New Zealand requires PCBUs (Persons Conducting a Business or Undertaking) to identify and manage the risks associated with manual and mechanical material handling. Key expectations include:
- Providing suitable plant and equipment 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
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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