Material handling and storage

You must provide sufficient safe clearances so equipment can pass, turn, load, and unload without creating hazards. Under 1910.176(a) the standard requires aisles, loading docks, and doorways used by mechanical handling equipment to allow safe passage and maneuvering and to be kept clear and in good repair.

• Keep aisles free of stored material, debris, or temporary obstructions that could create a hazard.
• Maintain clearance for the full turning radius and operating envelope of the equipment being used (consult equipment manufacturer specs).
• Inspect and repair aisle surfaces (no potholes, loose boards, or uneven surfaces) so equipment stability is not compromised.

Cite: 1910.176(a).

Yes. Permanent aisles and passageways must be appropriately marked to identify the travel route and keep them clear. 1910.176(a) requires permanent aisles and passageways to be marked.

• Common marking methods include painted floor lines, contrast striping, signs, and durable barrier posts.
• Markings should be visible in the lighting conditions present and maintained (repaint/replace when worn).
• Marking should reflect aisle use (e.g., pedestrian-only, forklift traffic, shared).

Cite: 1910.176(a).

No; aisles and passageways shall be kept clear of obstructions that could create a hazard. 1910.176(a) requires aisles and passageways to be clear and in good repair, with no obstruction across or in aisles that could create a hazard.

• If a temporary obstruction is unavoidable (e.g., short-term maintenance), control the area with barriers, signs, and spotters, and re-route traffic until cleared.
• Always evaluate whether the temporary condition creates a hazard to pedestrians or equipment operators and eliminate or control that hazard before allowing normal operations.

Cite: 1910.176(a).

They must be stacked, blocked, interlocked, and limited in height so they are stable and secure against sliding or collapse. 1910.176(b) requires storage tiers to be arranged for stability.

Best practices:

• Stack heavier items on the bottom and taper lighter items upward.
• Use pallets, chocks, or blocking to prevent movement and to interlock layers where possible.
• Stagger seams and interlock bundles to avoid continuous vertical seams that promote collapse.
• Limit stack height to what remains stable under normal handling; if in doubt, reduce height and secure with straps or racks.

Cite: 1910.176(b).

No; the standard does not set a numeric maximum height—stacks must simply be limited in height so they remain stable and secure. 1910.176(b) requires that tiers be limited in height to prevent sliding or collapse, but it does not prescribe a specific height.

• Employers must assess material type, container strength, storage method, and handling operations to determine a safe stack height.
• Use manufacturer guidance, engineering judgment, or supplier recommendations when available; consider reducing height for irregularly shaped or unstable items.

Cite: 1910.176(b).

Yes. Using pallets, blocking, and interlocking methods is acceptable to make stacks stable and secure. 1910.176(b) requires that stacked materials be blocked and interlocked as needed to prevent sliding or collapse.

• Ensure pallets are in good condition and rated for the load.
• Use blocking or chocks to prevent lateral movement, especially on uneven floors or during forklift operations.
• Interlock cartons or bundles so each layer helps restrain the layer above.

Cite: 1910.176(b).

Storage areas must be kept free from accumulations of materials that create hazards from tripping, fire, explosion, or pest harborage. 1910.176(c) requires housekeeping in storage areas and states that vegetation control will be exercised when necessary.

• Remove tripping hazards like loose debris, spilled materials, or stray pallets.
• Keep aisles and egress routes unobstructed for safe evacuation and equipment movement.
• Control combustible accumulations (dust, flammable waste) and inspect for potential ignition sources.
• Manage vegetation and outside storage to prevent pest harborage and fire risk.

Cite: 1910.176(c).

Clearance signs must be provided to warn of clearance limits wherever such limits present a hazard. 1910.176(e) requires clearance signs to warn of clearance limits.

• Post signs at locations with low overhead clearance, narrow doorways, or other areas where vehicles or loads might strike obstructions.
• Signs should state the clearance height or restriction in clear, legible characters and be visible under normal lighting.
• Where possible, combine signs with physical markers (flags, hanging bars) to provide an early warning to equipment operators.

Cite: 1910.176(e).

Derail and/or bumper blocks must be provided where a rolling car could contact other cars being worked, or enter a building, work area, or traffic area. 1910.176(f) requires these protective devices on spur tracks that pose that hazard.

• Install derails or bumper blocks at the ends of spurs that lead into buildings, loading docks, or pedestrian/vehicle traffic areas.
• Maintain and inspect derails/bumper blocks regularly to ensure they operate and will stop unintended rolling cars.
• Combine mechanical devices with safe operating procedures (e.g., wheel chocks, hand brakes, employee communication) for added protection.

Cite: 1910.176(f).

You must provide covers and/or guardrails to protect personnel from hazards posed by open pits, tanks, vats, ditches, or similar openings. 1910.176(g) requires guarding for these hazards.

• Covers should be secure and capable of supporting expected loads (personnel and equipment) and be clearly marked or color-coded when removable.
• Guardrails should meet applicable guardrail strength and height requirements to prevent falls into the opening.
• Use signage and restricted access controls where temporary work requires opening covers.

Cite: 1910.176(g).

