INTRODUCTION TO INTRODUCTION TO MATERIAL HANDLINGMATERIAL HANDLING

Have you ever been hurt while Have you ever been hurt while lifting material?lifting material?

Have you ever been involved Have you ever been involved in a crane or forklift accident, in a crane or forklift accident,

or rigging failure???or rigging failure???

Do you know how to safely Do you know how to safely store and dispose of material?store and dispose of material?

Training ObjectivesTraining Objectives

After completing this course, After completing this course, you will: you will: Know the basic OSHA requirements for Know the basic OSHA requirements for

the storage and disposal of materials.the storage and disposal of materials. Know hazards in both mechanical and Know hazards in both mechanical and

manual material handling.manual material handling. Understand hazards of rigging and crane Understand hazards of rigging and crane

operations and how to minimize them.operations and how to minimize them. Be aware of proper lifting techniques.Be aware of proper lifting techniques.

STATISTICSSTATISTICS

In 2002, accidents In 2002, accidents resulting from manual resulting from manual material handling material handling resulted in more than resulted in more than $10 Billion in losses!!!!$10 Billion in losses!!!!

In 2002, injuries In 2002, injuries associated with associated with repetitive motion, and repetitive motion, and improper lifting improper lifting technique cost $2.4 technique cost $2.4 Billion!!!Billion!!!

WHAT IS MATERIAL HANDLING?WHAT IS MATERIAL HANDLING?

Material handling is the art and Material handling is the art and science of moving, storing, science of moving, storing, protecting and controlling material. protecting and controlling material. Includes both Mechanical and Manual Includes both Mechanical and Manual

methodsmethods

DANGERS OF MATERIAL DANGERS OF MATERIAL HANDLINGHANDLING

Unsafe storage and Unsafe storage and materials movementmaterials movement

can lead to:can lead to: Back injuries (the number one Back injuries (the number one

cause of worker compensation cause of worker compensation claims).claims).

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

Electrocutions due to power Electrocutions due to power line contact.line contact.

Injury from falling materials.Injury from falling materials. Injury from slipping, tripping Injury from slipping, tripping

and falling.and falling.

SAFETY SLOGANSAFETY SLOGAN

““Is better to lose one minute in Is better to lose one minute in life... than to lose life in a life... than to lose life in a

minute.minute. “ “

Back Safety and Safe Back Safety and Safe LiftingLifting

Anatomy of the BackAnatomy of the Back

Why do injuries Why do injuries occur?occur? Knowing what Knowing what

causes back injuries causes back injuries can help you can help you prevent them.prevent them.

The Forces InvolvedThe Forces Involved

* * The amount of force you place on your The amount of force you place on your body during lifting may surprise you.body during lifting may surprise you.

• Think of your back as a leverThink of your back as a lever• With the fulcrum With the fulcrum

in the center, it onlyin the center, it only

takes ten pounds of takes ten pounds of

pressure to lift a ten pressure to lift a ten

pound object.pound object.

The Forces InvolvedThe Forces Involved

• If you shift the fulcrum to one side, it takes much more force to lift the same object. Your waist acts like the fulcrum in a lever system, on a 10:1 ratio.

Lifting a ten pound object puts 100 pounds of pressure on your lower back.

The Forces InvolvedThe Forces Involved

* When you add in the 105 pounds of the average human upper torso, you see that lifting a ten pound object actually puts 1,150 pounds of pressure on the lower back.

Moving Materials by HandMoving Materials by HandBack factsBack facts

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

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

Personal pain and inconvenience can Personal pain and inconvenience can not be measured.not be measured.

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

Common Causes of Back Common Causes of Back InjuriesInjuries

Lifting too much weight. Especially Lifting too much weight. Especially repetitivelyrepetitively Twisting at the waist while holding Twisting at the waist while holding a heavy load a heavy load Reaching and lifting overhead, or Reaching and lifting overhead, or away from the bodyaway from the body Lifting and carrying objects that have Lifting and carrying objects that have awkward shapesawkward shapes Working in awkward, uncomfortable Working in awkward, uncomfortable

positionspositions Sitting or standing too long in one positionSitting or standing too long in one position Slip / Trip / FallSlip / Trip / Fall

Things you can do to help your Things you can do to help your backback

You can minimize problems with your back You can minimize problems with your back by exercises that tone the muscles in your by exercises that tone the muscles in your back, hips and thighs.back, hips and thighs.

