INTRODUCTION TO
MATERIAL HANDLING
Have you ever been hurt while
lifting material?
Have you ever been involved in a
crane or forklift accident, or rigging
failure???
Do you know how to safely store
and dispose of material?
Training Objectives
 After
will:
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completing this course, you
Know the basic OSHA requirements for the
storage and disposal of materials.
Know hazards in both mechanical and manual
material handling.
Understand hazards of rigging and crane
operations and how to minimize them.
Be aware of proper lifting techniques.
STATISTICS


In 2002, accidents
resulting from manual
material handling resulted
in more than $10 Billion
in losses!!!!
In 2002, injuries
associated with repetitive
motion, and improper
lifting technique cost $2.4
Billion!!!
WHAT IS MATERIAL HANDLING?

Material handling is the art and science of
moving, storing, protecting and controlling
material.

Includes both Mechanical and Manual
methods
DANGERS OF MATERIAL
HANDLING

Unsafe storage and
materials movement
can lead to:

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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.
SAFETY SLOGAN
“Is better to lose one minute in life...
than to lose life in a minute. “
Back Safety and Safe Lifting
Anatomy of the Back

Why do injuries
occur?

Knowing what causes
back injuries can help
you prevent them.
The Forces Involved
* The amount of force you place on your body
during lifting may surprise you.
•
•
Think of your back as a lever
With the fulcrum
in the center, it only
takes ten pounds of
pressure to lift a ten
pound object.
The 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 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 Hand
Back facts


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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!
Common Causes of Back Injuries

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Lifting too much weight. Especially
repetitively
Twisting at the waist while holding
a heavy load
Reaching and lifting overhead, or
away from the body
Lifting and carrying objects that have
awkward shapes
Working in awkward, uncomfortable positions
Sitting or standing too long in one position
Slip / Trip / Fall
Things you can do to help your
back



You can minimize problems with your back by
exercises that tone the muscles in your back, hips
and thighs.
Before beginning any exercise program, you
should check with your doctor and follow his/her
advice concerning any exercise program. With
his/her approval you should:
Exercise regularly, every other day.


Warm up slowly . . . walking is a good way to warm up.
Inhale deeply before each repetition of an exercise and
exhale when performing each repetition.
How to prevent back injuries
Team Lifting
 Use



team lifting for:
Loads too heavy for one person.
Loads too bulky for one person.
Long loads such as pipes and rolls of
material.
 Talk
to your team-mate!
 Coordinate your lift!
PROPER LIFTING
TECHNIQUES

Use proper lift procedures . . . follow
these steps when lifting . .
1. Know where you are going. Is the path clear?
2. Size up the load. (Is it too heavy? Do I need gloves?)
3. Take a balanced stance,
feet shoulder-width
apart.
4. Squat down to lift, get
as close as you can.
PROPER LIFTING
TECHNIQUES
5. Get a secure grip,
hug the load.
6. Lift gradually using
your legs, keep load
close to you, keep back
and neck straight.
PROPER LIFTING
TECHNIQUES
7. Once standing, change
directions by pointing
your feet and turn your
whole body. Avoid
twisting at your waist.
8. To put load down, use
these guidelines in
reverse.
Take care of your back…

And it will take care of you

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Exercise daily
Avoid Heavy Lifting
Get Help with heavy or bulky objects
If you must bend over, do it properly
Avoid twisting at the waist when carrying
objects
Always watch where you’re going
What About Back Belts?


