New England
Roofing Industry
Partnership
Materials Handling, Rigging,
& Cranes
SUBPARTS
H,N,O
Materials Handling, Rigging & Cranes
Training Objectives
 After
completing this unit, you will:
– 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.
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SUBPARTS
H,N,O
Materials Handling, Rigging & Cranes
References
 29
CFR 1926.250; Subpart H, Materials
Handling, Storage, Use, and Disposal
Subpart N – Cranes,
Derricks, Hoists, Elevators, and
Conveyors
 29CFR1926.500,
Subpart O – Motor
Vehicles, Mechanized Equipment, and
Marine Operations
 29CFR1926.600,
 ANSI
and ASME Standards
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SUBPARTS
H,N,O Materials Handling, Rigging & Cranes
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.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
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!
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
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.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
6
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 don’t twist your back.
– Avoid lifting above shoulder height.
SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
A Proper Lift
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SUBPART
H,N,O Materials Handling, Rigging & Cranes
Keeping in Lifting Shape
 Keeping
your stomach and back
muscles strong can help prevent back
injuries.
 Even if you don’t work out in a gym, you
can prevent back injuries.
 Strength and flexibility exercises should
be done at least every other day.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
For Strength and Flexibility
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SUBPARTS
H,N,O Materials Handling, Rigging & Cranes
Mechanical Aids
 Use
hand trucks,
dollies, carts, wheel
barrows, and
wagons whenever
possible.
 Encourage
management to
include mechanical
aids whenever
possible.
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SUBPARTS
H,N,O Materials Handling, Rigging & Cranes
11
Mechanical Aids
Slab carrying rig
here has eliminated
bending over and
has provided secure
non-abrasive handholds.
SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
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!
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
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.
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SUBPARTS
H,N, O Materials Handling, Rigging & Cranes
Material Storage
 Five
basic rules for safe storage:
– 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.
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SUBPARTS
H,N,O Materials Handling, Rigging & Cranes
What Does OSHA Require?
 Basic
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.
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SUBPARTS
H,N,O
Materials Handling, Rigging & Cranes
OSHA Also Requires

Specific 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!
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SUBPARTS
H,N,O
Materials Handling, Rigging & Cranes
Setting Materials on the Deck
What could happen to these stacked materials?
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SUBPARTS
H,N,O
Materials Handling, Rigging & Cranes
Disposal of Waste Material

OSHA requirements:
– Scrap lumber, waste and trash must be regularly
removed from the work area.
– Burning must meet local regulations.
– 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.
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SUBPARTS
H ,N, O Materials Handling, Rigging & Cranes
Debris Chutes
Objectives in using a chute: material control,
dust control and protection of workers and
bystanders – note the differences here….
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Mechanical Materials Handling
 Depending
on the job, you might use
or work around:
– Buggies
– Roof Hoists
– Conveyors
– Skid-steers (“Bobcats”)
– Rough Terrain Forklifts (“Lulls”)
– Cranes
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Buggies
What are the safety concerns while moving
materials with these?
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Mechanical Equipment on Flat Roofs
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.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
23
Roof Hoists
What are the
manufacturer’s
instructions for
set up & use?
What does
OSHA say?
SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Roof Hoist Safety Concerns
 .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.
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SUBPARTS
H, N, O
Materials Handling, Rigging & Cranes
Is the Hoist Operator Protected?
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
26
Using Conveyors to Move Materials
SUBPART
H, N, O Materials Handling, Rigging & Cranes
Safety Concerns In Conveyor Use
 Set
up and used in accordance with the
manufacturer’s instructions?
 Guards
 Power
in place on pinch points?
line clearances maintained?
 Maintenance
program in place?
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SUBPART
H, N, O Materials Handling, Rigging & Cranes
28
Safety Concerns In Conveyor Use
 No
riders on conveyor!
 .555(a)
Means for stopping motor at
operator’s station and start up warning.
 .555(a)(5)
Protection for workers below
against falling objects.
 .555(a)(7)
Lockout/Tagout for maintenance.
SUBPART
H, N, O Materials Handling, Rigging & Cranes
29
Using Conveyors to Move Materials
Power line
clearance?
Back up alarm or
signal person?
Fall protection for
roof workers?
SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Using Skid Steers
on the roof – will it take the load?
 Is the operator qualified?
 If
– .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 (the “no-zone”).
 Is
the work area adequately barricaded?
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
31
Skid Steer Loader
What do we
need to know
about this
operator?
SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Operator sight distances
from eye level to ground
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The “NO-ZONE”
11’ 7”
Eye level 5 ft 5 in above
ground level
11’ 5”
21’ 8”
4’ 10”
6’ 1”
3’ 1”
6’ 3”
Vehicle:
S-44
Bobcat
SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
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?
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Getting Materials to the Roof
How can we protect against falls in these
situations?
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Using Forklifts
What precautions need to be taken around
the machine’s operating area?
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TS
SUBPARTS
H,
N,N,
O O Materials Handling, Rigging & Cranes
Operator sight distances Eye level 7 ft - 3 in above
from eye level to ground ground level
85’ 0”
18’ 2”
7’ 9”
10’ 9”
3’ 0”
39’ 0”
The “NO-Zone”
21’ 2”
14’ 10”
Vehicle: R-14793 High
Reach Fork Lift
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
37
Platforms on Forklifts