Before beginning any exercise program, you Before beginning any exercise program, you should check with your doctor and follow should check with your doctor and follow his/her advice concerning any exercise his/her advice concerning any exercise program. With his/her approval you should:program. With his/her approval you should:

Exercise regularly, every other day.Exercise regularly, every other day. Warm up slowly . . . walking is a good way to warm Warm up slowly . . . walking is a good way to warm

up.up. Inhale deeply before each repetition of an exercise Inhale deeply before each repetition of an exercise

and exhale when performing each repetition.and exhale when performing each repetition.

How to prevent back injuriesHow to prevent back injuriesTeam LiftingTeam Lifting

Use team lifting for:Use team lifting for: Loads too heavy for one person.Loads too heavy for one person. Loads too bulky for one person.Loads too bulky for one person. Long loads such as pipes and rolls Long loads such as pipes and rolls

of material.of material.

Talk to your team-mate!Talk to your team-mate! Coordinate your lift!Coordinate your lift!

PROPER LIFTING PROPER LIFTING TECHNIQUESTECHNIQUES

Use proper lift procedures . . . follow these Use proper lift procedures . . . follow these steps when lifting . .steps when lifting . .

1. Know where you are going. Is the path clear? 1. Know where you are going. Is the path clear?

2. Size up the load. (Is it too heavy? Do I need gloves?)2. Size up the load. (Is it too heavy? Do I need gloves?)

3. Take a balanced stance, 3. Take a balanced stance,

feet shoulder-widthfeet shoulder-width

apart.apart.

4. Squat down to lift, get4. Squat down to lift, get

as close as you can.as close as you can.

PROPER LIFTING PROPER LIFTING TECHNIQUESTECHNIQUES

5. Get a secure grip, 5. Get a secure grip,

hug the load.hug the load.

6. Lift gradually using6. Lift gradually using

your legs, keep loadyour legs, keep load

close to you, keep backclose to you, keep back

and neck straight.and neck straight.

PROPER LIFTING PROPER LIFTING TECHNIQUESTECHNIQUES

7. Once standing, change7. Once standing, change

directions by pointingdirections by pointing

your feet and turn youryour feet and turn your

whole body. Avoidwhole body. Avoid

twisting at your waist.twisting at your waist.

8. To put load down, use8. To put load down, use

these guidelines in these guidelines in

reversereverse..

Take care of your back…Take care of your back…

And it will take care of youAnd it will take care of you Exercise dailyExercise daily Avoid Heavy LiftingAvoid Heavy Lifting Get Help with heavy or bulky objectsGet Help with heavy or bulky objects If you must bend over, do it properlyIf you must bend over, do it properly Avoid twisting at the waist when Avoid twisting at the waist when

carrying objectscarrying objects Always watch where you’re goingAlways watch where you’re going

What About Back What About Back Belts?Belts?

The National Institute for Occupational Safety and The National Institute for Occupational Safety and Health (NIOSH) says:Health (NIOSH) says: Back belts Back belts may not reduce stress on the may not reduce stress on the

back.back. May increase blood pressure and heart May increase blood pressure and heart

rate.rate. May make you think you can lift heavier May make you think you can lift heavier

loads with a beltloads with a belt on and you could get hurt on and you could get hurt trying to.trying to.

If you want to wear a belt; don’t wear it too tight If you want to wear a belt; don’t wear it too tight and don’t lift more than you usually would.and don’t lift more than you usually would.

Safe Rigging PracticesSafe Rigging Practices

Know How to Do It Right!Know How to Do It Right!

Then Do It Right!Then Do It Right!

Job Site ConsiderationsJob Site Considerations

The person authorized and qualified to do rigging must always pay close attention to details. One careless moment or act can result in serious injury or death and tremendous property damage. Proper rigging is an art and should never be left to the inexperienced. If you don’t know how to do it properly, then don’t attempt it.

