STANDARD OPERATING PROCEDURE (SOP)

Tata Steel Meramandali

Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/HSM/MM/CRS/SOP/02 Effective Date 23-11-2025 REV. No. 01
SOP DESCRIPTION MATERIAL HANDLING SECTION HSM-MM
DEPARTMENT HOT STRIP MILL PAGE Page 1 of 7

Remarks /
Associated safety Hazards/ Env. Responsibility Safe process (tools & Equipment, PPEs, Training Reference
Step No. Details of Activity (WHAT)
Impacts/ Quality Requirements (WHO) etc.) (HOW) (Document &
Records)
SAFETY: Check the physical condition of the working persons. 1. A person should
Working Persons Physical 1. Poor posture leading to Engage in conversation with the individual and ask not be
Fitness/ Behavior Checking musculoskeletal injuries. about their health status. Observe their behavior and considered for
2. Unawarenessof prevailing responses carefully. the job if their
proximity hazards in the six health condition
directions (East, West, North, Required Personal Protective Equipment (PPE): is not
South, Top, and Bottom). Engineer/ Safety helmet, safety shoes, safety goggles, hand gloves satisfactory.
1. ENVIRONMENT: Excessive noise
levels affecting concentration and
health.
O P TSTSL
Technician/
Supervisor
(use cut resistant hand gloves when handling sharp
edge materials) and fluorescent jacket. 2. Clearly explain
the job plan and

d S 1. All personnel should undergo safety induction

training provided by Tata Steel.
2. All personnel must be familiar with the use of
its associated
hazards to all
team members.
QUALITY: NA

a l i common safety appliances or personal protective

equipment (PPE) in accordance with Tata Steel
Safety Standard SS/GEN-58.

Shifting Of Lifting Accessories

To The Working Area
SAFETY:

V
1. Risk of manual handling injuries.
2. Tripping hazards from tools and
equipment placed in walkways.
Required Tools and Equipment:
1. Lifting Equipment:
2. EOT Crane
3. chain pulley block/ Electric host
Ensure that all
personnel are
equipped with the
necessary Personal
3. Potential for tools to fall and 4. Forklift/ Hydra
TSTSL Protective Equipment
2. cause injury if improperly secured
Technician/ (PPE) before starting
during transport. Lifting Accessories:

ENVIRONMENT: NA
Supervisor
1. D-Shackles
2. Wire Rope Slings/ Chain Slings/ Web Slings
(Nylon/ Polyester)
O P work. This includes
safety shoes, safety
helmets, safety
3. Eye Bolts/ Spreader Bars
4. Swivel Hooks

d S goggles, and
fluorescent jackets.

PREPARED BY
Name and Designation: Mr. PRUTHIRAJ MOHAPATRA (MGR)
REVIEWED BY
Name and Designation: MR. AMAR KUMAR ADHYA (SR.
a l i APPROVED BY
Name and Designation: Mr. NALIN KUMAR (HEAD MM-HSM)

V
AREA MGR)
Signature with Date: 20.11.2025 Signature with Date: 20.11.2025 Signature with Date: 20.11.2025
Printed By -QR Scanned Copy Print valid till - 18-Feb-2026 Printed on - 08-Feb-2026 SOP Valid Till - 04-Nov-2026
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel Meramandali
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/HSM/MM/CRS/SOP/02 Effective Date 23-11-2025 REV. No. 01
SOP DESCRIPTION MATERIAL HANDLING SECTION HSM-MM
DEPARTMENT HOT STRIP MILL PAGE Page 2 of 7

QUALITY: Ensure all tools and 5. Lifting Beams/ Wooden Blocks

tackles are inspected for functionality. Note:
Confirm that tools are stored properly 1. Always inspect the condition of the tools and
equipment before use.
in the working area to prevent loss or
2. If a hammer and open-end spanner are required
damage. during the work, seek approval through the
designated checklist before using.
1. Take work permit in the Form
SAFETY:
1. Poor posture leading to EHSMSM/WORKS/446/4007 from Mill Mech
musculoskeletal injuries. shift in charge/ Engineer.
2. Unawarenessof prevailing 2. Ensure that proper positioning of equipment has
proximity hazards in the six been done and all equipment locks & Group
directions (East, West, North,
South, Top, and Bottom).

O P
Engineer/
Isolation lock are at the proper place as per
POSITIVE ISOLATION NORMS if required.
(Applicable for lifting of heavy weight gear
3. Getting Permit To Work Before
Starting The Job
ENVIRONMENT: NA

d S TSTSL
Technician/
Supervisor
boxes, Motors, Other Equipment from the mill
stands/ if any heavy equipment replacement

a l i required positive isolation.)

