MATERIAL HANDLING

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Basic Requirements
Before Starting the
Training
 MATERIAL HANDLING

Involves diverse operations:

• Manual handling
Carrying bags or materials
Unpacking materials

• Material handling via machine

Forklift
Crane
Rigging
 MATERIAL HANDLING

• Manual handling is a common activity in most workplaces

• It includes lifting, lowering, pulling, pushing, carrying, moving, holding

or restraining an object

• Injuries and musculoskeletal disorders affect the back, neck,

shoulder, arms & hands

• It can be prevented through a systemic approach of identification,

assessment and control of risks associated with manual handling.
 MATERIAL HANDLING

WHAT IS A LOAD ?

• Any movable object.

• There is no safe weight limit.

• No specific weight limits exist.

• Numeric guidelines exist.

• Working within them may reduce the risk of injury.

 MATERIAL HANDLING

SAFE LOADS?
 MATERIAL HANDLING
PRECAUTIONS
• The avoidance of manual handling operations whenever possible.
• when avoidance is not possible then the employer must.
• make a suitable and sufficient assessment.
• reduce the risk of injury SFAIRP.

• Ways to reduce the risk;

• Organise the workstations or task.
• Provide information on the load.
• Provide mechanical aids.
• Provide training and information.
 MATERIAL HANDLING
PRECAUTIONS
• Information for employees must be provided,
• on the weight of each load and the heaviest side of each load with an
offset centre of gravity.

• The assessment must be reviewed,

• When it is no longer valid or there has been a significant change in the
manual handling operation to which it relates.

• Employees must,
• Make full and proper use of any system of work
that is provided for use by the employer.
 MATERIAL HANDLING
The Six Point Lift
1. Look at the load.
2. Foot position.
3. Bend knees / back straight (natural position).
4. Test the load / firm grip / head up.
5. Lift with the legs / load close.
6. Put down with care.
 MATERIAL HANDLING
Basic rules of good lifting
• Plan your lift to avoid awkward positions

• Clear and well-lit travel route.

• Being close to the load.

• Secure grip, gloves may be necessary.

• Set load down if you’re losing your grip

• Correct foot position.

• A straight back and bend the knees.

• The load kept close to the body.

• Avoid twisting and jerking, Avoid sudden movements

 MATERIAL HANDLING
Basic rules of good lifting
• Size up the load before you lift

• Center yourself over the load


• Break load into parts

• Get help with heavy or bulky items

• Use handling aids - such as steps, trestles, shoulder pads, handles,

and wheels for heavy loads
• Avoid lifting above shoulder level

• Attach handles to loads to reduce the chances of getting fingers

smashed
 MATERIAL HANDLING
Manual Handling Injuries.

• Lifting overload or wrong by method can result in back injury,

neck strain, wrist sprains, shoulder pain

• Potential Cuts on the fingers

• Skin exposure to chemicals, dust, fumes & vapors or

respiratory issues

• Slip, trip and Fall of material due to

a) Absence of grip to hold the load

b) Obstruction of walking view

 MATERIAL HANDLING

If back pain occurs

• You may have a serious problem if:
• resting a few days doesn’t help
• you have a feeling of numbness in your lower limbs

• For on-the-job relief:

• get up a stretch if you sit for long periods
• shift your feet if you stand
• avoid leaning to one side if you stand

2a
 MATERIAL HANDLING

Injuries that occur to backs

• Strains and sprains
• Ruptured or slipped disks
• Chronic tension and stress
• Other forms of back pain
• Some injuries require surgery
• Some injuries lead to permanent disability
• Back injuries can limit activities on and off the job
 MATERIAL HANDLING

Other factors in back injuries

• Age of employee

• Improper postures when sleeping, standing, sitting

• Physical condition of employee

• Repetitive motions

10a
 MATERIAL HANDLING
Selection of PPE for Manual Handling
 Safety boots  Working apron or
overalls

 Protective gloves
 Goggles or safety
glasses

 Helmets  Face mask or

respirators
 MATERIAL HANDLING
Job Designs to Prevent Manual Handling Injuries
 Keep heavy loads around waist level

