Mechanical Lifting

Manual material handling is the lifting, carrying or moving

of materials, articles or things.

Mechanical materials handling is the movement of materials,

articles or things by such means as lift trucks, conveyors, or
cranes and hoists

Lifting Machine means a crane, crab, winch, teagle, pulley block,

gin wheel, transporter or run ways.

Lifting Tackle means chain, sling, rope, hook ,shackle, swivel ,

coupling, socket , clamp or tray or similar appliance ,whether
fixed or moveable , used in connection with raising or lowering of
persons or loads by use of lifting machine.
Advantages
•Save money. Automated systems speed up productivity. The work can
get done faster and with less people than with manual equipment.
Business owners save money by hiring fewer employees. Automated
material handling systems are an economical investment.

•Improve efficiency. Workers are better able to do their tasks using

automated equipment, meaning they can work much more efficiently. It
takes less time to do a job and it is more likely to be done correctly, which
means each employee is able to accomplish more.

•Maximize space. Automated systems like lifts make it easier to store

materials and products. Items can be stacked higher, and be accessed
easier, opening up workspace and
additional storage space in your warehouse or plant.

•Reduce accidents. One of the biggest advantages to automated

equipment is that fewer accidents occur.
Employee safety is a top concern for businesses in the industrial sector.
Automated equipment can eliminate the need for heavy lifting, reduce the
chances of workers tripping or falling, and make work stations ergonomic
•Better customer service. Make customers happy by
fulfilling orders faster, reducing or eliminating mistakes,
and improving shipping. You can even take on new
customers because increased productivity allows you to
fulfill more orders.

•Increase warehouse value. Resale value of your

warehouse and equipment goes up with automated
systems. In the event that you sell your workspace,
having automated systems in place not only attracts
more buyers, but it means you can ask a higher price for
the entire package or the individual pieces of equipment.

•Attract employees. If you’re looking for good quality

workers in your warehouse or plant, having automated
systems in place will help to recruit a higher caliber of
employees. Workers with experience and more specific
training to handle automated systems will be interested
Disadvantages

•initial cost of equipment. Automated equipment is more expensive up

front than manual equipment. However, what you save in man power
and what you gain in increased productivity, means the equipment will
eventually pay for itself and then some.

•Reduced flexibility for change. Once automated systems are in place,

it is likely not as easy to make changes in your workspace. But once
you go automated and see how smoothly everything runs, it’s not
likely you’ll want to return to manual equipment afterward.

•Possible down time due to malfunction. With automatic machines

there is always the chance of a problem or breakdown, which can lead
to considerable downtime while it is repaired. If the problem cannot be
fixed by anyone on site, an outside specialist may need to be called,
which could mean more time spent waiting. In some cases, work may
be able to continue manually in the meantime, but in some cases that
isn’t possible. Equipment malfunction can be avoided in most cases
with routine maintenance of all machinery. If proper care is taken to
keep automated systems in good shape, breakdowns should only
occur rarely, if ever.
•Maintenance costs. Some automated equipment needs
maintenance. Routine maintenance may be performed regularly
by onsite workers, but periodic professional maintenance should
be handled by specialists who are trained to inspect and tune-up
machinery so that it runs smoothly and efficiently. Properly
maintained equipment will save you money in the long run by
preventing problems and increasing the overall lifespan of your
systems. Carolina Material Handling offers many types of
automated equipment that require very low maintenance,
keeping costs low.
Double Gantry EOT Crane.
Single Gantry EOT Crane.
Jib Crane
Semi goliath Crane
Substructure Under Slung Single Gantry Crane
Substructure under slung double gantry Crane
Goliath Crane
Substructure over slung double gantry Crane
Monorail
Electric overhead traveling crane or EOT crane is one of the
most common types of overhead crane, or called bridge cranes,
which consist of parallel runways with a traveling bridge spanning
the gap.
Mobile Crane
Tower Crane
Lifting Hook
Rope Drum
Crane Pendants
Hoisting Limit Switch
Safety in Design, Construction and Operation :
General requirements are as under :
1. Hoist limit switch to cut of power and apply brakes when hook/cage rises to
a predetermined level to prevent over-winding.
2. Limit switches to prevent over travelling and over transferring.
These limit switches should automatically reset within a reasonable distance
travelled in the opposite direction.
3. Emergency push button for prompt use.
4. Isolation switch to cut off all power except lighting. Proper earthing.
5. Off position interlocking to prevent the circuit breaker from being closed
unless all controllers are in off position.
6. Screen on bare conductors.
7. Pilot lamp (red lens) to indicate on or off condition.
8. Hand lamp of 25 volt DC or AC.
9. Earthing as per Electricity Rules.