If you work off of
some attachment
it must:
(1) Be secured to forks.
(2) Have a guardrail.
(3) Have a Personal Fall
Arrest System tie-off.
(4) Used only while the
operator is in the seat.
SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Rigging and Crane Safety
 Rigging
is the lines or cables used to
lift and move materials by hoisting
with a crane.
 A rigger is a skilled mechanic who
prepares heavy equipment or loads
of material for movement.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Examples of Rigging
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
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.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
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!
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SUBPARTS
H, N, O
Materials Handling, Rigging & Cranes
The Rigger’s Duties
 The
rigger selects
the rigging.
 The rigger sets-up
the rigging.
 The rigger directs
the lift.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
43
OSHA Rigging Requirements

All slings and hardware must be manufactured
to meet demanding specifications which
include safety factors.

All web or alloy chain slings must be clearly
stamped, marked, or labeled, for capacity.

OSHA prohibits job made: slings, hooks, links,
and fasteners formed from bolts.

Before each use all components must be
inspected by a Competent Person.
SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
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.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Knowing Safe Working Loads
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Sling Angle
 The
safest sling angles are greater
than 450 from the horizontal.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Rigging the Load
Sling angles <450, load
unstable, worker not
protected.
Balanced load; sling angle >600
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
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.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Working Safely Around Rigging2
 General
safety practices:
– 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.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Crane Hand Signals
Only a qualified rigger will give hand signals.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
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?
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Basic Crane Safety2
 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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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Truck-Mounted Cranes/Boom Trucks
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Case Study: What went wrong?
Two employees were moving
structural steel building
beams to a storage area.
After setting the fourth beam
on the crib, the signal man
signaled the crane operator to
pull the sling from around a
cribbed structural beam which
was set on its flange side.
The second employee then
attempted to remove the
shackle from the beam when
the swaged fitting of the sling
apparently caught and
caused the steel beam to roll
off the cribbing, crushing the
second employee.
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SUBPARTS
H, N,O Materials Handling, Rigging & Cranes
Materials Handling
(1926.250 - 252)
Common OSHA Citations:
.251(a)(1) Rigging equipment inspection
and removal from service.
.251(e)(8) Synthetic Web Slings – removal from
service.
.252(a) Exterior drop chutes
.251(a)(4) Rigging capacity not marked – not prooftested.
How can the hazards addressed by these
Standards best be corrected, controlled, or
eliminated?
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Review Questions
 True
or False?
1. Back injuries are the number one cause
of worker compensation claims.
2. Using proper lifting techniques, staying in
shape, using mechanical aids, and team
lifting are the best ways to avoid back
injuries.
3. Using a back belt almost always prevents
a back injury.
4. Anyone can hook-up a sling and be a
rigger.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Review Questions
 True
or False?
5. Job-made slings, hooks, links, and fasteners
formed from bolts are allowed if a Competent
Person says so.
6. Proper knots are permitted in web-slings.
7. Slings should be inspected before each use
and pulled from service if found defective.
8. The safest sling angles are less than 45
degrees from the horizontal.
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SUBPARTS
H, N, O Materials Handling, Rigging & Cranes
Review Questions
 True
or False?
9. Cranes and rigging must stay at least 10
feet from power lines.
10. Materials can be stored within 10 feet of
the roof’s edge.
11. Materials dropped more than 20 feet
require a chute.
12. Materials must be kept at least 2 feet from
floor openings and hoistways.
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