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Safe Practices in Material handling

Know How to Do It Right! Then Do It Right!

MATERIAL HANDLING FACTS


Material Handling accounts for more than 20 25 % of all occupational injuries.

50 to 180 Tons of material is moved for

each ton of product produced

Strain, sprain, fracture, contusion, health problems, fire and explosion may be

resulted due to wrong method of material


handling

Job Site Considerations


The handling, setting and erection of materials and equipment is a hazardous occupation. Each operation presents its own peculiar problems and no two jobs are alike. With proper consideration taken, each job can be performed free of bodily harm to the employee and without damage to the equipment.

Job Site Considerations


The person authorized and qualified in material handling must always pay close attention to details. One careless moment or act can result in serious injury or death and tremendous property damage. Proper material handling is an art and should never be left to the inexperienced. If anyone dont know how to do it properly, then dont attempt it.

Injuries
Lifting objects is a major cause of back injuries in the work place
Improper storing and handling of material and equipment can cause struck by and crushed by injuries

Hazards

Improper

manual lifting or carrying loads that are too large or heavy Being struck by materials or being caught in pinch points Crushed by machines, falling materials or improperly stored materials Incorrectly cutting ties or securing devices

MATERIAL HANDLING

Manual Handling Mechanized material Handling


Powered Industrial Trucks Conveyers Elevators EOT Cranes, winches Lifts Hoists Chain pulley blocks Pneumatic conveying Pumps and pipe lines

Manual Handling aids

Definition of Manual Handling

The transporting or supporting of a load by hand or some other part of the body including the lifting, putting down, pushing, pulling, carrying, moving or intentionally dropping or throwing a load

Manual Material Handling


Consider the following Can the job be engineered to eliminate the manual handling Can the material be moved mechanically Can the employees be given handling aids, such as properly sized boxes, adequate trucks, hooks, barrel lifters etc. Will protective clothing, or other personal protective equipments help prevent injuries?

Manual Material Handling Tips


Following Tips can be given to those who handles materials Inspect material for sliver, jagged or sharp edges, burrs, rough or slippery surfaces. Grasp the object with firm grip Keep fingers away from pinch and sheer points especially when setting down the materials When handling lumbers, long objects, keep hands away from the ends to prevent from being pinched. Wipe off greasy, wet, slippery or dirty objects before trying to handle them. Keep hands free of oil and grease. Use COMPATIBLE PPES, personal protective equipments help prevent injuries?

Back Injuries are the 2ndmost common workplace problem

A back injury costs very


high in medical claims and lost time wages.

Most back injuries can be


prevented

(200 lbs.)

Lever effect -- can magnify weight by factor of up to 10


(40 lbs.)

100 lbs. 10 lbs.

Use Your Head and Save Your Back! Bend your knees not your back! Get Help with heavy or awkward loads!

Means using your head! Let your legs do the lifting Use the right tools!

STAND close to the load

Carrying the load


Hold the load close so you can see over it.

Keep the load balanced.


Avoid twisting the body Watch out for pinch points -- doorways, etc.

Face the way you will be moving.

For those Awkward Moments...


If you must lift or lower from a high place:
Stand on a platform instead of a ladder Lift the load in smaller pieces if possible Push the load to see how heavy and stable it is. Slide the load as close to yourself as possible before lifting up or down. Get help when needed to avoid an injury.

From hard-to-get-at places...


Get as close to the load as possible Keep back straight, stomach muscles tight Push buttocks out behind you. Bend your knees Use leg, stomach, and buttock muscles to lift -- not your back.

