Safety in Materials Handling

Topics for Discussion

 Safety during
Handling
 Safety during
Storage
 Safety during
Disposal
 Safety during
Rigging
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 Material Handling
Material handling is the function
of moving the right material to
the right place in the right time,
in the right amount, in sequence,
and in the right condition to
minimize production cost.
Goals of Material Handling
 To reduce unit costs of production
 Maintain or improve product quality, reduce
damage of materials
 Promote safety and improve working
conditions
 Promote productivity & to control inventory
 Promote increased use of facilities, space
etc.
 Handling and Storing Materials
Involves diverse operations:
Manual material handling
 Carrying bags or materials
 Unpacking materials

Material handling via machine

 Forklift
 Crane
 Rigging
 Conveyors

Stacking or storing
Drums, barrels, kegs, lumber,
loose bricks or other materials

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Hazards
 Falling objects
 Improperly stacked or
stored materials
 Twisting and turning
 Unsupported bending
 Improper manual lifting
or carrying loads that
are too large or heavy
 Being struck by
materials or being
caught in between two
objects

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 Injuries
These hazards can result in injuries
including:
• Back injuries (by manual lifting)
• Strains and sprains
• Fractures
• Cuts and bruises
• Disc Degeneration
• Sometimes, cause and effect not
as simple, more difficult to
analyze

•Out of 600,000 overexertion injuries:-

• 370,000 injuries caused by lifting
• 93,000 pushing/pulling 6
 General Work Practices

 Recognize material handling

hazards
(while dealing with manual material handling, Industrial
trucks, Conveyors & Cranes etc.)

 Become familiar with basic

methods of controlling these
hazards

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 General Work Practices
Get help for large loads or use mechanical
devices
When blocking a raised load:
○ Keep hands from underneath before
releasing load
○ Use blocking materials of adequate
strength
○ Look for cracks, splintered pieces,
rounded corners, etc.
Attach handles or holder to loads
Use appropriate PPE
○ Gloves, eye protection, safety boots
(for heavy loads)
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Responsibility of Employee
• Should know, how to lift safely
• Know, how to avoid
unnecessary physical stress
and strain
• Lift the load which you can
comfortably handle without
undue strain
• Should know proper use of
equipment
• Recognize potential hazards
and how to prevent / correct
them

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Safe Lifting
Break load into parts
Get help with heavy or bulky
items
 Keep back straight, do not twist
Use handling aids - such as
steps, trestles, shoulder pads,
handles, and wheels
Avoid lifting above shoulder level
Manual Lifting
 Manual lifting precautions
Avoid manual lifting when possible
Limit vertical lifting (knuckle-to-shoulder height)
Be in good physical shape
Plan the lifting operation
Get a good grip
Keep the load close to the body
Do not twist or bend sideways
Get help for large or heavy loads

Manual lifting
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Material Handling Equipment
When using material handling equipment, take the
following precautions:
Ensure the load is centered and stable on the equipment
Adjust the load to the lowest position when traveling
Do not exceed maximum weight restrictions

Pallet Jack
Operating a Forklift Safely
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 there’s an approved
seat
Don’t drive with forks raised
Wear safety belts or other restraint
devices
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 Powered Industrial Trucks
To help you work safely around powered industrial trucks,
you must:
 Be 18 years of age and receive
proper training before operating a
powered industrial truck
 Never place arms and legs between
the uprights of the mast
 Handle only stable and safely
arranged loads
 When dockboards are in use, make Powered Industrial
sure they are securely in place. Lift Truck
 Do not smoke, while driving
Conveyors
Conveyors can make moving materials easier, but there
are hazards involving their use.

Hazards
○ Nip points (rollers, near frame)
○ Material may fall from conveyor
○ Persons may be caught in the conveyor

When working around conveyors:

• Be sure you know where the emergency stop button
or pull cord is located
• Never sit or ride on a conveyor
• Guards over aisles or work areas
Cranes
 Check the load chart in the
cab
 Frequently inspect
 Never lift people
 Check overhead power
lines
 Ensure area of travel is
clear

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Rules for Rigging Safety
B
 Know the weight of the load
 Know the center of gravity of the load. A A
load is stable when, the hook is directly
above the center of gravity of the load. The longer set of
The longer the sling legs, the more stable sling legs (B) will
improve load
the load will be stability

 Estimate the center of gravity, Lift the

load just enough to clear the ground. If
the hook is not over the center of
gravity, then the hook will travel to the
center of gravity
Rules for Rigging Safety
 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
 A good operating practice is to keep sling angles
from going below 60 degrees
Rules for Rigging Safety
 Allow for D/d ratio on all wire rope
slings. (D - is diameter around which sling
is bent. & d - is diameter of the sling)
 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
Storing Materials

To prevent hazards when storing

materials, employers must:
 Keep aisles and passageways clear
 Separate non-compatible materials
 Place bound material on racks and
secure by stacking, blocking or
interlocking to prevent them from
falling
 Post safe load limits of floors
 Rules for Rigging Safety
 D - is diameter
around which
sling is bent.

