MATERIAL%20HANDLING

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MATERIAL HANDLING
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Safe Rigging Practices

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

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THE NEED FOR MATERIALS HANDLING

• Required to handle materials in office, home,
  site, etc.
• 25 of total accidents are due to materials
  handling
• Materials handling from Prehistoric times

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PRE-HISTORIC TIME MATERIALS HANDLING
The gigantic pyramid at Giza near Cairo (Egypt)
built about 2700 B.C. which is 764 ft square at
the base and 480 ft. high. About 2(1/3) million
stones from 2 to 30 tons in weight each were
transported from the quarry to the Nile River at
the flood season, ferried across the river on
rafts, dragged from river to the site of the
pyramid and piled up on each other to a height of
a 40 storied building. It is believed that a
ramp was built up on one side of the pyramid and
the stones were dragged up the slope by slaves
working in teams.
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MATERIAL HANDLING
WE SHALL DISCUSS ABOUT

• Material Handling Problems.
• Ropes.
• Rigging and safe rigging practice.
• D Shakle.
• Case Study.

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MATERIAL HANDLING PROBLEMS
LEAD TO INJURIES DURING THE COURSE OF MATERIALS
HANDLING e.g.

• CUT INJURIES
• BRUISES
• SPRAIN STRAIN
• CRUSH INJURIES
• FRACTURE

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MATERIAL HANDLING PROBLEMS.
THESE INJURIES ARE DUE TO

• UNSAFE WORKING PRACTICES
• IMPROPER LIFTING
• CARRYING TOO HEAVY LOADS MANUALLY
• INCORRECT GRIPPING
• NOT USING PPE
• FAILING TO HAVE PROPER FOOT AND HAND CLEARANCES,
  ETC.

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ROPES
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ROPES.
COMMONLY USE OF

• FIBRE ROPES
• WIRE ROPES

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FIBRE ROPES USAGE

• For light loads
• For construction
• Painting Jobs
• Marine Works

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FIBRE ROPES TYPES

• Coconut Coir Rope
• Cotton Rope
• Jute Rope
• Manila Rope

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FIBRE ROPES
10 USEFULL TIPS ON HANDLING CARE USE OF FIBRE
ROPE

• It should be hung up in loose coils on large
  diameter wooden pegs.
• It should be kept away from heat sources.
• It should be kept away from acid fumes.
• For opening a new coil of rope, the end of the
  rope should be at the bottom of the core or eye
  and the end should be pulled out through the
  core. If this is not followed kinks will be
  formed which will damage the rope.

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10 USEFULL TIPS .

• When used as slings should not be passed over
  sharp edges. Proper padding should be used.
• Strength of Fibre Ropes
• At 60 -- 86 of their strength when vertical
• At 45 -- 71 of their strength when vertical
• At 30 -- 50 of their strength when vertical
• Rope should not be dragged on ground to avoid
  abrasive action.
• Fibre rope should be inspected thoroughly before
  and after use.

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10 USEFULL TIPS .

• When a rope is condemned, it should be destroyed
  at once to cut up into short hand lines so that
  it cannot again be used for hoisting.
• If the rope is used for lifting loads with pulley
  blocks, it is advisable to reverse the ends
  periodically so that the rope is worn out more or
  less uniformly through-out.

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WIRE ROPES
A Wire Rope is usually made up of a number of
wires laid left or right handed into a strand and
number of wires laid left or right handed into a
strand and number of strands, usually 6 or 8,
laid right or left handed round a hemp rope
center to form the wire rope, or steel cable as
it is generally called.
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WIRE ROPES
CONSTRUCTION OF WIRE ROPES
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WIRE ROPES

• There are 4 different ways of laying the wire
  rope.
• Right-lay, regular-lay
• Left-lay, regular-lay
• Right-lay, lang-lay
• Left-lay, lang-lay

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WIRE ROPES
CONSTRUCTION OF WIRE ROPES
There are a different possible constructions of
wire rope. (Number of Strands) X (Number of Wires
in a Strand) Example 6X7 ? 6 Strands and 7 Wires
in each strand 6X19 ? 6 Strands and 19 Wires in
each strand 6X37 ? 6 Strands and 37 Wires in each
strand
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WIRE ROPES
COMMON USE OF VARIOUS CONSTRUCTION OF WIRE ROPES
6X7 (Regular Lay) ? Guys, Suspension Ropes,
etc. 6X19 (Regular lay with hemp core) ? Slings,
elevators, etc. 6X19 (Regular lay with steel
core) ? Blast furnace bell hoist 6X37 (Regular
lay with hemp core) ? Overhead Cranes, Mill
Hoist, etc. 6X37 (Regular lay with steel core) ?
Hot Metal Cranes, Blast Furnace bell, etc.
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WIRE ROPES
INSPECTION OF WIRE ROPES

