Pre-Task Plan: Material Handling

Date: [DATE] Work Area: [WORK AREA] Task Supervisor: [SUPERVISOR NAME]

1. Task Description

[Moving materials from one location to another, including manual lifting and using equipment.]

2. Task Duration

Estimated Start: [START TIME] Estimated Completion: [END TIME]

3. Personnel Involved

• [Equipment Operator]
• [Spotter]
• [Laborer]

4. Task-Specific Hazards and Controls

Hazard	Risk	Control Measures
Manual lifting of heavy objects [1]	Musculoskeletal injuries (MSIs) [2]	Use mechanical aids where possible. Assess the load before lifting, considering weight, size, and shape [2]. Use proper lifting techniques, and ensure training in safe lifting methods [1].
Motorized equipment operation [3]	Collisions, equipment malfunction	Ensure equipment is inspected before use [4]. Clearly mark pathways and maintain sufficient clearance 3, 7. Use a spotter when visibility is limited.
Improper storage of materials [5]	Materials falling, tripping hazards	Stack and secure materials to prevent sliding or collapse 6, 20. Keep aisles and passageways clear 9, 12. Do not exceed maximum safe load limits of floors 5, 20.
Use of damaged or inappropriate rigging equipment [4]	Load dropping, equipment failure	Inspect rigging equipment before each shift and remove any defective equipment from service 6, 13. Ensure rigging equipment has legible identification markings indicating the safe working load 6, 13. Never exceed the recommended safe working load 3, 6, 13.
Exposure to hazardous materials [1]	Health hazards, chemical burns	Review Safety Data Sheets (SDS) for proper handling and storage. Use appropriate PPE as indicated by the SDS. Ensure adequate ventilation.

5. Required PPE for Today's Task

• [Gloves]
• [Safety glasses]
• [Steel-toe boots]
• [High-visibility vest]
• [Respirator (if required by SDS)]

6. Tools and Equipment Needed

• [Forklift/Pallet Jack]
• [Hand Truck/Dolly]
• [Lifting straps/Slings]
• [Dockboards/Bridge Plates]

7. Pre-Start Checklist

Area Preparation

• Clear pathways and storage areas of obstructions 5, 12
• Ensure adequate lighting in the work area [5]
• Check floor load limits and ensure they are not exceeded 5, 20

Equipment Checks

• Inspect material handling equipment (forklift, pallet jack) for proper functioning 6, 13
• Verify rigging equipment (slings, chains) is in good condition and rated for the load 6, 13
• Ensure dockboards are secured and in good condition 6, 13

Communication

• Review task-specific hazards and controls with all personnel
• Establish clear communication signals between equipment operators and spotters [3]

8. Task Steps Overview

1. Assess the load for weight, size, and stability [2].
2. Select appropriate material handling equipment and PPE [4].
3. Clear the path and ensure adequate space for movement 3, 5, 12.
4. Lift and move the material using proper techniques or equipment [1].
5. Securely store the material in the designated area 5, 20.

9. Emergency Response for This Task

• Material falling → Clear the area immediately and assess for injuries.
• Equipment malfunction → Stop operation and report the issue to the supervisor.
• Chemical spill → Evacuate the area and follow spill control procedures.

10. Task-Specific Precautions

• Never exceed the safe working load of equipment or rigging 3, 6, 13.
• Use a spotter when operating equipment in congested areas or with limited visibility [3].
• Avoid manual lifting when mechanical aids are available [1].

Pre-Task Briefing Confirmation

All workers understand the task, associated hazards, and required controls.

Team Lead Initials: [___] Date: [DATE] Time: [TIME]

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