ObjectivesObjectives

Be familiar with OSHA’s regulations Be familiar with OSHA’s regulations regarding slings.regarding slings.

Understand safe sling use.Understand safe sling use. Be able to identify and describe Be able to identify and describe

conditions necessitating sling’s conditions necessitating sling’s replacement. replacement.

Understand how load angle effects Understand how load angle effects rigging capacity.rigging capacity.

29 CFR 1910.184 Slings29 CFR 1910.184 Slings

SlingSling: An assembly which connects : An assembly which connects the load to the material handling the load to the material handling (lifting) equipment. (lifting) equipment.

Three Types of SlingsThree Types of Slings

1.1. Chain SlingsChain Slings

2.2. Wire Rope SlingsWire Rope Slings

3.3. Synthetic Web SlingsSynthetic Web Slings

Frequency of Sling Frequency of Sling InspectionsInspections

1926.251 – Rigging equipment for material 1926.251 – Rigging equipment for material handling shall be inspected prior to use on handling shall be inspected prior to use on

each shift and as necessary during its use to each shift and as necessary during its use to ensure that it is safe. Defective rigging ensure that it is safe. Defective rigging

equipment shall be removed from service.equipment shall be removed from service.

Chain Sling Inspection ItemsChain Sling Inspection Items Cracks, stretches, severe nicks, gouges, welding splattered Cracks, stretches, severe nicks, gouges, welding splattered

or deformed master links, coupling links, chains or other or deformed master links, coupling links, chains or other components. components. 

One leg of a double or triple chain sling is longer than the One leg of a double or triple chain sling is longer than the others.  others.  

Hooks have been opened more than 25% of the normal Hooks have been opened more than 25% of the normal throat opening measured at the narrowest point or twisted throat opening measured at the narrowest point or twisted more than 10 degrees from the plane of the unbent hook.   more than 10 degrees from the plane of the unbent hook.   

Documented Inspections must be performed and Documented Inspections must be performed and maintained for each chain sling. Inspection data maintained for each chain sling. Inspection data must be compared with previous inspections.must be compared with previous inspections.

Chain SlingsChain Slings

Only chain slings purchased Only chain slings purchased from the manufacturer are from the manufacturer are

allowed.allowed.

No homemade No homemade

slings allowed!!slings allowed!!

Wire Rope Sling Inspection Wire Rope Sling Inspection ItemsItems

  Three randomly distributed broken Three randomly distributed broken wires in one strand, in one rope lay.wires in one strand, in one rope lay.

Wear or scraping of 1/3 the original Wear or scraping of 1/3 the original diameter of outside individual wires.diameter of outside individual wires.

Kinking, crushing or any damage Kinking, crushing or any damage resulting in distortion of the wire rope.resulting in distortion of the wire rope.

End attachments that are cracked, End attachments that are cracked, worn or deformed.worn or deformed.

Corrosion of the rope or end Corrosion of the rope or end attachments.attachments.

Synthetic Web Sling Synthetic Web Sling Inspection Items Inspection Items

Acid or caustic burns on the sling.Acid or caustic burns on the sling.

Melting or charring of any part of the sling’s surface.Melting or charring of any part of the sling’s surface.

Snags, punctures, tears, or cuts.Snags, punctures, tears, or cuts.

Stitching is broken or worn.Stitching is broken or worn.

The sling is stretched. To assist operators in determining if a The sling is stretched. To assist operators in determining if a sling is stretched, manufacturers incorporate a sling is stretched, manufacturers incorporate a colored colored wear wear cordcord inside of the sling. When this red wear cord can be inside of the sling. When this red wear cord can be readily seen upon inspecting the sling, the sling has been readily seen upon inspecting the sling, the sling has been stretched and is to be removed. stretched and is to be removed. The web sling may need to The web sling may need to be removed from service before the wear indicator is showing.be removed from service before the wear indicator is showing.

The Hazards of RiggingThe Hazards of Rigging

Possible contact with power lines.Possible contact with power lines. Rigging failures due to overloaded, Rigging failures due to overloaded,

improper, or defective rigging.improper, or defective rigging. Out of control loads.Out of control loads. Being struck by the crane’s swing Being struck by the crane’s swing

radius.radius.

