12 Aug Material Handling / Manual Lifting – JSA

Material Handling / Manual Lifting Job Safety Analysis (JSA)

Job / Task

Manual lifting, lowering, carrying, pushing, pulling, positioning, stacking, and handling of tools, equipment, supplies, construction materials, and other loads, including use of carts, dollies, hand trucks, pallet jacks, and other material-handling aids.

Purpose

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with material handling and manual lifting and establishes safe work practices and controls to prevent strains, sprains, musculoskeletal disorders, caught-between injuries, crushing injuries, cuts, falls, and other incidents.

Personnel Qualifications

Employees shall be trained to recognize material-handling and ergonomic hazards and shall understand safe lifting, carrying, pushing, pulling, and load-handling practices applicable to their work.

Employees shall:

• Evaluate the load and travel path before moving materials.
• Use mechanical lifting or material-handling equipment whenever practical to reduce manual handling.
• Use material-handling equipment only when trained and authorized.
• Request assistance when a load is too heavy, bulky, long, unstable, or awkward to handle safely alone.
• Use proper body positioning and avoid unnecessary twisting, reaching, and sudden movements.
• Keep hands and body parts clear of pinch points and crush zones.
• Inspect material-handling aids before use and remove defective equipment from service.
• Stop work when the load or conditions cannot be safely controlled.
• Report material-handling hazards, injuries, incidents, and near misses to supervision.

Required PPE

PPE shall be selected based on the material, task, equipment, and work environment and may include:

• Safety footwear with appropriate toe protection and slip-resistant soles.
• Work gloves appropriate for the material being handled.
• Safety glasses with side protection.
• Hard hat where overhead or falling-object hazards exist.
• High-visibility apparel where vehicles or mobile equipment are present.
• Cut-resistant or other specialized gloves where sharp materials are handled.
• Additional PPE required by the material, task, or worksite.

PPE does not replace mechanical lifting aids, proper load planning, safe body positioning, or other engineering and administrative controls.

JSA – Job Steps, Hazards, and Controls

Step 1 – Plan the Material-Handling Task

Potential Hazards

• Unknown load weight or center of gravity.
• Load too heavy or awkward for one person.
• Inadequate personnel or equipment.
• Poor travel path.
• Unexpected lifting or carrying distance.

Required Controls

• Determine what will be moved, where it will be placed, and the safest method of handling it.
• Estimate or verify the load weight, dimensions, stability, and center of gravity when practical.
• Use mechanical assistance whenever practical.
• Arrange a team lift when the load cannot be safely handled by one employee.
• Plan the travel path and final placement before lifting.

Step 2 – Inspect the Load

Potential Hazards

• Sharp edges, splinters, burrs, or protrusions.
• Leaking or hazardous materials.
• Loose or shifting contents.
• Damaged packaging.
• Unexpected load movement.

Required Controls

• Inspect the load before handling.
• Identify sharp edges, protrusions, damaged packaging, leaks, loose components, and unstable contents.
• Secure loose materials before movement.
• Use appropriate gloves and other PPE.
• Do not manually handle leaking, damaged, or hazardous materials without appropriate controls.

Step 3 – Inspect and Clear the Travel Path

Potential Hazards

• Slips, trips, and falls.
• Uneven surfaces.
• Obstructions.
• Stairs or elevation changes.
• Vehicle or equipment traffic.
• Poor visibility.

Required Controls

• Remove or avoid obstacles before moving the load.
• Ensure the route is adequately lit and provides sufficient clearance.
• Identify stairs, ramps, uneven ground, doorways, and other restrictions.
• Keep the travel path clear of cords, hoses, debris, and materials.
• Coordinate with vehicle or equipment operators where traffic hazards exist.

Step 4 – Prepare to Lift

Potential Hazards

• Back, shoulder, or other musculoskeletal strain.
• Poor grip.
• Pinch points.
• Sudden load shift.
• Overexertion.

Required Controls

• Position yourself close to the load.
• Establish stable footing with sufficient room to move.
• Test the load before fully lifting to determine weight and stability.
• Obtain assistance or mechanical aid if the load cannot be controlled comfortably.
• Establish a secure grip and identify pinch points before lifting.

Step 5 – Lift the Load

Potential Hazards

• Strains and sprains.
• Back injury.
• Loss of balance.
• Dropped load.
• Pinched fingers or hands.

Required Controls

• Keep the load close to the body when practical.
• Lift smoothly using the legs while maintaining a stable posture.
• Avoid jerking or sudden movements.
• Do not twist while lifting; turn by moving the feet.
• Keep fingers and hands clear of pinch points.
• Stop and lower the load safely if control is lost or excessive strain is felt.

Step 6 – Carry the Load

Potential Hazards

• Obstructed vision.
• Slips, trips, and falls.
• Musculoskeletal strain.
• Collision with people or objects.
• Dropped materials.

