Training Module – Material Handling

Safe Material Handling

We, at Reliance believes that “All injuries, occupational illnesses as well as
safety and environment incidents are preventable”

We therefore, request that you make yourself conversant with this guide and apply the
principles and rules when you have to conduct work in elevated places.
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Purpose of Module

To provide guidelines on:

• Handling Materials manually
• Using moving machinery like
➢ Fork Lift Trucks
➢ Conveyors
➢ Cranes and Derricks
➢ Tower Cranes
➢ Overhead and Gantry Cranes
➢ Mobile Cranes
➢ Passenger Lifts and Material Hoists

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 Associated Hazards

• Poor site layouts Factors contributing to injuries:

• Falls from Vehicle • Weight and bulkiness of objects

• Bending, twisting, turning movements
• Height Restriction

• Overturning

• Collisions

• Striking people and equipment

Types of injuries commonly reported:

• Sprains, strains, tears
• Soreness and pain
• Bruises and contusions
• Cuts, lacerations, punctures, crushing, and
amputations 4
Precautionary Measures to Avoid Manual handling Injuries

Avoiding/Minimizing Manual handling risks by considering the Task, the Individual, the Load and
the working Environment (LITE)

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Load and Individual

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Task

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Working Environment

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Controls

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 Proper Manual Lifting Techniques
• Not to carry loads above capacity
• Loads shall not exceed 50 kg. for men, 20 kg. For women
• Mechanical lifting is preferable
• Safe lifting postures
To avoid injury, follow these steps for proper lifting and material
handling:
• Warm Up: Your muscles need good blood flow to perform properly.
Consider simple exercises such as jumping jacks to get warmed up
prior to lifting tasks.
• Stand close to load: The force exerted on your lower back is
multiplied by the distance to the object. Stand as close to the load as
possible when lifting.
• Bend your knees: Bending your knees and keeping your upper body
upright allows you to use your legs to lift, rather than your back.
• Grip the load: Do not lift a load if you can't get a good grip. Some
loads are not too heavy, but are simply too large to grip easily.
Consider lifting such a load with someone else.
• Lower load in reverse: You can just as easily injure your back putting
something down as you did picking it up. Lower using your legs and
keep the load close to your body.
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Manually Operated Load handling Equipment

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Powered Load Handling Equipment's

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Overturning Prevention

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Precautions for Lifting accessories

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Precautions for Material Movement using Cranes

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Requirements for Lifting Operations

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Periodic Inspection and Examination

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 General Requirements – Mechanical Lifting
All lifting machines and lifting tackles bearing
• Trained Drivers and Operators
• Identification mark
• Adequately skilled
• Safe Working Load
• No persons below 18 years of age
• Date of Last test
• Fit for Use
Precautions:
•The Load is safe and secured while lifting
• Slinging method is proper
• Lifted load not exceeding safe working load
• Load is so slung, that it will not collapse or does not damage the sling
• No load is unattended when power is on or load is suspended above machinery
• No person shall ride on the suspended load or lifting machinery
• All persons shall strictly use helmets and safety shoes
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Cranes and Derricks
Unsafe Practices Remedial Measures

Use Hook latch to avoid

slings from getting
removed from hook

Non-Use of Hook Latch

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Cranes and Derricks
Tipping Axis
STABILITY

•A is a point in the Tipping of Crane

•To achieve the stability of Crane the

following equation should be satisfied

W3 •Moment about point A

W1
W2
A •W1 X L1 + W2 X L2 ≥ W3 X L3

L2
L1 L3
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Cranes and Derricks

When traveling up a gradient, the When traveling down a gradient,

load shall be derricked out the load shall be derricked into

Position shall be corrected on reaching the level ground

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 General Requirements
Except where Electrical Lines are de-energised

Minimum clearance between the electric lines and any part of crane

3 meters for ≤ 50kV

3 meters plus 1 cm for each 1 kV over 50 kV, for > 50kV

In transit with no load and boom lowered

1.2 meters for ≤ 50kV

3 meters for > 50kV and ≤ 345 kV

4.8 meters for > 345kV and ≤ 750 kV

A person shall be designated to observe clearance of the equipment. Any overhead wire shall be considered
to be an energized line unless and until the person owning such line or electrical utilities authority indicates
that it is not an energized line and has been visibly grounded. 24
Capacity of Slings

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 Rigging Equipment Slings

• Types of slings covered are those made from alloy steel chain,
wire rope, metal mesh, natural or synthetic fiber rope, and
synthetic web.

Chain Wire Rope Metal mesh Synthetic

PPT-110-01 26
Sling Inspection

• Inspect slings:
➢ Each day before use
➢ Where service
• conditions warrant
• Remove them from service
• if damaged or defective

PPT-110-01 27
 Remove From Service

• Immediately remove damaged or defective slings from service.

PPT-110-01 28
 Alloy Steel Chains

• Adapts to shape of the load

• Can damage by sudden shocks

• Best choice for hoisting very hot materials

• Must have an affixed tag stating size,

grade, rated capacity, and sling
manufacturer

PPT-110-01 29
Markings: Alloy Steel Chain

• It must be marked with grade or manufacturer’s mark

PPT-110-01 30
Alloy Steel Chain Attachments

• Rated Capacity

• 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

PPT-110-01 31
Unsuitable Attachments

• For Ally Steel Chain

Right Wrong

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

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

PPT-110-01 32
Chain Wear

• When a chain shows excessive wear, or is cracked or pitted,

remove it from service

• Non-alloy repair links can not be used

PPT-110-01 33
Wire Rope Slings

• Used to hoist materials

• Selection considerations:
• • Strength
• • Ability to bend without cracking
• • Ability to withstand abrasive wear
• • Ability to withstand abuse

PPT-110-01 34
Wire Rope Slings: Eye Splices

• Eye splices made in any wire rope must have at least three (3)
full tucks

PPT-110-01 35
Protruding Ends

• Cover or blunt protruding ends of strands

PPT-110-01 36
Wire Rope Clips

• When using U-bolt wire rope clips to form eyes, ensure the "U"
section is in contact with the dead end of the rope

Dead End

This is the correct method

PPT-110-01 37
Lubrication

• Regularly lubricate ropes and chains

PPT-110-01 38
Wire Rope Slings

• Remove From Service if these happen,

Bird Caging Kinking

Crushing
PPT-110-01 39
Synthetic Web Sling Markings

• Mark or code to show:

▪ Name or trademark of
manufacturer
▪ Rated capacities for the type
of hitch
▪ Type of material

PPT-110-01 40
Synthetic Web Slings Fittings

• Fittings must be:

• At least as strong as that

of the sling

• Free of sharp edges that

could damage the
webbing

PPT-110-01 41
Synthetic Web Sling Stitching

• Stitching is the only method allowed to attach end fittings to

webbing or to form eyes

Stitching

PPT-110-01 42
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
▪ Broken or worn stitches Heat Damage
▪ Distortion of fittings
PPT-110-01 43
Summary

• Manually handling materials:

• When lifting objects, lift with your legs, keep your back straight, do not
twist, and use handling aids

• Using cranes, forklifts, and slings to move materials:

• Watch for potential struck by and crushed by dangers
• For slings, check their load capacity, inspect them, and remove them
from service when they display signs of stress or wear

PPT-110-01 44
Thank You

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