LEARNER GUIDE

Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

LEARNER GUIDE

Operate moving equipment to stack,

de-stack and position materials.

Unit Standard Title: Operate moving equipment to stack, de-stack and position materials

Unit Standard ID No: 12207

Unit Standard Credits: 04

NQF Level: 02

Duration:

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

Course Objectives
The objectives of this course are:

 To indicate what the OHS Act requirements are in terms of safe stacking and storage.
 To instruct persons in the following:
- Principles of safe stacking and storage.
- Principles of stacking of different types of goods.
- How to conduct storage inspections.

Course Outcome
At the end of this course participants will be able to explain –

- Stack and de-stack goods.

- Inspect stacked and stored goods.
- Segregate goods for stacking, and ensure that goods are stored correctly.
- Ensuring that stacking & storage is done in a safe and healthy manner.

Introduction
 Stacking and storage of goods and materials happens in all businesses.
 Poor stacking and storage practices account for many serious and fatal injuries each year.
 There are a wide variety of storage systems and stacking methods available.
 Materials handling equipment is very diverse, and persons need to be trained in the use
thereof.
 Legal requirements include:
- OHS Act, no 85 of 1993 and regulations –
1. General Safety Regulation
2. Environmental regulations for Workplaces
3. Noise induced hearing loss regulations
- SANS 10263: The warehousing of dangerous goods
- CKS 370: Adjustable steel shelving

OHS Act – General Safety Regulations

 GSR 8(1): “Stacking of Articles”

- Stacking operation executed under supervision – person with specific knowledge and
experience.
- Base to be level and able to sustain weight of stack.
- Articles on lower level can sustain weight above.
- All articles on each tier to be the same size, shape and mass.
- Pallets and containers in good condition.
- All support structures sound and in good condition.

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

 GSR 8(2) and (3): “Stacking of Articles”

- Articles to be removes from top of stack only.
- Nobody to climb on stack unless by ladder or other safe means.
- Persons engaged in stacking do not come within reach of machinery which may
endanger their safety.
- Stacks in danger of collapse to be dismantled in a safe manner.
- Vehicles and machinery not to endanger stacks

 GSR 8(2) and (3): “Stacking of Articles”

- Stacks containing sacks, cases, cartons, tins or similar to be –
o Secured by laying articles in a header and stretcher fashion, with corners bonded.
o Stepped back half the depth of the container, every 5th tier, or at alternate tiers – to
achieve an angle of inclination to the vertical.
o Regular shaped containers may be stacked vertically, if the stack is stable.
o Vertical sides of stacks may not exceed 3 x the smaller dimension of the base of the
stack.

 GSR 8(5): “Stacking of Articles”

- Free standing stacks built with the aid of machinery, may be built to a height approved
by an inspector, provided that –
o Stacks are stable and do not overhang.
o Operators of machinery are rendered safe from falling objects.

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

A Safe System of Work

 Goods, materials, substance and equipment to be stored, stacked, and secured so as not to
be a danger to person.
 All stacked, stored & secured items shouldn’t flow, roll, move/collapse & constitute a danger
to people.
 All persons involved in stacking, storing and securing items to be fully trained in safe work
methods.
 A safe system of work is required to integrate, persons, materials and machinery to ensure a
safe and healthy work environment.

People
 People cause the majority of incidents and damage to property.
 People to be trained and instructed in safe work procedures (SWP).
 Comprehensive planning of work to be undertaken.
 Adequate supervision and control to be implemented and monitored.
 Adequate information to be passes onto employees regarding safe work practices.

Manual Handling
 Manual handling includes lifting, lowering, pulling, pushing, carrying,
moving, holding or restraining an object.
 Injuries and musculoskeletal disorders affect the back, neck, shoulders,
arms & hands.
 Lifting over 25kg load can result in back injury.
 Every situation must be assessed in order to identify the correct posture,
job design, equipment and/or methods to use.
 Posture:
- Keep heavy loads around waist level.
- Always keep your back straight while lifting.
 Equipment use:
- Hand trolleys.
- Pallet turntable bring the load closer.
- Use of levers reduce the force
required.
- Conveyor belts eliminates lifting.
- Forklift, cranes, etc.

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

 Job Design:
- Team handling for heavy or odd shape loads.
- Breaks to reduce muscular fatigue.
- Handlers job rotation between heavy and light activities.
- Rearrange workplace to reduces twisting, stretching & stooping.