Personal Protective Equipment

For loads with sharp or rough edges, wear gloves or other hand and forearm protection When loads are heavy or bulky, wear steel-toed safety shoes to prevent foot injuries if the load is dropped

Materials Handling Equipment

Employees must be trained in the proper use and limitations of the equipment they operate This includes knowing how to effectively use equipment such as forklifts, cranes, and slings

(1) the following provisions shall be complied with in respect of


every lifting machine and every chain, rope and lifting tackle for the purpose of raising or lowering persons, goods or materials:(a) all parts, including the working gear, whether fixed or movable, of every machine and every chain, rope or lifting tackle shall be(i) of good construction, sound material and adequate strength and free from defects; (ii) properly maintained; and

(iii)thoroughly examined by a competent person at least


once in every period of twelve months, or at such intervals as the Chief Inspector may specify in writing; and a register shall be kept containing the prescribed particulars of every such examination b)No lifting machine and no chain, rope or lifting tackle shall, except for the purpose of test, be loaded beyond the safe working load which shall be plainly marked thereon together with an identification mark and duly entered in the prescribed

register and a table showing the safe working loads of every kind and size of lifting machine or, chain, rope or lifting tackle in use shall be displayed in prominent positions on the premises;
(c)While any person is employed or working on or near the wheel track of a traveling crane in any place where he would be liable to be struck by the crane, effective measures shall be taken to ensure that the crane does not approach within six meters of that place.

Forklifts

Center the load on the forks and as close to the mast as possible to minimize the potential for the truck tipping or load falling Overloading a lift truck makes it hard to control and could make it tip over Place the load at the lowest position for traveling Dont place extra weight on the rear of a counterbalanced forklift to allow an overload

Operating a Forklift Safely


Keep arms and legs inside the truck Handle only stable loads Keep speed low - you may have to stop Be careful when making sharp turns with a raised load If a load blocks your view, travel in reverse No riders, unless theres an approved seat Dont drive with forks raised Wear safety belts or other restraint devices

Industrial Cranes

Overhead Cranes Common in industrial facilities Supported by overhead rails Components Bridge Trolley Hoist Often pendant or remote operated Easy to use, little training required, no stability problems

Industrial Cranes
Gantry cranes Similar to overhead cranes, but supported by a mobile frame which travels on the ground
Small (1000 10,000 pound capacity) gantry crane Large (600 ton capacity) gantry crane

Industrial Cranes

Jib cranes Pivot mounted boom with trolley and hoist

Floor-mounted jib crane Wall-mounted jib crane

Industrial Cranes
Power hoist Usually electric or air operated Chain hoist (or "chain fall") Hand operated

Rigging Equipment Slings


Types of slings covered are those made from alloy steel chain, wire rope, metal mesh, natural or synthetic fiber rope, and synthetic web.

Chain

Wire rope

Metal mesh

Synthetic

Basic Sling Operating


Whenever any sling is used, the following practices shall be observed!
1. Slings that are damaged or defective shall not be used.

2. Slings shall not be shortened with knots or bolts or other makeshift devices.

Basic Sling Operating Practices


3. Sling legs shall not be kinked. 4. Slings shall not be loaded in excess of their rated capacity. 5. Slings used in a Basket Hitch shall have the load balanced to prevent slippage. 6. Slings shall be securely attached to the load.

Basic Sling Operating Practices


7. Slings shall be padded or protected from the sharp edges of their loads.
8. Suspended loads shall be kept free of obstructions. 9. All employees shall be kept clear of loads about to be lifted and of suspended loads.

Basic Sling Operating Practices


10.Hands or fingers shall not be placed between the sling and its load while the sling is being tightened around the load.
11. Shock loading is prohibited. 12. A sling shall not be pulled from under a load when the load is resting on the sling.

Basic Sling Operating Practices


INSPECTION
Each day before being used, the sling and all fastenings and attachments shall be inspected for damage and defects by a competent person designated by the employer. Additional inspections shall be performed during sling use as often as necessary to assure the safety of the operation.

Basic Sling Operating Practices


REPLACEMENT Severe localized Abrasion or Scraping.

Ten Randomly Distributed Broken Wires in one Rope Lay, or Five Broken Wires in One Rope Strand in One Rope Lay.
Evidence of Heat Damage. (Cut with a Torch)

Basic Sling Operating Practices


REPLACEMENT
Kinking, Crushing, Birdcaging, or Any Damage Resulting in Distortion of the Rope Structure. Damaged, Distorted or Field Welded Hooks.

