Material Handling Safety

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Physical plant must be safe

Clear, marked, unobstructed work area

Workers must be trained, evaluated & licensed
Training must be equipment-specific and site-specific
Equipment must be safe to operate

Daily inspections

Removal from service when repairs are needed

Service areas, such as battery charging stations, must be safe in design and operation
What materials are handled?
What machines are used to handle them?
What precautions are taken to avoid accidents and injuries?
Used for hoisting of material

Alloy steel chain

Wire rope

Metal mesh

Natural or synthetic fiber rope

Synthetic web
Never use damaged / defective slings
Never shorten slings with makeshift devices
Never use kinked sling legs
Never load slings in excess of rated capacities
Balance loads in basket hitches to prevent slippage.
Attach slings securely to loads.

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Pad / protect slings from sharp edges.

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Keep suspended loads clear of obstructions

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Keep employees clear of loads to be lifted and suspended loads.

10. Never place hands or fingers between sling and load while sling is being tightened.
11. Shock loading is prohibited take up the slack in the sling slowly.
12. Never pull a sling out from under a load while the load rests on it.
Industrial Truck Safety Facts

The center of gravity of a lift truck changes.

Most trucks are rear steer.

Most trucks have no suspension system.

It is NOT safe to alter the lift trucks counterweight!

Rigging equipment for material handling shall be inspected prior to use on each shift and as necessary
during its use to ensure that it is safe.

Defective rigging equipment shall be removed from service.

Rigging equipment shall not be loaded in excess of its recommended safe working load.

Types of slings covered are those made from alloy steel chain, wire rope, metal mesh, natural or synthetic
fiber rope, and synthetic web.

Inspections

Equipment must be inspected prior to use and each shift.

Also, as necessary during its use

Damaged or defective equipment must be removed from service.

Hooks, rings, oblong links, or other attachments, when used with alloy steel chains, must have a rated capacity at
least equal to that of the chain.

Job or shop hooks and links, or makeshift fasteners, formed from bolts, rods, etc., or other such
attachments, shall not be used.

Kinked or knotted chains must not be used for lifting.

Chains must not be shortened by bolting, wiring or knotting.

A thorough periodic inspection of slings must be made on a regular basis.

At least annually

Inspection determined on the basis of:

Frequency of sling use

Severity of service conditions

Nature of lifts being made

Experience gained on service life of slings

Considerations when selecting wire rope

Strength

Flexibility or resistance to bending fatigue

Resistance to abrasion

Resistance to crushing

Resistance to rotation

Resistance to corrosion

Eye splices made in any wire rope must have at least three full tucks.

Wire rope must not be used if in any length of eight diameters:

Total number of visible broken wires exceed 10% of the total number of wires

Rope shows excessive wear, corrosion, or defect

Synthetic Web Slings

Remove from service if any of the following conditions are present:

Acid or caustic burns

Melting or charring of any part

Snags, punctures, tears or cuts

Broken or worn stitches

Distortion of fittings

Materials Handling Dangers

Unsafe storage and materials movement

can lead to:

Back injuries (the number one cause of worker compensation claims).

Struck-by or crushed by falling loads due to rigging failures.

Electrocutions due to power line contact.

Injury from falling materials.

Injury from slipping, tripping and falling.

Moving Materials by Hand: Back Facts

8 out of 10 Americans will have a back injury during their life.

Approximately 1 out of 3 injuries at work are back injuries.

Personal pain and inconvenience can not be measured.

Back injuries cost employers an estimated 10 billion dollars each year!

Preventing Back Injuries

You can avoid back injuries by:

Using mechanical aids.

Using proper lifting techniques.

Keeping in lifting shape.

Working as a team when 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 and keep it close to your body.

Tighten your stomach muscles.

Keep your back straight and use your legs.

Turn with with your feet dont twist your back.

Avoid lifting above shoulder height.

The Hazards of Rigging

Possible contact with power lines.

Rigging failures due to overloaded, improper, or defective rigging.

Out of control loads.

Being struck by the cranes swing radius.

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 certified.

Improper rigging or unqualified operators can be deadly!

The Riggers Duties

The rigger selects the rigging.

The rigger sets-up the rigging.

The rigger directs the lift.

Safe Working Load (SWL)

The maximum load allowed on rigging is the Safe Working Load (SWL).