Can Anyone Rig or Lift Can Anyone Rig or Lift Loads?Loads?

Rigging must be done under the Rigging must be done under the supervision of a supervision of a Competent Competent PersonPerson..

The crane operator must be The crane operator must be highly qualified and certified.highly qualified and certified.

Improper rigging or unqualified Improper rigging or unqualified operators can be deadly!operators can be deadly!

The Rigger’s DutiesThe Rigger’s Duties

The rigger The rigger selects the selects the rigging.rigging.

The rigger sets-The rigger sets-up the rigging.up the rigging.

The rigger The rigger directs the lift.directs the lift.

OSHA Rigging OSHA Rigging RequirementsRequirements

All slings and hardware must be:All slings and hardware must be: Manufactured to meet demanding Manufactured to meet demanding

specifications.specifications. Clearly stamped, marked, or Clearly stamped, marked, or

labeled.labeled.

OSHA prohibits job-made: slings, hooks, OSHA prohibits job-made: slings, hooks, links, and fasteners formed from bolts.links, and fasteners formed from bolts.

Before each use all components must be Before each use all components must be inspected by a inspected by a Competent Person.Competent Person.

Knowing Safe Working Knowing Safe Working LoadsLoads

DefinitionsDefinitions

Hitch “Basket” - loading with the sling passed under Hitch “Basket” - loading with the sling passed under the load and both ends on the hook or a single the load and both ends on the hook or a single master link.master link.

DefinitionsDefinitions

Hitch “Choker” – loading with the sling passed Hitch “Choker” – loading with the sling passed through one eye and suspended by the other.through one eye and suspended by the other.

DefinitionsDefinitions

Hitch “Vertical” – loading with the the load Hitch “Vertical” – loading with the the load suspended vertically on a single part or leg of the suspended vertically on a single part or leg of the sling.sling.

Sling CapacitiesSling Capacities

45 degrees 30 degrees60 degrees

60

30

A sling capable of lifting 1000 lbs in a vertical basket hitch, can only lift 866 lbs at a 60 degree angle, and 707 lbs at a 45 degree angle, and 500 lbs at a 30 degree angle.

Wire Rope Sling CapacitiesWire Rope Sling Capacities

Working Safely Around Working Safely Around RiggingRigging

General safety guidelines:General safety guidelines: Keep at least Keep at least ten feet awayten feet away from power from power

lines.lines. Never hoist loads over workers.Never hoist loads over workers. Never stand too close or under a load.Never stand too close or under a load. Never ride a load.Never ride a load. Use sling angles greater than Use sling angles greater than 45 degrees45 degrees.. Attach tag lines to control loads while lifting.Attach tag lines to control loads while lifting. Test lift the rigging.Test lift the rigging. Use proper equipment, make sure it is Use proper equipment, make sure it is

marked, not home-made, and in good shape.marked, not home-made, and in good shape.

Rigging the LoadRigging the Load

Balanced load; sling angle >600

Sling angles <450, loadunstable, receiver notprotected.

Safe Usage PracticesSafe Usage Practices Never shock load slings.Never shock load slings.

Keep loads balanced to Keep loads balanced to prevent overloading slings.prevent overloading slings.

Always lift loads straight up.Always lift loads straight up.

Never rest a load on a sling, Never rest a load on a sling, or pinch a sling between the or pinch a sling between the load and the floor.load and the floor.

Slings should be stored off Slings should be stored off of the floor and hung on of the floor and hung on racks whenever possible in racks whenever possible in a clean, dry environment.a clean, dry environment.

Never drag slings across the Never drag slings across the floor. floor. 

A sling should not be A sling should not be pulled from under a load pulled from under a load when the load is resting on when the load is resting on the sling.the sling.

Make sure the hook is Make sure the hook is always over the center of always over the center of gravity of the load before gravity of the load before lifting it.lifting it.

Do not apply a load to a Do not apply a load to a twisted, knotted or kinked twisted, knotted or kinked chain.chain.

Do not force or hammer Do not force or hammer hooks or chains into hooks or chains into position.position.