10. Means of anchoring when the hoist/crane is left unattended or under

storm conditions.
11. Others : Sheaves guard to retain ropes in grooves, safe means of
access, ladders and guards on moving/rotating parts. Examination for wear,
malfunction, damage and proper operation of hooks, ropes, brakes, clutches
and limit switches.
12. Safety points for operation : No loading over SWL. Marking of SWL and
load indicators for varying SWL. Pick up load only when it is directly under
the hook, otherwise stresses will develop. Full vision in driver's cabin. Fire
extinguishers, warning device, safe operating precautions for raising and
lowering loads, moving loads over workers working underneath and
duties of drivers while leaving the cabin, should be prescribed and followed.
People should not be lifted or transported by hoist or crane
Testing, Inspection and Maintenance:
Testing includes insulation tests for electric wiring. Test voltage should be DC (more
than twice the rated voltage) and insulation resistance of each wiring circuit should be
more than 2 m ohms.
Tests for satisfactory operation of each controller, switch, contactor, relay, interlocks,
sequence of operation, protective devices. Tolerance on specified speeds at full load
shall be within 10%.

Overload test by 125% of the working load. Proof (test) load may vary from 1.5 to 4
times of the SWL as mentioned in Part 3.3.3. Sample of wire ropes should be tested.
Periodic inspections to detect unsafe conditions, warn or damaged parts, wear and
other defects in wire and fibre ropes, lifting gear, tyres etc. are necessary.
Gear wheels and pinions should be maintained in good condition, properly keyed and
in their correct gear mesh. Gear wheels and pinions with broken teeth or cracked
areas, rims or bosses should be discarded and replaced. The faces of all ratchets, jaw
clutches, gear locks and collars should be kept in their correct relationship to ensure
safety in use.

Repairs shall be carried out by 'permit to work' system. All power shall be
disconnected while doing such work.

Notices like 'under repair' 'out of order' 'don't' . start' etc. shall be displayed.
Goods Lift.
 Good Design

The Factories Act requires as under

Every hoist and lift shall be of good mechanical construction, sound

material and adequate strength, properly maintained and examined by a
competent person at least once in every twelve months.

Good construction means as per standards (e.g. IS). Sound material

means as per required quality of the material. Adequate strength means proper
design, factor of safety and good workmanship.

Properly maintained means following safe and standard procedures, work

permits, manufacturer's and other guidelines.

Every hoist or lift shall have the safe working load plainly marked on it and
no load greater than such load should be carried on it. The cage of every hoist
or lift used for carrying persons should be fitted with a gate on each side from
which access is afforded to a landing and such gates should be fitted with
interlocking or other efficient devices to ensure that they cannot be opened
except when the cage is at the landing and the cage cannot be moved unless
all the gates are closed.
 Loose Gears.
Loose gears are removable parts of a lifting appliance that are used to attach a load to it. They
are used for lifting cargo and other heavy loads.

Examples of loose gears

blocks, chains, hooks, rings, shackles, swivels, slings, grab buckets, spreaders, and lifting
beams.

Importance of loose gear inspection

•Loose gear inspections ensure that the lifting equipment is safe to use

•Inspections confirm that the gear can lift the safe working load (SWL) plus the required load

How to identify loose gear

•Loose gear should be marked with a visible alphanumeric identification mark

•The mark should be durable and legible

•The mark can be incised, stamped, or outline-welded

•The SWL should be marked on the equipment if possible

Loose gear. : Any gear by means of which a load can be attached
to a lifting appliance but which does not form an integral
part of the appliance or load.
 Lifting Tackles
Engine Lifting Tackle Pipe Lifting Tackle

Gear Box Lifting Tackle Spreader Beam