The National Institute for Occupational Safety and Health
(NIOSH) says:
 Back belts may not reduce stress on the back.
 May increase blood pressure and heart rate.
 May make you think you can lift heavier loads
with a belt on and you could get hurt trying to.
If you want to wear a belt; don’t wear it too tight and don’t
lift more than you usually would.
Safe Rigging Practices
Know How to Do It Right!
Then Do It Right!
Job 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.
Objectives
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Be familiar with OSHA’s regulations
regarding slings.
Understand safe sling use.
Be able to identify and describe
conditions necessitating sling’s
replacement.
Understand how load angle effects
rigging capacity.
29 CFR 1910.184 Slings
Sling: An assembly which connects the
load to the material handling (lifting)
equipment.
Three Types of Slings
1.
Chain Slings
2.
Wire Rope Slings
3.
Synthetic Web Slings
Frequency of Sling Inspections
1926.251 – 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.
Chain Sling Inspection Items
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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 25% of the normal throat
opening measured at the narrowest point or twisted more than
10 degrees from the plane of the unbent hook.
Documented Inspections must be performed and
maintained for each chain sling. Inspection data must
be compared with previous inspections.
Chain Slings
Only chain slings purchased from
the manufacturer are allowed.
No homemade
slings allowed!!
Wire Rope Sling Inspection Items

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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.
Synthetic Web Sling Inspection
Items

Acid or caustic burns on the sling.

Melting or charring of any part of the sling’s surface.

Snags, punctures, tears, or cuts.

Stitching is broken or worn.

The sling is stretched. To assist operators in determining if a
sling is stretched, manufacturers incorporate a colored wear
cord inside of the sling. When this red wear cord can be
readily seen upon inspecting the sling, the sling has been
stretched and is to be removed. The web sling may need to be
removed from service before the wear indicator is showing.
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 crane’s 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 Rigger’s Duties
The rigger
selects the
rigging.
 The rigger setsup the rigging.
 The rigger
directs the lift.

OSHA Rigging
Requirements
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All slings and hardware must be:
 Manufactured to meet demanding
specifications.
 Clearly stamped, marked, or labeled.
OSHA prohibits job-made: slings, hooks,
links, and fasteners formed from bolts.
Before each use all components must be
inspected by a Competent Person.
Knowing Safe Working
Loads
Definitions
Hitch “Basket” - loading with the sling passed under
the load and both ends on the hook or a single
master link.
Definitions
Hitch “Choker” – loading with the sling passed
through one eye and suspended by the other.
Definitions
Hitch “Vertical” – loading with the the load
suspended vertically on a single part or leg of the
sling.
Sling Capacities
60 degrees
45 degrees
30 degrees
A sling capable of lifting 1000 lbs in a vertical basket hitch, can only lift 866
60
lbs at a 60 degree angle, and 707 lbs at a 45 degree angle, and 500 lbs at a
30
30 degree angle.
Wire Rope Sling Capacities
Working Safely Around Rigging

General safety guidelines:
 Keep at least ten feet away from power lines.
 Never hoist loads over workers.
 Never stand too close or under a load.
 Never ride a load.
 Use sling angles greater than 45 degrees.
 Attach 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.
Rigging the Load
Sling angles <450, load
unstable, receiver not
protected.
Balanced load; sling angle >600
Safe Usage Practices

Never shock load slings.

Keep loads balanced to prevent
overloading slings.

Always lift loads straight up.

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Never rest a load on a sling, or
pinch a sling between the load
and the floor.

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Slings should be stored off of
the floor and hung on racks
whenever possible in a clean,
dry environment.

Never drag slings across the
floor.

A sling should not be pulled
from under a load when the
load is resting on the sling.
Make sure the hook is
always over the center of
gravity of the load before
lifting it.
Do not apply a load to a
twisted, knotted or kinked
chain.
Do not force or hammer
hooks or chains into
position.
Always hook with a “closed
hook” arrangement (hooks
facing out).
Safe Usage Practices (Cont.)

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Hands and Fingers shall not
be placed between the sling
and the load while the sling
is being tightened around
the load.
Clean chains regularly as dirt
and grit can cause excessive
wear at the link bearing
points.