Damaged or Worn End Attachments.


If In Doubt, Dont Use It!

Definitions
Balanced load equally distributed on each side of the point of support. Breaking strength the approximate point, when under maximum load, the load handling device fails.

Definitions
Balanced load equally distributed on each side of the point of support. Bridle sling A sling composed of multiple legs gathered in a fitting that goes over the lifting hook. Competent person selected or assigned by the employer as being qualified to perform a specific job. Factor of safety ratio of breaking strength to the force to be applied.

Definitions
Hitch Basket - loading with the sling passed under the load and both ends on the hook or a single master link.

Definitions
Hitch Choker loading with the sling passed through one eye and suspended by the other.

Definitions
Hitch Vertical loading with the the load suspended vertically on a single part or leg of the sling.

Definitions
Master link a steel link or ring used to support all legs of a chain or wire rope sling.

Mousing lashing between the neck and the tip of a hook to prevent the load coming off. Rated capacity the maximum allowable working load.

Definitions
Rigging the connecting of a load to a source of power so that it can be lifted and moved safely and predictably. Safe working load the maximum allowable working load established by the manufacturer. Sheave a wheel with a grooved circumference over which a rope is bent.

Definitions
Wire rope consists of many individual wires laid into a number of strands which are in turn, laid around a center core.

Safety Factors
To guard against failure of a wire rope in service, the actual load on the rope should only be a fraction of the breaking strength. The safety factor includes reduced capacity of the rope below its stated breaking strength due to wear, fatigue, corrosion, abuse, and variations in size and quality.

Wire Rope Construction

Wire Rope Construction

Wire Rope Capacities

Wire Rope Capacities

Wire Rope Sling Capacities

Wire Rope Sling Choker Adjustments

Types of Wire Wire Rope Slings

Type of Wire Wire Rope Sling Damage

Birdcage damage

Type of Wire Wire Rope Sling Damage

Damage as a result of a kink in the wire rope

Synthetic Slings

Synthetic Slings
Sling capacity varies from manufacturer to manufacturer, no set standard like wire rope has. User must look at Individual Sling Capacity Tag to determine Safe Lifting Capacity of that sling. If the Tag is not readable or is missing, Do not use it! Inspect sling before each days use, and as often as necessary during the day to assure safety of sling! Sharp edges can slice a sling in two without warning as the load is tensioned. Use softeners or padding on corners.

Chain Slings
Only Grade 8 or better ALLOY Chain can be used for overhead lifting purposes! All chain is not rated the same! Chain must have a capacity tag attached to it.

Chains will withstand more rough handling and abuse, but a chain with the same rated lifting capacity of wire rope will be much larger in diameter and heavier in weight. Chains must be inspected daily before use and as often as necessary during use to assure safety.
It is the riggers responsibility to do the inspections!

Chain Slings

Rigging Protection From Cutting or Slipping


Softeners, padding or use of blocking..

Protecting Rigging From Damage or Environment


Rigging components are expensive to buy and to replace!
Use them properly and store them properly! Keep wire rope slings lubricated and all rigging stored out of the weather. Treat the rigging as though your life depended on it! Because it does if it fails!

Dont use makeshift rigging or attempt to repair any rigging components.


Knots tied in rigging reduces the strength by 50% or more!

How Would You Rig This?


What would you need in the way of rigging materials?

How Would You Rig This?


What would you need in the way of rigging materials?

How Would You Rig This?


Would it matter if the tank were full or empty?

Removing Jewelry and Wearing Gloves!


Cause? Not wearing gloves and not taking off the ring.

Summary
Manually

handling materials When lifting objects, lift with your legs, keep your back straight, do not twist, and use handling aids Using cranes, forklifts, and slings to move materials Watch for potential struck by and crushed by dangers For slings, check their load capacity, inspect them, and remove them from service when they display signs of stress or wear Also Keep work areas free from debris and materials Store materials safely to avoid struck by/crushed by hazards

Any Questions?

If the student hasnt learned, the instructor hasnt taught!

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