 Use of mechanical handling aid

 Package heavy materials into smaller

container
 MATERIAL HANDLING
Job Designs to Prevent Manual Handling Injuries
 Provide handles, hand grips or indents for loads

 Loads to be free from dust, oil, corrosive deposits,

sharp corners, jagged edges or rough surfaces

Indents &
Handles
 MATERIAL HANDLING

Proper Manual Handling – Team

• Team/buddy lifting

10a
 MATERIAL HANDLING

Lifting bulky sacks

Single Person Two Persons

 MATERIAL HANDLING
Handling Cylinders

1 2

3 4

How should one person lift a cylinder onto a platform

 MATERIAL HANDLING
Handholds on load
• Use hook grips on loads with Cut-out hand holds

Curl your fingers around the edge Do not hold the load with finger tips.
 MATERIAL HANDLING

Handholds on Load

Use the "ledge grip" to handle

regularly shaped objects without
handles Hold the object with hands placed
diagonally.
 MATERIAL HANDLING
Handling materials using trolley

1 2 3

Place the lip of the Move off. The

Tip the truck back with assisting person
trolley under the object
assistance. directs the
& use your body weight
to tilt the object. movement.
 MATERIAL HANDLING
Plan ahead
• Use material handling equipment if load is too heavy
• Forklifts
• Hoists
• Dollies

9c
 MATERIAL HANDLING
PERSONAL PROTECTIVE EQUIPMENT
•For loads with sharp or rough edges,
wear gloves or other hand and
forearm protection
•When loads are heavy or bulky, wear
steel-toed safety shoes to prevent
foot injuries if the load is dropped

26
 MATERIAL HANDLING
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
•Don’t place extra weight on the rear of a
counterbalanced forklift to allow an overload
•Machine inspection shall be done by authorized
personnel and certificate shall be available with
the operator all the time
 MATERIAL HANDLING
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

 MATERIAL HANDLING
CRANES
•Check the load chart in the cab
•Frequently inspect all the lifting equipment
•Never lift people
•Check overhead power lines
•Ensure area of travel is clear
•Check third party certificates and all the
documents
•Employees must be trained in the proper
use and limitations of the equipment they
operate

29
 MATERIAL HANDLING
Lifting Gear & Tackle
• Includes
• Chain Slings
• Wire Rope Slings
• Shackles
• Fibre Slings
• Webbing Strops and slings
 MATERIAL HANDLING

Main Hazards
• Overloading
• Incorrect use (wide angles, vehicle recovery, etc).
• Defective equipment
• Damage caused by sharps
• Incorrect slinging methods
 MATERIAL HANDLING
Alloy Steel Chains
• 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
• Must have an affixed tag stating size,
grade, rated capacity, and sling
manufacturer
• It must be marked with grade or
manufacturer's mark
• When a chain shows excessive wear,
or is cracked or pitted, remove it from
service
32
 MATERIAL HANDLING
Unsuitable Alloy Steel Chain Attachments

Right Wrong

Job or shop hooks and links, or makeshift fasteners, formed from

bolts, rods, etc., or other such attachments, can’t be used

33
 MATERIAL HANDLING
Sling Inspection
Inspect slings:
 Each day before use
 Where service conditions warrant
 check wear and tear/ deformation/
cracks/ sharp nicks
 inspection by competent person
inspect slings, wire ropes, shackles Crushing
and loose lifting gear-12 monthly

Bird
Remove them from service if Caging
damaged or defective
34
 MATERIAL HANDLING
Wire
Wire Rope Slings Core

• Eye Splices Center

Eye splices made in any wire rope
must have at least three full tucks
Strand
•Cover or blunt protruding ends of strands
Wire rope
•When using U-bolt wire rope clips to form
eyes, ensure the "U" section is in contact with
the dead end of the rope

•Lubrication shall be done on the regular basis

to avoid corrosion and damage

Dead
End
35
 MATERIAL HANDLING
Synthetic Web Sling
• Mark or code to show:
Name or trademark of manufacturer
Rated capacities for the type of hitch
Type of material

• Fittings must be:

 At least as strong as that of the sling
 Free of sharp edges that could damage
the webbing
• Stitching
 Stitching is the only method allowed to
attach end fittings to webbing, or to form
eyes
36
 MATERIAL HANDLING
Synthetic Web Slings
• Remove from service if any of these
are present:
Acid or caustic burns
Melting or charring of any part
Snags, punctures, tears or cuts Heat Damage

Broken or worn stitches

Distortion of fittings

37
 MATERIAL HANDLING
Storing Materials
• Secure materials stored in tiers by stacking,
racking, blocking, or interlocking to prevent
them from falling

• Post safe load limits of floors

• Keep aisles and passageways clear

• Don’t store noncompatible materials together

• In buildings under construction, don’t place

stored materials within 6 feet of a hoist way or
floor opening
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 MATERIAL HANDLING
HAZARDS
• Improper manual lifting or carrying loads that are too large or
heavy

• Being struck by materials or being caught in pinch points

• Crushed by machines, falling materials or improperly stored

materials

• Incorrectly cutting ties or securing devices

• The lifting appliance itself

• collapse, overturning, unsuitable bases, etc.
• The lifting tackle
• Overloading, incorrect use.
• System of Work
• Overhead lines, incorrect or misunderstood signals.
 MATERIAL HANDLING

SAFE OPERATION
• Information on weights
• Training for driver, banksman, slingers
• Means to prevent overhead cranes coming within 20ft of
persons at work on or near the track
• Appropriate hand signals
• Used within SWL
• Means to prevent overrun
• PPE (Head Protection)
• Failure is reportable under RIDDOR
 MATERIAL HANDLING
Precaution from Surroundings
Avoid hazards during erection
• Overhead cables
• Permits or permission for adjoining airspace
• Strength of the ground
• Fuel storage
• Safety of third parties
• Designated lifting zones
• Covered or netted loads
 MATERIAL HANDLING
Safety Precautions

• wear gloves while handling ropes

• defective equipment should be returned to rigging
dept.,
• do not use kinked or damaged slings
• keep ropes, chains and fiber slings away from flame
and hot work
• don’t walk under a load
• All lifting equipment shall be Certified and Tested
• Thorough examination every six months
• Correct eye bolts shall be used
 MATERIAL HANDLING
Safety precautions
• lifting equipment marked with designed working
load
• use only for the purpose designed
• do not wrap the hoist rope around the load
• ensure identical material when using more than
one sling
• ensure slings are of the same material
• No site repairs allowed
• Used for the correct purpose
• Information, instruction, training and supervision
 MATERIAL HANDLING
Precautions with Slings
• don’t wrap around hook

• do not bend the eye section

• use multiple slings for lifting rigid objects,

ensure at least two should support the
total weight

• choker hitch eye shall not be forced down

 MATERIAL HANDLING

Precautions
 mouse the hook latch
unless built in
 use standard hand or radio signals
 check C of G and adjust
the slings
 MATERIAL HANDLING
Crane and lifts Precautions
• competent operators
• No riding on
- lifting block
- headache ball
- any hoisting device
• stay clear when lifting
• stay away from slings under load
• Keep out of pinch points when
- hooking
- coupling
- hitching
 MATERIAL HANDLING
Task Risk Assessment
• Always evaluate the safety factors
• operator must be briefed where
applicable
• consider weight & C of G
• operate within the capacity

Precautions
• do not use cranes in adverse weather conditions
• check ground stability before tracking a crane
• extend outriggers fully
• cranes should have back-up alarms
 MATERIAL HANDLING
Signaling

• one signal man shall direct a crane at a time

• another man is required to relay the directions.
• Use visual directions, wherever possible
• multiple crane lifts require radio communication
• maintain communication equipment in good
condition
• use helper while driving in congested areas
 MATERIAL HANDLING
precautions before loading

• inspect hooks
• remove hooks where the throat opened more
than 15%
• remove hooks if twisted up to 10% from the
plane.
• shutdown equipment when
- oiling
- fueling
- water checking
- adjusting moving parts
• review crane safety checklist
• report malfunction
• visual inspection for sling shackles and hooks
 MATERIAL HANDLING
Lifting the Load
• checks the slings before lifting
• Check for the marking on the sling
• don’t use twisted or knotted slings
• don’t lift one leg of a multi leg sling until the other legs
are secured
• don’t subject the hook to point loading
• avoid impact loading
• take care of pinch points
• use proper type of slings
• remove loose materials
from the load before lifting
• don’t leave a suspended
load in the air
 MATERIAL HANDLING