3. Fix the personal lock in the group isolation box
and then start the job.

QUALITY: NA
V 4. Follow the given ESI documents for this job if
applicable. (There is no separate ESI for
material lifting only applicable as per the
requirement).
SAFETY: 1. Assess the weight, size, and shape of the material
Factors that increase the risk of strains, before lifting. 1. Horizontal
4.
Material Handling By Manual
Lifting
sprains and other muscular disorder:
1. The number of times the load is
lifted or moved.
TSTSL
Technician/
Supervisor
2. For loads that are unstable and/or heavy, follow
management guidelines for: Equipment use/
Reducing the weight of the load/ Repacking
O P 2.
distance to object
less than 25 cm.
Height of grip

(e.g., grease drum, oil drum,

2. The person's posture when lifting.
3. The distance the load is to be
containers to increase stability.
3. Plan The Lift:

d S less than 25 cm
above knuckle

PREPARED BY
Name and Designation: Mr. PRUTHIRAJ MOHAPATRA (MGR)
REVIEWED BY
Name and Designation: MR. AMAR KUMAR ADHYA (SR.
a l i APPROVED BY
Name and Designation: Mr. NALIN KUMAR (HEAD MM-HSM)

V
AREA MGR)
Signature with Date: 20.11.2025 Signature with Date: 20.11.2025 Signature with Date: 20.11.2025
Printed By -QR Scanned Copy Print valid till - 18-Feb-2026 Printed on - 08-Feb-2026 SOP Valid Till - 04-Nov-2026
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel Meramandali
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/HSM/MM/CRS/SOP/02 Effective Date 23-11-2025 REV. No. 01
SOP DESCRIPTION MATERIAL HANDLING SECTION HSM-MM
DEPARTMENT HOT STRIP MILL PAGE Page 3 of 7

small beam, channel, etc.) moved.  Wear appropriate shoes to avoid slips, trips, or height.
The design of the work area and falls.
layout of the workplace, e.g.,  If you wear gloves, choose the size that fits 3. Lifting duration
whether the load is to be moved in properly. Depending on the material the gloves are of less than one
a restricted space or on an uneven made of, and the number of pairs worn at once, hour per day.
surface. more force may be needed to grasp and hold 4. Frequency of
4. movements, forces and vibration objects. For example, wearing a single pair of heat- lifting less than
relating to the task resistant gloves can reduce your grip strength up to or equal to 0.2
5. The duration of the task. 40 percent. Wearing two or more pairs of gloves at lifts per minute.
6. Poor Lightening Condition. once can reduce your grip strength up to 60
percent.
 Lift only as much as you can safely handle by
yourself.
ENVIRONMENT: NA

O P  Keep the lifts in your power zone (i.e., above the

knees, below the shoulders, and close to the body),
if possible.

S
QUALITY:  Use extra caution when lifting loads that may be
1. All the safety PPEs used unstable.

l i d
during the activity - such as
gloves, cut-resistant gloves,
safety shoes, safety helmet,
 While Lifting: Get a secure grip, Use both hands

a
whenever possible. All personnel must be
safety goggles and FR jackets  Avoid jerking by using smooth, even motions. familiar with the

V
should be in good condition.
2. Use cut resistant hand gloves
when handling sharp edge
materials




Keep the load as close to the body as possible.
To the extent feasible use your legs to push up and
lift the load, not the upper body or back.
Do not twist your body. Step to one side or the
Material Handling
Equipment Safety
Standard
SS/ENGG-11
other to turn.

Note: As per TSM Safety Guidelines Lifting has

recommended for two handed lifting under ideal
conditions of:

O P


25 Kg for Males
15 Kg for Female

d S
PREPARED BY
Name and Designation: Mr. PRUTHIRAJ MOHAPATRA (MGR)
REVIEWED BY
Name and Designation: MR. AMAR KUMAR ADHYA (SR.
a l i APPROVED BY
Name and Designation: Mr. NALIN KUMAR (HEAD MM-HSM)

V
AREA MGR)
Signature with Date: 20.11.2025 Signature with Date: 20.11.2025 Signature with Date: 20.11.2025
Printed By -QR Scanned Copy Print valid till - 18-Feb-2026 Printed on - 08-Feb-2026 SOP Valid Till - 04-Nov-2026
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel Meramandali
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/HSM/MM/CRS/SOP/02 Effective Date 23-11-2025 REV. No. 01
SOP DESCRIPTION MATERIAL HANDLING SECTION HSM-MM
DEPARTMENT HOT STRIP MILL PAGE Page 4 of 7

SAFETY: 1. Ensure all required PPEs (helmet, safety shoes, All personnel must be
Material Handling Of Medium 1. Risk of hand injury, finger gloves, goggles, FR jacket) are worn and in familiar with the
Size Materials pinch, or crush due to improper good condition. Material Handling
handling. Equipment Safety
2. Check all lifting tools and tackles (slings,
(e.g., grease drum, oil drum, 2. Back strain or muscle injury Standard
small beam, channel, etc.) from manual lifting without trolleys, cranes, hooks, chains) for damage SS/ENGG-11
proper posture. before use.
3. Falling or swinging load due to 3. Confirm the lifting equipment capacity is
improper slinging or suitable for the material to be shifted.
overloading. 4. Plan and clear the shifting route; ensure the path
4. Slip, trip, or fall during is dry, level, and obstruction-free.
movement on uneven or oily