Incidents
 Pallets and racking systems are common to many materials handling and storage systems.
 Incidents occur due to:
- Poor pallet design.
- Poor pallet construction.
- Use of unsuitable pallets for load or storage method.
- Continued use of damaged pallets.
- Bad handling of pallets.

Racks & Shelves

 Racking systems failures – six reasons
- Design fault (rack is inherently unsafe)
- Installation fault.
- Material handling equipment fault.
- Material handling equipment operator fault.
- Supervisor’s negligence.
- Store and warehouse structural fault.

Equipment and Environment

 Equipment – a wide range is available, e.g.
- Pallet jacks / trucks.
- Forklift trucks.
- Stackers.
- Hand driven trolleys / motorised trolleys.

- Warehouse robots.
 Environment
- Good lighting and ventilation
- Good housekeeping.

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

Floors / supporting surfaces

 Floor loadings are critical.
 Level floors are essential.
 Stacks may be supported off the floor using timber or concrete.
 Floor to be strong enough to support extra weight such as waterlogged material due to rain,
loaded vehicles, etc.

Rack & Shelve Design

 Adequately designed to contain materials.
 Water tight if required.
 Able to handle shock loading from placing materials.
 Able to handle accidental contract from handling equipment.
 Partitions to be sufficient strength to contain stored material.
 Fire-protective partitions to be used for combustibles
 Corners/ ends of shelving / racks to be protected from damage.

Pallet Construction and Loading

 Pallets to be of sound construction/ strength.
 Pellets on lower tiers to be able to support weight above.
 Stability of stacked pallets to be maintained by bonding.
 Avoid excessive stack heights.
 Pallets can be shrink wrapped, taped, bonded to increase stability.
 Defective pallets to removed from stacks.

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

Types of Stacks
 Stacks can be categorized as follows:
- Column – Single articles placed one above the other.

- Square – Any stack, other than a column, with all sides

vertical. (Note the stack does not have to be ‘square’ in the
ordinary sense of the word.)

- Pyramid – a stacking which the plan area is reduced in

every succeeding tier.

- Stepped – Stacks with two or more adjacent tiers of

the same area and each succeeding group of tiers of a
smaller area than the group on which it is set.

- Triangular – Stacks in pyramid of stepped form on two

opposite sides, the other two sides
being vertical.

- Lean-to – Pyramid or stepped on one side and vertical on the other three sides.
(Note the term against a support.)

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

Positioning of Stack
 No stacks to be built within 450mmfrom a wall – this gap enables to be checked.
 Stacks not to be erected within 1,5m of a rail track.
 Stacked articles not to be subjected to vibration – sacks or bales, will creep and lose stability.
 Stacks, shelving and other fixtures to be so laid out to ensure sufficient access for safe
loading/ unloading by manual/ mechanical means.
 1m clear space around all stacks – good
must not be stacked within 1m of ceiling,
roof or sprinkler heads.
 Stacks not to be created which block
gangways, aisles, walkways, thoroughfares,
doors and exits.
 Storage areas to be specifically designated,
clearly marked, and be in the charge of a
responsible person – aisles to be marked, be
of adequate width and kept free of
obstacles and waste materials.
 Base areas and stack heights to be kept as
small as possible.
 Goods to be kept clear of lights, piping, appliances, fire fighting and alarm equipment and
doors.
 No stack, shelving, fixture to be placed in a position or extended in height that it or a person
or machinery can come into contact with live electrical conductors.
 No materials to be loaded/ unloaded from stacks, shelving or fixtures if contact with live
electrical conductors or unguarded machinery is possible.
 Storage racks, shelves to be non-combustible and not to retain water.
 Where un-palletized material (sacks etc.) is handled by cranes, lift trucks, it should be placed
on battens to aid the use of slings or forks.
 Suitable means to be used to protect workers from injury due to sharp corners to be clearly
marked.
 Safe access by means of ladders, platforms or walkways to be provided for workers who
climb on and remove goods from stacks.
 Safety harnesses and scaffolding may be used for high stacks
and awkward shapes.
 Work platforms used with lift trucks to be approved by an
inspector.
 Marking labels/ identification signs on stacked articles to be
clear and easy to read.