Winches and Cables

• minimum two full cable wraps must
remain on drum
• provide locking paws for hand operated
winches
• maintain safe distance from tension cables
 MATERIAL HANDLING
CRITICAL LIFT
Critical lifts coordination meeting prior to lift
• Analysis conducted by the following departments
- production
- engineering
- rigging
- maintenance
- dimension control
- HSE
- others as required
- employees involved will attend a safety briefing to review
hazards and take necessary precautions
 MATERIAL HANDLING

Categories of Hazardous Chemicals

• Corrosive
• Flammable
• Toxic
• Reactive
• Biological (infectious)
• Carcinogen (cancer-causing)
• Radioactive
 MATERIAL HANDLING

Physical States of Hazardous Materials

• Liquid
• Solid
• Gas
• Vapor
 MATERIAL HANDLING

How to Handle Chemicals Properly

• Use cautions
• Always follow procedures
• Read all labels
• Keep yourself and the work area clean
• Plan ahead
 MATERIAL HANDLING

Routes of Exposure Symptoms of Possible Overexposure

• Inhalation • Eye discomfort

• Ingestion • Breathing difficulty
• Absorption • Dizziness
• Injection • Headache
• Nausea
• Vomiting
• Skin irritation
 MATERIAL HANDLING

Incompatible Chemicals
• Flammables and oxidizers
• Flammables and any ignition source
• Acids and cyanides
• Strong acids and strong alkalines
• Concentrated acids and water
• Organic solvents and corrosives
• Corrosives and other reactive materials
 MATERIAL HANDLING

Handling Flammable Chemicals

• Keep containers closed when not in use
• Keep away from ignition sources
• Avoid contact with incompatible materials
• Only transfer to approved containers
• Bond all receiving containers
• Clean up spills and dispose of waste properly
 MATERIAL HANDLING

Proper Storage of Flammable Chemicals

• Ensure that storage areas meet regulatory requirements

• Replace all bung caps with drum vents after receiving containers
• Ground all drums properly
• Store quantities in approved storage rooms and cabinets
• Store only in small quantities
 MATERIAL HANDLING

General Safety Tips

• Never eat, drink, or smoke while using hazardous chemicals
• Use personal protective equipment as required
• Make sure all chemical containers are properly labeled
• Always wash up after using chemicals
• Never smell or taste a chemical to identify it
• Know all emergency procedures and equipment
• Always read labels’ MSDSs prior to use
• Store all hazardous chemicals properly
• Always use hazardous chemicals as intended
 MATERIAL HANDLING

Primary Container Labels

• Identity of the hazardous chemical
• Appropriate hazard warnings
• Name and address of the manufacturer
or importer
• Target organ effects

Secondary Container Labels

• Identity of the hazardous chemical
• Hazard warning information
 MATERIAL HANDLING
Handling Chemical Emergencies
• Know emergency phone numbers
• Know how to control the spill
• Know proper equipment shutdown procedure
• Know proper evacuation routes and assembly areas

What Emergency Personnel Should Know

• Emergency cleanup and disposal measures
• Required protective equipment
• Use of cleanup equipment
• Firefighting and other emergency measures (i.e., first aid)
• Use of other emergency equipment
 MATERIAL HANDLING
First Aid for Chemicals in the Eyes
• Don’t rub the eyes
• Hold eyelids open and flush with water for 15 minutes
• Be careful not to contaminate the other eye
• Seek additional medical attention

First Aid for Chemicals on the Skin

• Flush area with lukewarm water for 15 minutes
• Remove clothing and jewelry from burn area
• Seek additional medical attention
 MATERIAL HANDLING

First Aid for Chemical Ingestion

• Induce vomiting only if told to do so by Poison Control
• Get immediate medical attention

First Aid for Chemicals Inhalation

• Move victim to fresh air
• Get immediate help