The sling may actually be able to hold 5 times the SWL.

A safety factor is the ratio of the ultimate strength to the SWL.

If a rigger exceeds the SWL, then they lose some of the safety factor.

Sling Angle

The safest sling angles are greater than 450 from the horizontal.

Working Safely Around Rigging

General safety practices:

Keep at least ten feet away from power lines up to 50 kV.

Increase power line clearance distance by .4 per kV >50kV

Never hoist loads over workers.

Never stand too close or under a load.

Never ride a load.

Use tag lines to control loads while lifting.

Test lift the rigging.

Use proper equipment, make sure it is marked, not home-made, and in good shape.

Basic Crane Safety

Do we have the right crane for the job?

Is the operator qualified on that crane?

Has the crane been inspected?

Is the crane set up on solid ground?

Full outriggers with cribbing?

Level, with tires off the ground?

Are power line clearances known?

Do we know the weight of the load?

Is everyone aware that a lift is being made?

Is the load properly rigged for a stable, vertical lift?

Is there a high wind condition?

Is the swing radius barricaded?

Can a tagline be properly used?

Can the crane make the lift and set the load without interference?

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Lifting and moving loads manually is one of the most common causes of injury at work.

There is no truly safe weight limit for manual handling operations so try to find alternatives.

When you have to manually handle loads consider: Remember : TILE

Rules for Rigging Safety

Know the weight of the load
Know the center of gravity of the load.
Make load attachment above the center of gravity of the load.
Select hitch that will hold and control.
Know the rated capacity of slings and hardware.
Select sling best suited for load.

Inspect all rigging before the lift.

Protect sling from sharp surfaces
Proper calculation of increased tension caused by sling angles (on all rigging components!).
Allow for D/d ratio on all wire rope slings.
Calculate reductions when using choker hitch.
Keep personnel clear from lift area.
Lift load a few inches then check rigging
Know limitations of all lifting devices used.
Lift slowly and stop slowly
Rigging equipment for material handling
Rigging equipment inspections (By a Competent Person)

Prior to use on each shift

As necessary during its use to ensure that it is safe

Defective rigging equipment removed from service

Not be loaded in excess of its recommended safe working load

Marked to indicate the safe working loads
Be proof-tested prior to use to 125 percent of their rated load
Wire rope slings
Shall not be shortened with knots or bolts or other makeshift devices.
Legs shall not be kinked
Basket hitch shall have the loads balanced to prevent slippage
Padded or protected from the sharp edges
Wire rope
Hands or fingers shall not be placed between the sling and its load while the sling is being tightened around
the load
A sling shall not be pulled from under a load when the load is resting on the sling
Calculating the load on sling legs

Divide the total load by the number of sling legs

This quotient is the load on each leg if vertical

Measure the sling from the load attachment point, to the point where it connects with the hook or
lifting device; this is L

Measure the vertical height from the top of the load to the hook or lifting device; this is H

Divide the length of the leg by the height of the sling

Load Number of legs) X (L H) = Load each sling leg

Forklifts
Center the load on the forks and as close to the mast as possible to minimize the potential for the
truck tipping or load falling
Overloading a lift truck makes it hard to control and could make it tip over
Place the load at the lowest position for traveling
Dont place extra weight on the rear of a counterbalanced forklift to allow an overload
Keep arms and legs inside the truck
Handle only stable loads
Keep speed low - you may have to stop
Be careful when making sharp turns
with a raised load
If a load blocks your view, travel in reverse
No riders, unless theres an approved seat
Dont drive with forks raised
Wear safety belts or other restraint devices
Cranes
Check the load chart in the cab
Frequently inspect
Never lift people
Check overhead power lines
Ensure area of travel is clear

When a chain shows excessive wear, or is cracked or pitted, remove it from service
Wire Rope Slings
Used to hoist materials
Selection considerations:

strength

ability to bend without cracking

ability to withstand abrasive wear

ability to withstand abuse

Summary
Manually handling materials

When lifting objects, lift with your legs, keep your back straight, do not twist, and use
handling aids

Using cranes, forklifts, and slings to move materials

Watch for potential struck by and crushed by dangers

For slings, check their load capacity, inspect them, and remove them from service when
they display signs of stress or wear

Keep work areas free from debris and materials

Store materials safely to avoid struck by/crushed by hazards

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