Materials Handling

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Materials Handling

• IENG 331 Safety Engineering
• Carter J. Kerk, PhD, PE, CSP, PE
• Industrial Engineering Program
• South Dakota School of Mines Technology

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Reading Assignment

• Brauer, Chapter 15

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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

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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

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Types of Injuries Accidents

• Mass - Motion Hazards
• Human Body
• Pinch, fracture, sever, crush
• Facilities, Equipment, Materials
• gas lines, electrical lines, load-bearing walls,
  fires

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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)

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Material Storage (continued)

• Egress
• keep aisles and exits clear
• During high production swings
• be prepared for problems
• Over-stacking
• egress blocking
• creative storage

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Industrial Trucks

• Electric and internal combustion
• Forklifts, tractors, platform lift trucks,
  motorized hand trucks, farm tractors, specialized
  industrial trucks

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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

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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?

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Truck Operations (continued)

• Lighting requirements (illumination analysis)
• Visibility
• Hitchhikers elevators
• Unattended trucks (out of sight or gt 25)
• Daily inspections (horns, lights, brakes)
• Training Programs (29 CFR 1910.178)

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Forklift Tipover and Stability
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Forklift Transitions and Chocking
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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)

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Types of overhead cranes.
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Hand-held pendant for overhead crane. Human
factors issues directional incompatibility
between crane movement and controls.
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Block Tackle

• Free body diagram

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Securing Wire Rope Loops
Dont 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.
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Hoist Chains vs. Chain Slings
Hoist chains are commonly misinterpreted to
include chain slings. A separate standard exists
for slings.
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Crane Hook Inspection
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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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Sling Angle
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