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

Stability and Bonding of Stacks

 Stable construction of stacks is dependent on the following:
- Safe relation of height to dimension of base.
- Sound interlocking of goods.
- Contents of sacks or cartons.
- Compact construction and avoidance of any stress.
- Shape of articles (meat carcasses etc.)
 Determination of the aggregate weight on lower tiers.
 Good placing of all components of the stack-on overhanging on any side of the stack.
 Stability of stacks maintained by bonding, stepping, tying or other means.
 Height to base ratio not to exceed 3:1.
 Shape of goods or packages will have a bearing on the type of bonding to be used.
 Natural bonding occurs when articles can be interlocked themselves – this creates stack
stability.
 Artificial bonding occurs when other materials (battens, piling sticks, etc.) are used to
stabilize the stack.
 Outdoor stacks are affected by weather if left open and the stability of stacks may be
compromised.
 In windy conditions, materials may have to be fastened down to prevent them from being
blown away.

Bagged Goods
 Bags to be spread flat.
 Interlocking to be done if possible.
 Mouths of bags to be on inside of the stack.
 Bagged material of differing sizes, (seeds, granules, etc.) not to be stacked on top of each
other unless movement by settling and vibration can be controlled – use of pallets or
bonding can prevent this.
 New synthetic bags, sacks will slip when new.

Cartons and Cases

 Cartons
- Weight exerted on lower cartons is critical.
- Dampness will reduce strength of cartons.
- Reduced strength will cause collapse of stack.
- Interlocking of stacked cartons may be used.
 Cases (boxes)
- Most boxes are reinforced with external battens
- Stack on battens not the boxes.

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

Cases and Frozen Carcasses

 Bales
- Stacks should lean into their centre.
- New synthetic bales will tend to slip.
 Frozen Carcasses
- Can be interlocked due to their shape.
- Mesh netting can be used to retain carcasses on pallets – hygienic considerations.

Wire, Bottles and Jars

 Coiled wire
- Can be stacked vertically or horizontally –
 Wedges, chocks, stakes, etc., to be used to prevent spreading.
 Glass Bottles and Jars
- Small quantities can be laid on their sides on top of each other using wedges.
- Normally stacked in cases, boxes, cartons, racks specifically designed for this
purpose.

Drums & Cylindrical Objects

 Drums and cylindrical objects
- May be stacked on end or on their sides.
- If stacked on their sides, wedges to be placed at
the ends of each row to prevent movement.
- If stacked on end, chains or other means to be
provided to prevent toppling.
- Valves of gas cylinders under pressure to be
protected. – SANS 10263-2
- Pipes and drums can be stacked on end – provided that suitable equipment is
available to work safely – space is saved.

Sheet Materials
 Sheet Materials
- Metals, glass, etc. can be stacked flat or on edge.
- Sharp edges to be protected to prevent injuries.
- Suitable support to be used for edge stacking.
- Racks and floors not to be overloaded.

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

Sawn Timber and Board Materials

 Sawn Timber and Board Materials
- Floors/ ground to be flat and even, with a minimum slope of 2%.
- Top surface to be asphalt, tarmac or concrete, well maintained with no potholes.
- Ground to be consolidated, well drained, its stability not to be affected by weather
conditions, and strong enough to withstand stack load and that of machinery.
- External stacks may be affected by wind – place stack “head on” to prevailing wind.
- Check external stacks after high winds/ poor weather.
- If stacks are covered, check attachments to covers etc.

Bearers
 Bearers
- Bearers support packs of timber; they keep them off the
ground and allow lift trucks to lift the packs.
- All bearers to be straight, equal in length and must have a
square cross section, in good condition and strong enough to
handle the load.
- Bearers to equal length of pack – if too long, it will protrude
and cause incidents.
- Bearers to be positioned correctly to avoid offsets in the stack.

Banding
 Banding
- Used to secure packs, bands can be polyester, metal, polypropylene, etc.
- Bands to be re-fitted if shrinkage or expansion occurs.
- Bands to be fitted squarely to the face of the pack, use branding fasteners.
- Use eye protection when bands are removed.
- Bands to be inspected regularly, and re-banding to be carried out if required (loose,
broken, etc.)

Stack Height and Stacking Practices

 Indoors the height of stacks not to be more than ratio of 3:1.
 Risk assessment may reduce stack height to ratio of 2:1, e.g. vehicle access, public access,
etc.
 Balled, rolled packs or offset bearers may reduce stack height ratio to 2:1.

