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Material Handling


Title: Confined Space Awareness Author: CAWarnick Last modified by: Vosburgh, Linda - OSHA Created Date: 6/16/2010 6:57:50 PM Document presentation format – PowerPoint PPT presentation

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Title: Material Handling

Module 11
Material Handling
  • 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.

  • After this module you should be able to
  • identify the most common material handling
  • 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, dont use it until it is

Load Weight
  • Refer to the shipping ticket or other
  • Ensure load is within the load chart rating for
    the boom length and load radius the operator is
  • remember that the crane is rated by the maximum
    weight it will lift at minimum boom length and
    minimum radius
  • the further from the cranes 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

the results of an improperly loaded crane are
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
companys 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 cranes window is badly cracked
Corrective Action this crane must be taken out
of service until the window is replaced
this cranes 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)

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

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
Corrective Action use proper rigging and sling
all slings whether nylon, wire rope, or chain
must have permanently affixed durable
information includes the size, grade, capacities,
and manufacturer if you cant read it, the sling
should be pulled from service
knowing the slings 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
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
the shackle has an improper pin and the hook has
a broken safety latch
Corrective Action replace both safety latch and
shackle pin
Material Handling Hazards
  • 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
  • Slipping, tripping, and falling due to improper
    materials storage

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
  • 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 dont 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

Proper Lifting Technique
  • 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 dont twist your back
  • keep the load close to your body
  • avoid lifting above shoulder height

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

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
  • 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
  • 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