 d - is diameter of D
the sling.
 D/d Ratio > 12
d

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 Stacking Techniques
Stacking materials can be dangerous if safety guidelines are not
followed. When stacking materials:
• Secure the material to prevent it from sliding, falling or collapsing
• In buildings under construction, don’t place stored materials within
6 feet of a hoist-way or floor opening
Remove all nails from used lumber, Lumber shall be stacked on
level and solidly supported sills so that it remains in a stable and
safe position & Lumber piles shall not exceed 20 feet in height
• Consider the need for availability of the material.
• Material that cannot be stacked due to size, shape, or fragility can
be safety stored on shelves or in bins
 HOUSEKEEPING
 Storage areas shall be kept free
from accumulation of materials that
constitute hazards such as:
Explosions,
Fire,
Tripping and falling of workers, and / or
Harboring rats and pests
 Vegetation control measures should be
exercised when necessary
Disposal of waste materials
 Disposal of Scrap and
Flammable Materials
• Remove all scrap lumber, waste
material, and rubbish from the
immediate work area as work
progresses

• Keep all solvent waste, oily rags,

and flammable liquids in fire
resistant covered containers
until removed from worksite

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Disposal of Waste Materials
 Use an enclosed chute
when you drop
material more than 20
feet outside of a
building

 If you drop debris

through holes in the
floor without chutes,
enclose the drop area
with barricades

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Disposal of waste materials
 Debris dropped through holes in the
floor without the use of chutes
Completely enclosed with barricades not
less than 42 inches high
Not less than 6 feet back from the projected
edge of the opening above
Signs warning of falling materials shall be
posted at each level
 Removal shall not be permitted in this lower
area until debris handling ceases above
Safety during Rigging
Three Types of Slings
1. Chain Slings

2. Wire Rope Slings

3. Synthetic Web Slings

 CHAIN SLINGS - TYPES

 Alloy steel chains

 Welded alloy steel chain
slings
 Permanently affixed
durable identification
stating
○ Size
○ Grade
○ Rated capacity
○ Sling manufacturer
○ Chain length
 CHAIN SLINGS- GRADES

 Four grades:
Grade 28 General Utility Chain
Grade 43 High Test Chain
Grade 70 Binding Chain
Grade 80 Alloy Steel Chain: The only one used for
overhead lifting & hoisting very hot material.

G 80
Alloy Steel Chain Attachments
Rated Capacity

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

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 CHAIN SLINGS INSPECTION

 Clean Slings before inspection

 Stretch the chain on a level floor. Remove all twist
 Measure the sling length. Discard, if a sling has
been stretched.
 Make link by link inspection and discard if
 Wear exceeds 15% of a link diameter
 Cut, Cracked, Corrosion or pilted
 Twisted or bent
 Stretched (Links tend to close up and get longer)
 Chain Sling Inspection
 Cracks, stretches, severe nicks, gouges, welding
splattered or deformed master links, coupling links,
chains or other components.
 One leg of a double or triple chain sling is longer than
the others.
 Hooks have been opened more than 15% of the
normal throat opening measured at the narrowest point
or twisted more than 10 degrees from the plane of the
unbent hook.
 Chain size at any point of any link is less than stated in
the chart on the next slide, the sling shall be
removed.
 Chain Sling Wear Chart
Chain Size Minimum Chain Size Minimum
(inches) Allowable (inches) Allowable
Chain Size Chain Size
(Inches) (Inches)
¼ 15/64 1 13/16
3/8 19/64 1 1/8 29/32
½ 25/64 1¼ 1
5/8 31/64 1 3/8 1 3/32
¾ 19/32 1½ 1 3/16
7/8 45/64 1¾ 1 13/32
 Wire Rope Slings
 Protruding ends of strands in splices on
slings and bridles covered or blunted
 Wire rope shall not be secured by knots
 Except for eye splices in the ends of
wires and for endless rope slings, each
wire rope used in hoisting or lowering, or
in pulling loads, shall consist of one
continuous piece without knot or splice
Wire Rope Slings

Mechanical Splice
Wire Rope Slings
Eye Splices

 Eye splices made in any wire rope must

have at least three full tucks

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Rigging equipment for material
handling

Swaged Forged Eye

 Protruding Ends

Cover or blunt protruding ends of strands

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 Wire Rope Clips

When using U-bolt

wire rope clips to
form eyes, ensure
the "U" section is in
contact with the
dead end of the
Dead End
rope
This is the correct method

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 Wire Rope Sling Inspection
 Three randomly distributed broken wires in one
strand, in one rope lay.
 Wear or scraping of 1/3 the original diameter of
outside individual wires.
 Kinking, crushing or any damage resulting in
distortion of the wire rope.
 End attachments that are cracked, worn or deformed.
 Corrosion of the rope or end attachments.
 Wire Rope Slings
Remove From Service
If these happen, remove the wire rope sling from service