Required Controls

• Maintain a clear view of the travel path.
• Keep the load close to the body and within a comfortable carrying position.
• Walk at a controlled pace.
• Do not carry loads that block vision; use assistance or another handling method.
• Take breaks or reposition the load when needed to avoid fatigue.
• Use extra caution on stairs, ramps, and uneven surfaces.

Step 7 – Perform a Team Lift

Potential Hazards

• Uncoordinated movement.
• Unequal load sharing.
• Pinch or crush injuries.
• Dropped load.
• Unexpected movement.

Required Controls

• Select enough employees to safely control the load.
• Designate one person to direct the lift when coordination is necessary.
• Agree on commands before lifting, moving, or lowering.
• Lift, carry, and lower together in a coordinated manner.
• Ensure all employees have secure footing and adequate hand placement.
• Stop immediately if any team member loses control.

Step 8 – Use Carts, Dollies, Hand Trucks, or Pallet Jacks

Potential Hazards

• Equipment failure.
• Struck-by or caught-between injuries.
• Runaway load.
• Overexertion.
• Tip-over.
• Foot injuries.

Required Controls

• Inspect the device before use and verify it is suitable for the load.
• Do not exceed rated capacity.
• Secure or stabilize the load before movement.
• Push rather than pull when practical and when doing so provides better control and visibility.
• Keep hands and feet clear of wheels, frames, and pinch points.
• Use caution on slopes and uneven surfaces; do not use equipment on grades beyond its safe capability.

Step 9 – Push or Pull Materials

Potential Hazards

• Shoulder, back, or arm strain.
• Loss of footing.
• Pinch points.
• Unexpected movement.
• Collision.

Required Controls

• Evaluate the surface, load, and resistance before movement.
• Use mechanical assistance where practical.
• Keep the body aligned with the direction of force.
• Use controlled force rather than sudden jerking movements.
• Push when practical instead of pulling, provided visibility and control are maintained.
• Do not place yourself between a moving load and a fixed object.

Step 10 – Lower and Position the Load

Potential Hazards

• Pinched hands or fingers.
• Crushing injuries.
• Back strain.
• Unstable placement.
• Load shift or collapse.

Required Controls

• Ensure the destination is clear and capable of supporting the load.
• Lower the load in a controlled manner using stable body positioning.
• Keep hands and feet clear of pinch and crush points.
• Use blocks, spacers, or other means when necessary to provide hand clearance.
• Do not release the load until it is stable and secure.

Step 11 – Stack and Store Materials

Potential Hazards

• Falling or shifting materials.
• Collapse of stacks.
• Blocked aisles or exits.
• Manual handling injuries.
• Protruding or unstable materials.

Required Controls

• Store materials on stable surfaces.
• Stack, block, interlock, or secure materials to prevent sliding, falling, or collapse.
• Place heavier materials lower when appropriate.
• Do not exceed rack, shelf, or storage-system capacities.
• Keep aisles, exits, stairs, emergency equipment, and access routes clear.
• Avoid storage arrangements that require excessive reaching or awkward lifting.

Step 12 – Repetitive or Extended Material Handling

Potential Hazards

• Fatigue.
• Cumulative trauma.
• Musculoskeletal disorders.
• Reduced grip or control.
• Overexertion.

Required Controls

• Use mechanical aids and engineering controls to reduce repetitive handling.
• Adjust work height or material placement to reduce bending, reaching, and twisting.
• Rotate tasks or vary activities when practical.
• Use reasonable work/rest practices for demanding repetitive work.
• Report ergonomic concerns early so the task can be evaluated and controls implemented.

General Safe Work Requirements

• Use engineering controls and mechanical material-handling equipment whenever practical to eliminate or reduce manual lifting.
• Do not attempt to manually lift or move a load that cannot be safely controlled.
• Maintain good housekeeping and clear travel paths before moving materials.
• Avoid lifting from floor level or above shoulder height when the task can be redesigned or the material repositioned.
• Avoid twisting while carrying a load; change direction by moving the feet.
• Keep loads close to the body and within a comfortable handling zone whenever practical.
• Do not place hands, feet, or other body parts beneath suspended, raised, or unstable materials.
• Store materials so they remain stable and can be retrieved without unnecessary reaching, bending, or overexertion.
• Stop work and obtain assistance when conditions change or the material cannot be moved safely.

Training

Employees shall receive training appropriate to the material-handling activities they perform. Training shall include recognition of lifting and ergonomic hazards, load assessment, proper lifting and carrying techniques, team lifting, use of mechanical aids, pushing and pulling practices, material storage, pinch-point awareness, and procedures for reporting hazards and injuries. Employees operating powered material-handling equipment shall meet applicable training and authorization requirements.

References

• OSHA 29 CFR 1926.21 – Safety Training and Education.
• OSHA 29 CFR 1926.25 – Housekeeping.
• OSHA 29 CFR 1926.250 – General Requirements for Storage.
• OSHA 29 CFR 1910.176 – Handling Materials – General.
• NIOSH – Ergonomic Guidelines for Manual Material Handling.