Never shorten a sling with
knots, bolts or other
makeshift devices. Knots in
slings reduce the capacity by
as much as 50%!!
Protect the chain’s surface
from contact with sharp
corners, which can cause
permanent damage through
gouging or abnormal stress
and wear.
Rigging Protection From
Cutting or Slipping
Softeners, padding or use of blocking..
Mechanical Materials
Handling

Depending on the job, you might use or work around:
 Buggies
 Roof Hoists
 Conveyors
 Skid-steers (“Bobcats”)
 Rough Terrain Forklifts
 Cranes
Buggies
What are the safety concerns while moving
materials with these?
Mechanical Equipment on Flat
Roofs
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Will the deck support the weight of the equipment?
Has the equipment been inspected?
Are all equipment guards in place?
Is the operator trained?
 See Subpart C - .20(b)(4)
Are all aware that the equipment is not to be
operated outside warning lines due to the fall
hazard?
 See Subpart M - Fall Protection -.502
 Closest approach is 6 feet parallel and 10
feet perpendicular to direction of travel.
Roof Hoists
What are the
manufacturer’s
instructions for
set up & use?
What does
OSHA say?
Roof Hoist Safety
Concerns
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.552(a)(1) Compliance with manufacturer’s specifications
and limitations.
.552(a)(2) Load capacity, hazard warnings and instructions
must be posted.
.552(a)(3)(i-iv) Wire rope replacement
criteria.
.552(a)(4) Hoist rope is to be installed in accordance with
manufacturer’s instructions.
.501(b)(3) Fall Protection (Subpart M) in
hoist area.
Is the Hoist Operator
Protected?
Using Conveyors to Move
Materials
Safety Concerns In
Conveyor Use
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Set up and used in accordance with the
manufacturer’s instructions?
Guards in place on pinch points?
Power line clearances maintained?
Maintenance program in place?
No riders on conveyor!
.555(a) Means for stopping motor at
operator’s station + start up warning.
.555(a)(5) Protection for workers below.
.555(a)(7)Lockout/Tagout for maintenance.
Skid Steer Loader
What do we
need to know
about this
operator?
Using Skid Steers

If on the roof – will it take the load?

Is the operator qualified?
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.20(b)(4) – Again! Training is available from
some manufacturers.
Skid Steers are powerful, work in close quarters
with people and are very quick, with large areas
where the operator cannot see.
Is the work area adequately barricaded?
Using Forklifts to Move
Materials

What do we need to know?
 Is the operator trained?
 See .602(d)
 Has the machine been inspected and properly
maintained?

Is the backup alarm audible?

Are ground personnel protected?

Is the balanced load within capacity?

Are workers on roof protected from falls?
MATERIAL STORAGE, AND
DISPOSAL OF WASTE MATERIAL
SUBPARTS
Material Storage
 Five
basic rules for safe
storage:

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Keep total weight within the safe
loading limits of the building’s
floors.
Keep passageways clear.
Control materials so they do not
slide, fall, or collapse.
Provide cribbing for heavy
loads on unstable surfaces.
Store materials away from
traffic.
What Does OSHA
Require?
 Basic
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requirements:
Don’t put materials within 10 feet of roof
edge.
Don’t store materials on scaffolds or
runways.
Keep materials at least 6 feet from floor
openings and hoistways.
Keep aisles clear.
Keep work area free from tripping, fire,
explosion, pest and vegetation hazards.
Setting Materials on the
Deck
What could happen to these stacked materials?
OSHA Also Requires
 Specific

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
requirements:
Stack bagged materials by stepping back
the layers and cross-keying the bags at
least every 10 bags high.
Stack bricks no higher than 7 feet.
Taper masonry blocks back one-half block
per tier for stacks above 6 feet.
Stack lumber on sills and on level solid
ground - never exceed 16 feet high and
always remove nails!
Disposal of Waste
Material
 OSHA
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
requirements:
Scrap lumber, waste and trash must be regularly removed
from the work area.
Materials dropped more than 20 feet require a chute.
Solvent waste, oily rags, and flammables must be kept in
fire resistant containers until removed.
If the waste is considered hazardous, your employer will
have to follow federal, state, and local regulations.
Debris 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 END