Always hook with a “closed Always hook with a “closed hook” arrangement (hooks hook” arrangement (hooks facing out).facing out).

Safe Usage Practices Safe Usage Practices (Cont.)(Cont.)

Hands and Fingers shall Hands and Fingers shall not be placed between not be placed between the sling and the load the sling and the load while the sling is being while the sling is being tightened around the tightened around the load.load.

Clean chains regularly as Clean chains regularly as dirt and grit can cause dirt and grit can cause excessive wear at the excessive wear at the link bearing points.link bearing points.

Never shorten a sling with Never shorten a sling with knots, bolts or other knots, bolts or other makeshift devices. Knots makeshift devices. Knots in slings reduce the in slings reduce the capacity by as much as capacity by as much as 50%!! 50%!!

   Protect the chain’s Protect the chain’s

surface from contact with surface from contact with sharp corners, which can sharp corners, which can cause permanent damage cause permanent damage through gouging or through gouging or abnormal stress and wear.abnormal stress and wear.

Rigging Protection FromRigging Protection FromCutting or SlippingCutting or Slipping

Softeners, padding or use of blocking..

Mechanical Materials Mechanical Materials HandlingHandling

Depending on the job, you might use or work Depending on the job, you might use or work around:around: BuggiesBuggies Roof HoistsRoof Hoists ConveyorsConveyors Skid-steers (“Bobcats”)Skid-steers (“Bobcats”) Rough Terrain ForkliftsRough Terrain Forklifts CranesCranes

BuggiesBuggies

What are the safety concerns while moving materials with these?

Mechanical Equipment on Mechanical Equipment on Flat RoofsFlat Roofs

Will the deck support the weight of the Will the deck support the weight of the equipment?equipment?

Has the equipment been inspected?Has the equipment been inspected? Are all equipment guards in place?Are all equipment guards in place? Is the operator trained?Is the operator trained?

See Subpart C - .20(b)(4)See Subpart C - .20(b)(4) Are all aware that the equipment is not to be Are all aware that the equipment is not to be

operated outside warning lines due to the fall operated outside warning lines due to the fall hazard? hazard? See Subpart M - Fall Protection -.502See Subpart M - Fall Protection -.502 Closest approach is 6 feet parallel and 10 Closest approach is 6 feet parallel and 10

feet perpendicular to direction of travel.feet perpendicular to direction of travel.

Roof HoistsRoof Hoists

What are the manufacturer’sinstructions for set up & use?

What does OSHA say?

Roof Hoist Safety Roof Hoist Safety ConcernsConcerns

.552(a)(1) Compliance with manufacturer’s .552(a)(1) Compliance with manufacturer’s specifications and limitations.specifications and limitations.

.552(a)(2) Load capacity, hazard warnings and .552(a)(2) Load capacity, hazard warnings and instructions must be posted.instructions must be posted.

.552(a)(3)(i-iv) Wire rope replacement.552(a)(3)(i-iv) Wire rope replacement

criteria.criteria. .552(a)(4) Hoist rope is to be installed in accordance .552(a)(4) Hoist rope is to be installed in accordance

with manufacturer’s instructions.with manufacturer’s instructions. .501(b)(3) Fall Protection (Subpart M) in .501(b)(3) Fall Protection (Subpart M) in

hoist area.hoist area.

Is the Hoist Operator Is the Hoist Operator Protected?Protected?

Using Conveyors to Move Using Conveyors to Move MaterialsMaterials

Safety Concerns In Safety Concerns In Conveyor UseConveyor Use

Set up and used in accordance with the Set up and used in accordance with the manufacturer’s instructions?manufacturer’s instructions?

Guards in place on pinch points?Guards in place on pinch points? Power line clearances maintained?Power line clearances maintained? Maintenance program in place?Maintenance program in place? No riders on conveyor!No riders on conveyor! .555(a) Means for stopping motor at.555(a) Means for stopping motor at operator’s station + start up warning.operator’s station + start up warning. .555(a)(5) Protection for workers below..555(a)(5) Protection for workers below. .555(a)(7)Lockout/Tagout for maintenance..555(a)(7)Lockout/Tagout for maintenance.

