Material Handling

Module 11 Material Handling

DISCLAIMER This material was produced under grant number SH-22248-1 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.

Objectives • After this module you should be able to • identify the most common material handling hazards • take the steps necessary to avoid those hazards

Crane Hazards • Improper loading • Not using outriggers or leveling crane • Not calculating load weight correctly • Lifting on unstable support surface • Working around powerlines • Damaged windows and other crane parts • No barrier around swing radius • No or poor regular inspections • No boom angle indicator • Wind and other side forces

Preplanning the Lift • Level the crane to within 1% and ensure support surface is firm, able to support the load • Know the location and voltage of any overhead powerlines; stay 10’ away • Barricade the area within the swing radius • Determine your pickup and drop locations • Calculate the weight of the load and determine how to safely lift that weight • Inspect the crane

Daily Crane Inspection • Some items to inspect include • tires properly inflated • clearance for tail swing • wire rope wear • physical damage to crane • loose or missing hardware • fluid leaks • Inspection must be done by a competent person • If it needs fixed, don’t use it until it is repaired

Load Weight • Refer to the shipping ticket or other documentation • Ensure load is within the load chart rating for the boom length and load radius the operator is using • remember that the crane is rated by the maximum weight it will lift at minimum boom length and minimum radius • the further from the crane’s center point the load is, the less the crane will handle safely

Load Limiting Factors • An operator must also consider the following when calculating for a safe lift • wind • side loads • on wheels or outriggers • lifting over the side • use of extensions, jibs, or other attachments • the limits of rigging • the actual weight of the rigging must be considered

the results of an improperly loaded crane are obvious

the crane operator must have reference to and be familiar with rated load capacities, operating speeds, and special hazard warnings

an illustration of the hand signals used in your company’s crane operations must be posted at the job site

do not stand under a suspended load at any time; use tag lines to guide the load

a warning barrier must be placed so that a worker will not enter the swing radius of the crane

this crane’s window is badly cracked Corrective Action: this crane must be taken out of service until the window is replaced

this crane’s outriggers are fully extended and the crane is level; therefore, it is stable

a boom angle indicator must be installed on every crane with variable angle booms

these sheaves are damaged which causes excessive wear on the wire rope Corrective Action: replace the sheaves when they are worn or broken or when their damage will cause damage to the wire rope

a thorough, annual inspection of the hoisting machinery must be made by a competent person the employer shall maintain a record of the dates and results of the inspections

Working Safely Around Rigging • General safety guidelines • keep at least 10’ away from powerlines • never hoist loads over workers • never stand too close or under a load • never ride a load • use sling angles greater than 45° • attach tag lines to control loads while lifting • test lift the rigging • use proper equipment (make sure it is marked, not homemade, and in good condition)

Rigging must be done under the supervision of a competent person The crane operator must be highly qualified and certified Improper rigging or unqualified operators can be deadly Can Anyone Rig or Lift Loads?

Sling Angle • The safest sling angles are greater than 45° from the horizontal • The ideal sling angle is 60° from horizontal

this pipe is about to be lifted with a makeshift chain sling; the chain is not lifting grade, has no markings, and is too short for a safe sling angle Corrective Action: use proper rigging and sling angle

all slings whether nylon, wire rope, or chain must have permanently affixed durable identification information includes the size, grade, capacities, and manufacturer; if you can’t read it, the sling should be pulled from service

knowing the sling’s capacity is important; capacity changes depending on how we rig the load; the same goes for wire rope and chain slings

makeshift slings and other rigging devices are unacceptable Corrective Actions: never try to repair a broken or badly damaged rigging device; use only approved rigging devices

Homemade Hooks • Job or shop hooks and links, or makeshift fasteners made from bolts, rods, etc., or other such attachments cannot be used

this heavily worn sling is a dangerous situation Corrective Action: inspections of rigging devices should be performed daily; defective rigging should be pulled from service and tagged, then destroyed

the shackle has an improper pin and the hook has a broken safety latch Corrective Action: replace both safety latch and shackle pin

Back injuries (the number one cause of worker compensation claims) Struck by or crushed by falling loads due to improper rigging and sling failures Electrocution due to power line contact Struck by falling materials which are improperly stored Slipping, tripping, and falling due to improper materials storage Material Handling Hazards

Manual Lifting Back Facts • 8 out of every 10 Americans will have a back injury during their lifetime • Approximately 1 out of 3 injuries at work are back injuries • Personal pain and inconvenience cannot be measured • Back injuries cost employers an estimated $10 billion each year

back strains are one of the most common injuries at any workplace use proper lifting techniques and don’t try to lift, by yourself, an object that is too heavy or bulky

Preventing Back Injuries • You can avoid back injuries by • using proper lifting techniques • keeping in lifting shape • using mechanical aids • working as a team while lifting • knowing the truth about back belts

Basic moves of a proper lift plan your lift use a wide-balanced stance get close to the load tighten your stomach muscles keep you back straight and use your legs turn with your feet; don’t twist your back keep the load close to your body avoid lifting above shoulder height Proper Lifting Technique

Material Storage • 5 basic rules for safe material storage • keep total weight within the safe loading limits of the structure’s floors • keep passageways clear • control materials so that they do not slide, fall, roll, or collapse • provide cribbing for heavy loads on unstable surfaces • store materials away from traffic

correct use of pipe chocks to keep pipe from rolling off rack

this placement of the slips presents a tripping hazard Corrective Action: move and store slips out of the way to prevent a trip

neat and proper storage is a big part of safety

neatly stacked materials that are level, plum, and maintained at a safe height

Applicable Standards • 1910 Subpart N Materials Handling and Storage • 1926.251 Rigging Equipment for Material Handling • 1926 Subpart W Rollover Protective Structures; Overhead Protection • 1926 Subpart CC Cranes and Derricks in Construction

Your Employer Is Responsible For • Providing training to operators of material handling equipment • Ensuring that equipment is properly inspected, maintained, and repaired when damaged • Providing proper and replacement rigging devices when damaged

You Are Responsible For • Using proper manual lifting and storage techniques • Inspecting the equipment and rigging devices you use daily • Preplanning all crane lifts

Case Study A worker was attempting to lift an adapter flange without aid. He suffered severe back sprain and was taken to the hospital.

Always Remember • Proper lifting techniques will prevent most back a injuries • Inspect cranes and rigging before each use • Operate and use cranes and rigging according to the manufacturer • Stay at least 10’ from overhead powerlines • Aisles, passageways, and steps should not be used for storage

Memory Check • What material handling-related injury is known to be the number one cause of workers compensation claims? • workers being struck by falling materials • equipment contacting powerlines • back injuries • none of the above

Memory Check • Slings that have no labels or labels too worn to read must be • used with extreme caution • used on only lightweight loads • pulled from service, tagged, and destroyed • none of the above

Memory Check • Which of the following is NOT a factor that affects the load calculation of a crane lift? • the limits of the rigging • the weight of the rigging • the wind speed • all of the above must be considered

Memory Check • Which of the following is the safest sling angle? • 5° • 10° • 30° • 60°

Material Handling