Safe Work Practices

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

 Un-stacking/ de-stacking
- Before un-stacking, check for instability or stack faults such as broken bands, bearers,
sticks, pack balling, etc.
- Take down packs tier by tier – move only one at a time.
- Do not remove individual pieces of timber.
- To access top of stack, use secured ladder, mobile elevating work platform, or work
platform on lift truck (approved cage).

Rules for un-staking (dismantling)

 Un-stacking is the reverse of stacking.
 Most incidents occur due to the collapse of stacked material during un-stacking.
 The rules are –
- One person only to be responsible for un-stacking: - especially when groups are
employed.
- If the person in charge of un-stacking had no role in erecting the stack, he must
familiarize himself before work begins.
 Stacks to be taken down tier by tier.
 When large stacks are Dismantled, work should be from the centre outwards, to prevent
persons from falling off.
 If fencing has been erected around stacks, it must be dismantled and adjusted as the stack
height is decreased.
 Systematic work methods are essential on stacks, as there are high tripping hazards.
 All persons and equipment must at all timed be clear of overhead cranes and electrical
installations.
 Proper signalling arrangements must be put in place if required.
 All stacking and un-stacking must be carried out under competent supervision.

Storage Area Management and Layout

 Assess vehicle movement in and around storage are.
 Good visibility required for pedestrians and vehicles.
 Designate walkways for pedestrians.
 Reduce blind spots, install mirrors on vehicles and in the storage are.
 Institute speed restrictions for vehicles – also install reverse alarms.
 Roadways, aisles to be strong enough to withstand weight of loaded vehicles.
 Roads, floors aisles to be maintained, repair potholes, etc.
 Regular stack inspections will identify faults.

Inspection and Maintenance

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

 Frequency of inspection depends on usage, generally heavily used raking systems should be
visually inspected daily by experienced personnel.
 All connections must be inspected to ensure that bolts and other structural members are not
loose or damaged.
 Almost 90% of damage occurs between floor and 1st horizonal beam.
 Components that are severely buckled or bent must be replaced.
 Components that are dented or slightly skewed may be corrected by adding bracing strong
enough to carry the intended load.
 Stored materials to be inspected regularly to determine if they are susceptible to damage,
heat, deterioration, swelling, shrinking, corrosion or attack by insects or rodents.
 All identified hazards should be eliminated.
 Incoming goods should be inspected for damage prior to storage.
 Racks, shelving, fixtures and other equipment should be inspected regularly for damage and
other defects.
 All defective equipment should be taken out of service until repaired.
 All electrical equipment and fittings to be inspected and tested.
 All fire protection equipment including fire doors etc. to be inspected, tested and maintained
in good working order.
 Fire doors to kept closed at all times, unless required to be opened.
 All repairs, maintenance or alteration work in storage areas to be closely monitored.
 Hot work permit system to be used where required.

Segregation of Stock
 Flammable Liquids, gas cylinders, aerosols, materials liable to spontaneous combustion and
hazardous chemicals must not be stored in the same area as other goods.
 Chemicals liable to react with each other or other materials should not be stored together,
unless adequately protected from contacting each other directly or by spillage.
 Acids should not be stored in plastic containers for long periods or in direct sunlight.
 Flammable liquids in drums, cans or similar containers, as well as toxic or poisonous
chemicals/ substances should be stored separately in a purposely designed building.
 Flammable storage areas and buildings must be adequately signposted regarding the
contents therein, and that naked flames and smoking is prohibited.
 All electrical installations should be explosion. Fire proof, and protective equipment for
emergencies should be available.
 All containers, drums, cans should be clearly labelled.
 Workers handling corrosives and hazardous chemicals
should be stored in well ventilated areas out of direct
sunlight, and well away from sources of ignition.
 Earthing or bonding should be used to eliminate static
build-up

Fire Safety

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

 Fire instructions to be prominently displayed in all storage areas.

 Workers to be trained in the operation of ire alarms and emergency evacuation
procedures.
 “No Smoking” – rules to be strictly enforced in all storage areas.
 Shrink wrapping operations to be under the supervision of competent persons – the
shrinkage process involves heat.
 No plant or production processes should be allowed in storage areas.
 Vehicles should not be garaged or refuelled close to stored goods/ materials.
 An inventory of all goods held in store to be maintained daily.
 Local Fire Brigade to be notified of quantities of hazardous chemicals/ substances and
flammables stored on site.
 Movement of large quantities of such goods should be notified to Local Fire Brigade
immediately.
 Smoking not permitted within 6 meters of stacks, no naked lights.
 Fire breaks kept around outdoor stacks.
 Bulk storage of combustibles to be sited so as to minimize risk of fire occurring within the
stack or spreading from adjacent areas.
- Clearance distances are vital between stacks and perimeters.

