OSHA Materials Handling and Storage Checklist

Utilize the OSHA Materials Handling Checklist to ensure compliance with OSHA guidelines for proper materials handling and storage for safe workplaces.

OSHA Materials Handling and Storage Checklist



Materials Handling

1. Is there safe clearance for materials handling equipment through aisles and doorways?


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2. Are aisles permanently marked and kept clear to allow unhindered passage?


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3. Are hand trucks, pallet jacks, powered industrial trucks, and other equipment used for materials handling maintained in safe operating condition?


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4. Are motorized hand and hand/rider trucks designed so that when the operator releases the grip on the device that controls the truck’s travel, the brakes are applied and power to the drive motor shuts off?


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5. Are trucks and trailers secured from movement during loading and unloading operations?


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6. Are dock boards (bridge plates) used when loading and unloading operations are taking place between vehicles and docks?


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7. Are dock boards capable of supporting the maximum intended load?


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8. Are chutes and gravity roller sections firmly placed or secured to prevent displacement?


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9. Are chutes equipped with sideboards of sufficient height to prevent the materials being handled from falling off, and are provisions made to brake the movement of the handled materials at the delivery end of rollers or chutes?


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10. Are pallets inspected before being loaded or moved?


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Powered Industrial Trucks

1. Are workers properly trained and certified by the employer to use the type(s) of powered industrial truck(s) (PIT) they operate, and do only trained workers operate the PIT?


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2. Is operator training and evaluation conducted by someone who has the knowledge, training, and experience to train PIT operators?


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3. Is PIT operator performance evaluated at least once every three years, and are workers retrained as necessary?


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4. Is overhead protection provided on high-lift rider trucks unless it interferes with the operating conditions?


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5. Are any modifications and additions that affect PIT capacity and safe operations only performed with the manufacturer’s prior written approval?


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6. Are PITs equipped with non-factory installed front-end attachments marked to identify the attachments and show the approximate weight of the truck and attachments combination at maximum elevation with the load laterally centered?


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7. Are warning labels, tags, decals, plates, markings, etc., updated, legible, and maintained?


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8. Is directional lighting provided on PITs that operate in areas with inadequate general lighting (less than 2 lumens per square foot)?


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9. Are PITs operated at speeds that allow them to stop in a safe manner, under all travel conditions and acceptable loading levels?


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10. Do parking brakes prevent the PIT from moving when unattended?


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11. Are PITs that operate in hazardous environments approved for use in such locations?


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12. Are safe distances maintained from the edges of elevated ramps and platforms?


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13. Do workers not stand or pass under elevated portions of PITs, whether loaded or empty?


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14. Are unauthorized workers not permitted to ride on PITs?


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15. Do operators refrain from driving up to anyone standing in front of a fixed object?


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16. Are arms and legs not placed between the uprights of the mast or outside the running lines of the PIT?


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17. Do loads handled not exceed the rated capacity of the PIT?


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18. Are PITs inspected at the beginning of each work shift for any safety concerns?


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19. Are PITs in need of repair removed from service immediately?


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20. Are fuel tanks not filled while the engine is running?


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21. Are PITs operated and maintained such that harmful concentrations of dangerous gases or fumes do not occur?


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22. Do PITs have a warning horn, whistle, gong, or other device that can be clearly heard above normal noise in the areas where they are operated?


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Hoist And Auxiliary Equipment

1. Is hoisting equipment available and used for lifting heavy objects, and are hoist ratings and characteristics appropriate for the task?


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2. Are overhead and gantry cranes periodically inspected for defects or safety concerns in 1 to 12-month intervals depending on equipment activity, severity of service, and environment?


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3. Is a thorough inspection of all ropes conducted at least once a month, and is a certification record kept on file, including the inspection date, inspector signature, and an identifier for inspected ropes?


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4. Is equipment with obvious signs of deterioration, leakage, or deformation inspected daily?


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5. Are hooks with deformation or cracks and hoist chains, including end connections, visually inspected daily, and is a monthly inspection documented with a certification record?


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6. Is each overhead electric hoist equipped with a limit switch/device to stop the hook at its highest and lowest point of safe travel?


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7. Does each hoist automatically stop and hold any load up to 125 percent of its rated load if its actuating force is removed?


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8. Is the rated load of each hoist legibly marked and visible to the operator?


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9. Are stops provided at the safe limits of travel for trolley hoists?


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10. Are pendant control boxes constructed to prevent electrical shock and have clearly labeled functions?


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11. Are pendant control stations kept clean, and are function labels kept legible?


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12. Is each cage-controlled hoist equipped with an effective warning device?


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13. Are close-fitting guards or other suitable devices installed on each hoist to ensure that hoist ropes will be maintained in the sheave grooves?


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14. Are hoist chains or ropes long enough to handle the full range of movement of the application while maintaining two full wraps around the drum at all times?


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15. Are guards provided for nip points or contact points between hoist ropes and sheaves permanently located within 7 feet (2.1336 meters) of the floor, ground, or working platform?


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16. Do workers refrain from using twisted or kinked hoist chains or hoist ropes?


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17. Do workers avoid using hoist ropes or hoist chains wrapped around the load as a substitute for a sling?


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18. Is the load well secured and properly balanced before it is lifted more than a few inches?


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19. Are operators instructed to avoid carrying loads above people, and are provisions made to ensure that no one is below-hoisted material or equipment?


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20. Are all unsafe conditions, identified by inspections corrected by designated workers before crane operation resumes?


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21. Are safety latches and other devices used to prevent slippage of materials off hoisting hooks?


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22. Are chains, ropes, chokers, and slings adequate for the materials they are securing?


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23. Are hoist controls plainly marked to indicate the direction of travel or motion?


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Checklist by GoAudits.com – Please note that this checklist is intended as an example. We do not guarantee compliance with the laws applicable to your territory or industry. You should seek professional advice to determine how this checklist should be adapted to your workplace or jurisdiction.

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