Skid Steer LoaderSkid Steer Loader

What do weneed to know about this operator?

Using Skid SteersUsing Skid Steers If on the roof – will it take the load?If on the roof – will it take the load?

Is the operator qualified?Is the operator qualified?

.20(b)(4) – Again! Training is available from .20(b)(4) – Again! Training is available from some manufacturers.some manufacturers.

Skid Steers are powerful, work in close Skid Steers are powerful, work in close quarters with people and are very quick, quarters with people and are very quick, with large areas where the operator cannot with large areas where the operator cannot see.see.

Is the work area adequately barricaded?Is the work area adequately barricaded?

Using Forklifts to Move Using Forklifts to Move MaterialsMaterials

What do we need to know?What do we need to know? Is the operator trained?Is the operator trained?

See .602(d)See .602(d) Has the machine been inspected and properly Has the machine been inspected and properly

maintained?maintained?

Is the backup alarm audible?Is the backup alarm audible?

Are ground personnel protected?Are ground personnel protected?

Is the balanced load within capacity?Is the balanced load within capacity?

Are workers on roof protected from falls?Are workers on roof protected from falls?

MATERIAL STORAGE, AND MATERIAL STORAGE, AND DISPOSAL OF WASTE DISPOSAL OF WASTE

MATERIALMATERIAL

Material StorageMaterial Storage Five basic rules for safe Five basic rules for safe

storage:storage: Keep total weight within the Keep total weight within the

safe loading limits of the safe loading limits of the building’s floors.building’s floors.

Keep passageways clear.Keep passageways clear. Control materials so they do not Control materials so they do not slide, fall, or collapse. slide, fall, or collapse. Provide cribbing for heavy Provide cribbing for heavy loads on unstable surfaces.loads on unstable surfaces. Store materials away from Store materials away from traffic.traffic.

SUBPARTS

What Does OSHA What Does OSHA Require?Require?

Basic requirements:Basic requirements: Don’t put materials within 10 feet of Don’t put materials within 10 feet of

roof edge.roof edge. Don’t store materials on scaffolds or Don’t store materials on scaffolds or

runways.runways. Keep materials at least 6 feet from Keep materials at least 6 feet from

floor openings and hoistways.floor openings and hoistways. Keep aisles clear.Keep aisles clear. Keep work area free from tripping, fire, Keep work area free from tripping, fire,

explosion, pest and vegetation hazards.explosion, pest and vegetation hazards.

Setting Materials on Setting Materials on the Deckthe Deck

What could happen to these stacked materials?

OSHA Also RequiresOSHA Also Requires Specific requirements:Specific requirements:

Stack bagged materials by stepping Stack bagged materials by stepping back the layers and cross-keying the back the layers and cross-keying the bags at least every 10 bags high.bags at least every 10 bags high.

Stack bricks no higher than 7 feet.Stack bricks no higher than 7 feet.

Taper masonry blocks back one-half Taper masonry blocks back one-half block per tier for stacks above 6 feet.block per tier for stacks above 6 feet.

Stack lumber on sills and on level solid Stack lumber on sills and on level solid ground - never exceed 16 feet high ground - never exceed 16 feet high and and

always remove nails!always remove nails!

Disposal of Waste Disposal of Waste MaterialMaterial

OSHA requirements:OSHA requirements: Scrap lumber, waste and trash must be regularly Scrap lumber, waste and trash must be regularly

removed from the work area.removed from the work area.

Materials dropped more than 20 feet require a chute.Materials dropped more than 20 feet require a chute.

Solvent waste, oily rags, and flammables must be Solvent waste, oily rags, and flammables must be kept in fire resistant containers until removed.kept in fire resistant containers until removed.

If the waste is considered hazardous, your employer If the waste is considered hazardous, your employer will have to follow federal, state, and local will have to follow federal, state, and local regulations.regulations.

Debris ChutesDebris Chutes

Objectives in using a chute: material control, dust control and protection of workers and bystanders – note the differences here…. Material Chutes must be entirely enclosed, and designed of such strength as to eliminate failure.

THE ENDTHE END