• BROKEN WIRES
• WORN OUT WIRES
• REDUCTION IN ROPE DIA.
• ROPE STRETCH
• BIRD CAGE
• KINKS
• CORE PROTRUSION

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WIRE ROPES
BROKEN WIRES

• 6 OR MORE BROKEN WIRES IN ONE LAY
• 3 OR MORE BROKEN WIRES IN ONE STRAND IN ONE LAY
• MORE THAN 5 IN ANY LENGTH OF 10 DIAMETERS

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WIRE ROPES
REDUCTION IN ROPE DIA. REPLACE THE WIRE ROPE IF
THE DIA REDUCES BY

• 1mm FOR ROPE DIA UPTO 19mm
• 1.5mm FOR ROPE DIA UPTO 22-28mm
• 2mm FOR ROPE DIA UPTO 32-38mm

ROPE STRETCH
150 mm PER 30m LENGTH OF SIX STRANDED ROPE
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WIRE ROPES
BIRD CAGES
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WIRE ROPES
CORE PROTRUSION
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INSPECTION PROCEDURE

• Coding
• Once in a month
• Coloring
• Announce
• Record

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U CLAMPS
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DISTANCE BETWEEN THE ROPE CLIPS 6 X Dia.
CLIPS AND SPACING FOR SAFE APPLICATION
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RIGGING
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SLINGS
TENSION ON SLINGS
T W x L H x N T TENSION W WEIGHT
OF THE LOAD L LENGTH OF SLING N NO. OF
SLING LEGS
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SLINGS
TENSION ON SLINGS
If L is greater than S then sling angle is OK
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SLINGS - HITCHES
BASKET HITCH
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SLINGS - HITCHES
CHOKER HITCH
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RIGGING PRECAUTIONS

• Weight of ALL loads
• Allowances for unknown factor
• Capacity of equipment marked

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RIGGING PRECAUTIONS

• Rapid swinging increases the stress
• Avoid bending splice/ eye section around the
  corners.
• Avoid dragging of sling beneath loads

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RIGGING PRECAUTIONS

• Sharp Bends , Pinching crushing avoid for
  slings provide packing- curve 7 lays

• Never wrap a wire rope around a hook.

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RIGGING PRECAUTIONS
LIFTING

• Suspended loads securely slung properly
  balanced
• Tag Line
• Safely landed blocked
• Lifting beams SWL marked.
• Hoist rope dont wrap it around the load.
• Multiple part lines dont twist
• Slack rope condition ensure it is seated
  properly on the drum
• Stand clear of the load

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"D" SHACKLE
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SHACKLES
INSPECTION OF D-SHACKLES
DEFECTS

• SAFE WORKING LOAD MISSING
• OR UNREADABLE
• IDENTIFICATION MISSING
• OR UNREADABLE
• INCORRECT PIN
• DAMAGED THREAD ON PIN OR IN
• TAPPED EYE
• DISTORTED BODY
• WORN OUT BODY OR PIN
• NICKS, GOUGES, CRACKS,
• CORROSION

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Shackle
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Case Studies
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Observation

• Alignment of the boom top and the centre of the
  load was not proper during lifting operation
  which caused swinging of the load

Remedy

• Before lifting of load the top of the boom and
  the centre of the load to be aligned properly to
  avoid swinging.
• Experienced Signal man should facilitate the same

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Observation

• Defective storing. Plates were kept in
  vertically inclined position by means of make
  shift arrangement
• Work method / Job Safety analysis not prepared

Remedy

• Suitable stands to be used for keeping plates
  vertically
• Work method statement / Job Safety analysis to be
  prepared and implemented

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Observation

• Used worn threaded D-shackle
• Checking of casing pipe and operation of the rig
  were simultaneous
• The rig is operated inside the excavation. No
  space to run off
• Routine checkup not made before starting fresh
  pile
• Over confidence / carelessness of both rigger as
  well as rig operator
• Though the pin of D-shackle released from its
  position is happened repeatedly none has given
  solution to avoid its recurrence

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Remedy

• Routine visual check-up should be made before
  starting each pile by job engineer
• While checking welded joints of the casing pipe,
  the rig hammering should be paused
• Worn threaded D-shackle shall be discarded by
  means of lifting tools n tackles check, colour
  code etc.
• Frequent pep talk and toolbox meeting to be
  conducted

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Observation

• Use of improper sling
• Tag line / guiding ropes were not used for
  guiding the load from a safe distance, from crane
• The plate was tied with a single sling. In order
  to compensate the sling length, plate width and
  ground clearance the boom of Hydra was lifted to
  almost full, leading to just a gap of approx. 1
  foot between the rear end of plate and front
  wheel of Hydra
• The victim was walking in front of crane holding
  the rear end in very close proximity to the
  wheel, at the left side of the road

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Remedy

• Proper sling to be used
• The use of guide ropes for controlling the load
  while travelling with crane in order to keep
  workmen away from the crane range and load,
  should be ensured
• Worker should not be very close to the crane
  while walking along with the load

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Thank u for your attention