Materials Handling Equipment

 Materials Handling Equipment is legislated in terms of regulation 18 of the Driven Machinery
Regulations –
- “Lifting machines and lifting tackle”.
 Trolleys, hand trucks, pallet trucks, chain blocks, slings etc., which are used for stacking and
storage operations, to be kept in a serviceable condition.
 Workers to be trained in the safe use of such equipment.
 Mechanical equipment such as cranes, hoists, scoops, stackers, lift trucks, ladders etc., to be
kept in a serviceable condition, and be inspected regularly.
 Materials handling equipment to be used only for the purpose for which it is designed.
 No persons to ride on equipment used for moving, handling or storing materials unless it is
designed for the purpose.
 All equipment to be operated in a safe manner, and not be overloaded.

Safe Stock Movement

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

 Goods must be stacked to prevent movement during transport, and be secured to prevent
falling from vehicles.
 Workers must be protected from moving vehicles in storage areas.
 Good lighting to be installed in storage
areas, worker to be issued reflective
clothing- if required.
 Lift trucks to be fitted with hooters and
lights – for reversing purposes.
 Flammable liquids to be handled with
great care.

Housekeeping
 Housekeeping is legislated in terms of regulation 6 of the Environmental Regulations for
Workplaces:
- “Housekeeping”
 Waste should not be allowed to accumulate.
 Regular waste removal and cleaning programs should be maintained.
 Storage refuse, insects, rodents and incorrectly stored materials.

Lighting
 Lighting is legislated in terms of regulation 3 of the Environmental Regulations for
Workplaces:
- “Lighting”
 Sufficient and suitable lighting to be provided (natural or artificial) to all storage areas.
 Dark shadows and glare should be avoided in the working and storage areas.
 Lighting may be supplemented by painting appropriate surfaces white or off-white.

Noise
 Noise is legislated in terms of the Noise Induced Hearing Loss Regulations.
 Only approved hearing protection to be provided to all relevant employees.
- Ear Muffs,
- Ear Plugs, or
- Custom made ear protection
 Employers are required to take all practical steps to protect workers from harmful noise.
 Employers are required to control noise in the workplace via engineering methods or similar.
 If noise control is impossible or practicable, control Measures must be implemented.

Protective Clothing and Equipment

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 LEARNER GUIDE
Operate moving equipment to stack, de-stack and position materials

NQF Unit Standard ID No: 12207 NQF level 2 Credits 4

 Protective clothing and equipment are legislated in terms of regulation 2 of the General
Safety Regulations –
- “Personal Safety Equipment and Facilities”
 Employees shall be trained in the use, care and maintenance of the equipment issued.
 Where hazardous chemical substances are stored (acids), emergency showers, eye wash
fountains must be provided.
 Protective clothing and equipment shall be issued if required – this could include overalls,
gloves, aprons, gauntlets, safety helmets, ear protection, eye protection, safety footwear,
face masks, respirators, safety harness, etc.
 Employees shall wear this equipment when necessary.

Training of Employees
 Training of employees is legislated in terms of Section 8: “General duties of employers to
their employees” in the OHS Act, 1993.
 Fire teams to be selected and trained.
 First aid training to be carried out.
 Employees involved in storage, stacking, loading and unloading of materials, must be trained
to carry out these tasks safely.
 They must be informed of the nature of the stored goods, hazards involved, and the
precautions to be taken.
 They must be informed of the protective clothing and equipment to be issued and worn, as
well as the action to be taken in event of emergencies.
 Employees who operate mechanical equipment need special training.
 Employees must be trained to deal with breakages, spillages, and neutralizing of hazardous
chemicals and substances.
 Fire fighting and emergency procedures should be explained to all personal.
 Practical fire fighting training to be carried out.

Conclusion
 Employers/ Employees involved in stacking and storage activities, should have the necessary
skills to be able to work safely.
 Employers/ Employees should have the necessary knowledge to be able to manage their
stacking and storage operations in a safe and efficient manner.
 Safe work procedures should be drawn up and put into place for stacking and storage
options.
 Monitoring of stacking and storage operations are critically important.

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