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Materials Handling. IENG 331 – Safety Engineering Carter J. Kerk , PhD, PE, CSP, PE Industrial Engineering Department South Dakota School of Mines & Technology. Reading Assignment. Brauer, Chapter 15 Review Questions, p. 278-9 6,8,10,12. 29 CFR 1910 Subpart N.

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materials handling

Materials Handling

IENG 331 – Safety Engineering

Carter J. Kerk, PhD, PE, CSP, PE

Industrial Engineering Department

South Dakota School of Mines & Technology

reading assignment
Reading Assignment
  • Brauer, Chapter 15
  • Review Questions, p. 278-9
    • 6,8,10,12
29 cfr 1910 subpart n
29 CFR 1910 Subpart N
  • 176 – Handling materials – general
  • 177 – Servicing multi-piece and single piece rim wheels
  • 178 – Powered industrial trucks
  • 179 – Overhead and gantry cranes
  • 180 – Crawler locomotive and truck cranes
  • 181 – Derricks
  • 183 – Helicopters
  • 184 - Slings
introduction
Introduction
  • Non-manual materials handling
    • industrial trucks, tractors, cranes, conveyors
  • MH responsible for 20-25% of occupational injuries
  • MH responsible for 6% of OSHA general industry citations
  • Industry moves 50 – 180 tons of material for each ton produced
  • Manual materials handling (e.g., lifting)
    • IENG 321
types of injuries accidents
Types of Injuries & Accidents
  • Mass - Motion Hazards
  • Human Body
    • Pinch, fracture, sever, crush
  • Facilities, Equipment, Materials
    • gas lines, electrical lines, load-bearing walls, fires
materials storage
Materials Storage
  • Stacking
    • items should be stacked, blocked, interlocked, and limited in height
    • standards are not specific as to “how”, but are expected to achieve a desired “result”, therefore this is a “performance standard”
  • Housekeeping
    • sloppy storage housekeeping can lead to trip hazards, fire, pests, vegetation (outside)
material storage continued
Material Storage (continued)
  • Egress
    • keep aisles and exits clear
  • During high production swings
    • be prepared for problems
    • Over-stacking
    • egress blocking
    • “creative” storage
industrial trucks
Industrial Trucks
  • Electric and internal combustion
  • Forklifts, tractors, platform lift trucks, motorized hand trucks, farm tractors, specialized industrial trucks
industrial truck selection
Industrial Truck Selection
  • Complex because there are 11 different design classifications segregated by
    • type of power: diesel, electric, gasoline, LP gas
    • degree of hazard for which approved
  • Biggest hazard: fires & explosions
    • more expensive trucks have features to prevent ignition of fires and explosions
  • See next three diagrams for selection process
industrial truck operations
Industrial Truck Operations
  • Fueling
    • no smoking around re-fueling stations
    • battery charging in designated areas only
      • better control of acid spillage, lifting of batteries, battery gases and fumes (ignitable)
      • good ventilation, emergency eyewash and shower
  • Internal Combustion Engines
    • CO hazard (50 ppm for 8 hour TWA)
    • Switch to electric? Better ventilation? Unnecessary idling?
truck operations continued
Truck Operations (continued)
  • Lighting requirements (illumination analysis)
  • Visibility
  • Hitchhikers & “elevators”
  • Unattended trucks (out of sight or > 25’)
  • Daily inspections (horns, lights, brakes)
  • Training Programs (29 CFR 1910.178)
cranes
Cranes
  • Many types (see next slide)
  • Rated loads (included safety factor) must be plainly marked
  • “Two-blocking” and “over-travel”
    • Prevent with: limit switches and bumpers
  • Electric shocks & power failures
  • Pendants - human factors issues (see slide)
  • Braking & “plugging”
  • Maintenance (lockout/tagout)
slide19
Hand-held pendant for overhead crane. Human factors issues: directional incompatibility between crane movement and controls.
block tackle
Block & Tackle
  • Free body diagram
securing wire rope loops
Securing Wire Rope Loops

“Don’t saddle a dead horse.” Right and wrong ways to secure wire rope loops using U-bolt clips. (a) Incorrect – “saddle” is on dead end of rope; (b) Incorrect – clips are staggered both ways; (c) Correct – all clips are placed with the saddle assembly on the live portion of the rope and the U-bolt on the dead end.

hoist chains vs chain slings
Hoist Chains vs. Chain Slings

Hoist chains are commonly misinterpreted to include chain slings. A separate standard exists for slings.

slings
Slings
  • Rope, fiber, chain, etc.
  • Rated capacity needed in conjunction with leg angles
  • 3 legs are better than 2, but 4 are not better than three, why?
  • Inspections
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