Plan aisles to provide sufficient safe clearance for the specific equipment's turning radius, load dimensions, and travel path so turns and passages can be made without hazard. 1910.176(a) requires sufficient safe clearances wherever turns or passage must be made.

• Measure the loaded turning radius of your trucks (including any attachments or elevated loads) and add a safety margin for human error.
• Account for door thickness, posts, dock edges, and shelving overhangs.
• Where space is tight, consider using traffic controls, mirrors, or spotters to reduce collision risk.

Cite: 1910.176(a).

Vegetation control is required when plant growth creates hazards such as fire fuel, pest harborage, or obscures safe passage and egress. 1910.176(c) explicitly states vegetation control will be exercised when necessary.

• Remove or trim vegetation that hides tripping hazards, blocks signs, or provides rodent/insect shelter.
• Keep firebreaks or cleared strips where combustible vegetation could spread fire to stored materials.

Cite: 1910.176(c).

Interlocked stacking means arranging units so layers tie into each other (like brickwork) so the stack resists sliding and collapse; you should interlock when possible to increase stability. 1910.176(b) requires stored tiers to be interlocked where needed for stability.

• Use interlocking for cartons, bricks, or bundled materials: offset seams between layers to prevent vertical seams.
• Combine interlocking with blocking, strapping, or shrink-wrap for additional stability.

Cite: 1910.176(b).

Yes; clearance signs must be provided and visible under the conditions where they are needed to warn employees and equipment operators of clearance limits. 1910.176(e) requires clearance signs to warn of clearance limits.

• Ensure signs are reflective, illuminated, or accompanied by physical markers (e.g., hanging bars) where lighting is low or during night operations.
• Regularly inspect signs for visibility and replace faded or obstructed signs promptly.

Cite: 1910.176(e).

The employer must provide derail and/or bumper blocks where a rolling car could enter a building, work, or traffic area. 1910.176(f) specifies that derails/bumper blocks shall be provided on spur tracks in those situations.

• Employers should evaluate spur track layouts and install appropriate devices to stop or divert unintended rolling cars.
• Maintain derails/bumper blocks and train employees in their operation as part of safe switching procedures.

Cite: 1910.176(f).

Yes; when material handling creates a potential for head injury from falling objects, employers must ensure affected employees wear protective helmets. While 1910.176(g) requires guarding of pits and openings, OSHA's head protection rule and interpretation make clear head protection applies where overhead hazards exist. OSHA's interpretation on crane operations explains that 29 CFR 1910.135(a)(1) requires helmets where there is potential for head injury from falling objects and that employers must assess the workplace and require head protection when hazards exist (see OSHA letter on head protection for crane operators at https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2).

• Perform a hazard assessment to determine whether overhead lifting creates a falling-object hazard.
• Provide helmets that meet ANSI Z89.1 consensus standards and require their use for employees exposed to overhead hazards.
• Where possible, limit loads being carried over personnel in accordance with crane operation rules.

Cite: OSHA head-protection interpretation at https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2 and 1910.176(g).

Yes; if the lanes are permanent passageways used by mechanical handling equipment, they must be appropriately marked. 1910.176(a) requires permanent aisles and passageways to be marked, and 1910.176(b) requires storage not create hazards that could obstruct those aisles.

• Mark forklift lanes using paint, signs, or physical separation; indicate direction, speed limits, and pedestrian crossings.
• Keep marked lanes free from stored materials, debris, and parked equipment.

Cite: 1910.176(a) and 1910.176(b).

No; storage must not create hazards, including blocking exits or access to fire protection equipment. 1910.176(b) says storage shall not create a hazard, and 1910.176(c) requires areas be kept free of accumulations that constitute fire hazards.

• Maintain clear access to exits, fire extinguishers, alarm pull stations, and sprinkler control valves at all times.
• Follow local fire code and egress requirements in addition to OSHA standards.

Cite: 1910.176(b) and 1910.176(c).

An acceptable cover must protect personnel from falling into the opening and be secure and strong enough to support expected live loads. 1910.176(g) requires covers and/or guardrails to protect personnel from hazards of open pits, vats, and ditches.

• Covers should be anchored or otherwise prevented from accidental displacement.
• Use rated materials sized to support workers, equipment, or both as necessary.
• Mark removable covers and train employees in safe procedures for removing and replacing them.

Cite: 1910.176(g).

No; irregular or fragile items should not be stacked to heights that would make them unstable—stacks must be limited in height to remain stable and secure. 1910.176(b) requires stored tiers to be stable against sliding or collapse.

• Store irregular or fragile items on shelving, in bins, or on racks designed for their shape and weight rather than in tall open stacks.
• Use additional restraints (strapping, shrink-wrap, partitions) if vertical storage is necessary.

Cite: 1910.176(b).

Aisles and passageways should be inspected regularly and repaired or cleaned as needed to remain clear, safe, and in good repair. 1910.176(a) requires aisles to be kept clear and in good repair.

• Perform daily visual checks in active areas and more formal inspections weekly or monthly depending on traffic and operations.
• Promptly repair surface damage, replace worn markings, and remove accumulations of debris or spilled materials.
• Document inspections and corrective actions as part of a facility safety program.

Cite: 1910.176(a).