Bird Caging Kinking

Crushing

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 Lubrication

Regularly lubricate ropes and chains

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 Synthetic Web Slings
 Light weight and easy to handle
 Non Sparking, Non conductive and can be used in
explosive atmosphere
 Not affected by Grease, Oil , Moisture and certain
chemicals
 Can get easily cut and have poor abrasion resistance.
 Needs protection from hot surfaces above 90 deg C ,
open flame and welding splatter
 Nylon Slings resists caustic and polyester slings resists
acids
 Do not lengthen or shorten sling by tying knots.
 Synthetic Web Sling
(Nylon, Polyester and Polypropylene )

Each Slings shall have

mark or code to show:
Name or trademark of
manufacturer
Rated capacities for
the type of hitch
Type of material

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Synthetic Web Slings
Fittings

Fittings must be:

At least as strong as
that of the sling
Free of sharp edges
that could damage
the webbing

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Synthetic Web Sling
Stitching

Stitching


Stitching is the only method allowed to attach
end fittings to webbing, or to form eyes

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 Synthetic Web Slings -
Remove from Service
 Remove from service if any of
these are present:
Acid or caustic burns
Melting or charring of any
part
Snags, punctures, tears or
cuts
Broken or worn stitches
Distortion of fittings
Heat Damage
Red wear cord is visible.

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 ACCESSORIES-SHACKLES

Recommended Not Recommended

Recommended

Screw Pin Anchor Round Pin Anchor Bolt Type Anchor

Shackle Shackle Shackle
ACCESSORIES-SHACKLES
TYPES OF SHACKLES
 Anchor (Bow Type)
 Chain (D Type)
used with screw, round pin or Nut bolt
arrangements
ACCESSORIES-SHACKLES
Safe Usages Practices
 Select the right size of shackles
 Inspect shackles regularly and before
each use
 Replace shackles that are bend ,
shows wear more than 10% of the
original diameter or have an
elongated eye / holes, increase in
distance between the eyes
ACCESSORIES-SHACKLES
• Never replace a shackle pin with a bolt, otherwise
the load will bend the bolt.
• Avoid side loading. Select higher size of
Shackles. (SWL decreases by 50% in case of 90
deg off from inline)
• Use Shackles with nut bolts in case of handling
moving load.
• Do not hammer or force Shackles into Positions.
ACCESSORIES-SHACKLES

Avoid eccentric Proper chocking of

loads. shackles.

Bad Good
Bad Good
ACCESSORIES-SHACKLES

Check wear Check cracks,

bending and
twisting
Check wear and
straightness

Pin always seated

Check opening
width
ACCESSORIES-HOOKS

LOAD
Hooks are designed to
apply the load at the
bottom of the saddle.
ACCESSORIES-HOOKS

Check for Wear and

Deformation

Signs of
Check for
“Opening Up”
Cracks and
Twisting 15% 10º

Check that
Hook is Not
Twisted

Check for Wear and Cracks

SLING USAGES
SLING USAGES

Approximately 70%-80% of a straight

pull
SLING USAGES

90° basket hitch is approximately twice the capacity of a straight pull

SLING CAPACITY
How horizontal angle affects slings capacity

500 LBS
500 LBS

BS

57
1000 LBS 1000 LBS

7L
7L

70
S
LB

7
BS
57

LB
90 60° 45° 30°

7
70

S
1000 LBS 1000 LBS 1000 LBS 1000 LBS

Note: A good operating practice is to keep sling angles

from going below 60 degrees
SLING CAPACITY

L
H

LOAD

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

SLING CAPACITY
 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
 Safe Usage Practices-Slings
 Slings should be stored off  Never drag slings across the
of the floor and hung on floor.
racks whenever possible in a
clean, dry environment.  Always hook with a “closed
hook” arrangement (hooks
facing out).
Safe Usage Practices (Cont.)
 Never shock load slings.  A sling should not be pulled
from under a load when the
 Keep loads balanced to prevent load is resting on the sling.
overloading slings.
 Make sure the hook is
 Always lift loads straight up. always over the center of
gravity of the load before
 Never rest a load on a sling, or lifting it.
pinch a sling between the load
and the floor.  Do not apply a load to a
twisted, knotted or kinked
 Do not leave suspended load chain.
unattended

 Do not force or hammer
Cordon off the area.
hooks or chains into
position.
Safe Usage Practices (Cont.)
 Hands and Fingers shall  Never shorten a sling
not be placed between the with knots, bolts or
sling and the load while the other makeshift
sling is being tightened devices.
around the load.
 Clean chains regularly as
 Protect the chain’s
dirt and grit can cause
excessive wear at the link surface from contact
bearing points. with sharp corners,
 Lower working load limit in which can cause
case of : permanent damage
 Suspected severe impact through gouging or
 Side/Angle loading abnormal stress and
 Temp above 425 deg C
wear.
In Conclusion

 Select the right sling for the job.

 Inspect slings prior to use, removing
from service any in question.
 Remember the effect of sling angles
on load capacities.
 Properly store slings when finished
to avoid damage.
THANK YOU

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