P
surfaces. 5. Use suitable handling equipment such as
5. Collision hazard with other hydraulic trolley, truck, dumper, or EOT crane All personnel must be

5.
personnel or equipment during
shifting.
6. Falling object hazard while
S O TSTSL
Technician/
based on material weight and size.
6. Secure and balance the load properly using
slings, drum clamps, or belts before lifting or
familiar with the
Rigging Equipment
(Slings & Wire

l i d
using crane or hydraulic trolley.
7. Fire or explosion risk while
Supervisor movement.
7. Move slowly and smoothly; avoid sudden jerks,
Ropes) Safety
Standard

cylinders.
ENVIRONMENT:
V a
handling oil drums or oxygen

1. Oil or grease leakage leading to

soil or floor contamination.
sharp turns, or passing under suspended loads.
8. Use authorized and trained personnel for
operating crane or vehicle during material
SS/ENGG-06

shifting.
2. Emission or spillage from 9. Place the material gently at the designated
damaged drums or containers.
location using guiding ropes if required.
3. Noise and dust from vehicle or
trolley movement in the area. 10. After completion, park equipment safely, lower
4. Improper waste disposal (used oil-
soaked cloths) can cause
pollution.
hooks, and report any abnormality or damage
immediately.
11. Always ensure that only one person gives
O P
QUALITY:
1. Ensure no damage or dent

d S
signals to the crane operator. In case of visibility
obstruction, use walkie-talkie for effective

PREPARED BY
Name and Designation: Mr. PRUTHIRAJ MOHAPATRA (MGR)
REVIEWED BY
Name and Designation: MR. AMAR KUMAR ADHYA (SR.
a l i APPROVED BY
Name and Designation: Mr. NALIN KUMAR (HEAD MM-HSM)

V
AREA MGR)
Signature with Date: 20.11.2025 Signature with Date: 20.11.2025 Signature with Date: 20.11.2025
Printed By -QR Scanned Copy Print valid till - 18-Feb-2026 Printed on - 08-Feb-2026 SOP Valid Till - 04-Nov-2026
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel Meramandali
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/HSM/MM/CRS/SOP/02 Effective Date 23-11-2025 REV. No. 01
SOP DESCRIPTION MATERIAL HANDLING SECTION HSM-MM
DEPARTMENT HOT STRIP MILL PAGE Page 5 of 7

occurs to the material during communication with the crane operator.

shifting.
2. Always use tested and
certified slings/tackles.
SAFETY: 1. Ensure all required PPEs (helmet, safety shoes,
Material Handling Heavy 1. Load fall hazard due to sling gloves, goggles, FR jacket) are worn and in good
Weight Materials failure, overloading, or poor condition.
rigging. 2. Conduct pre-use inspection of lifting tools and
(e.g., Heavy duty gear boxes, 2. Crushing or pinch injury to tackles (slings, chains, hooks, D-shackles, cranes, All personnel must be
motors, heavy duty equipment hands, feet, or body during load forklifts) for any damage or wear. familiar with the
assemblies, etc.) alignment. 3. Verify the Safe Working Load (SWL) of all lifting Material Handling
3. Collision hazard between devices and ensure it exceeds the material weight. Equipment Safety
moving load, crane, or other 4. Plan the lifting activity in advance — identify the Standard
equipment.
4. Structural failure of crane or
lifting beam due to improper
O P lifting path, load weight, center of gravity, and
destination point.
5. Use certified and tested lifting tackles such as wire
SS/ENGG-11

6.
loading.

to oil, water on floor.

d S
5. Slip, trip, and fall hazards due Crane Operator/
TSTSL
rope slings, chain slings, or lifting beams suitable
for the load.
6. Ensure the load is properly rigged, balanced, and

ENVIRONMENT:

a l i
1. Improper disposal of damaged
Technician/
Supervisor
secured before initiating lifting.
7. Maintain clear communication between operator,
signalman, and rigger during lifting and shifting.

V
slings or oily rags can pollute
the work area.
2. Property damage due to fall of
heavy equipment due to tools/
8. Keep all personnel clear of the lifting zone; never
stand under a suspended load.
9. Move the load slowly and steadily, keeping it as
close to the ground as safely possible.
All personnel must be
familiar with the
Rigging Equipment
tackles failure. 10. Gently lower the load at the destination, ensure it is Safety Standard
QUALITY: stable, and release lifting tackles carefully. SS/ENGG-06
1. Ensure no impact or dent occurs 11. Always ensure that only one person gives signals to
on the material surface during
handling.
2. Use soft slings or padding to
O
use walkie-talkie for effective communication with
the crane operator.
P
the crane operator. In case of visibility obstruction,

prevent damage to machined or

painted surfaces.

d S
PREPARED BY
Name and Designation: Mr. PRUTHIRAJ MOHAPATRA (MGR)
REVIEWED BY
Name and Designation: MR. AMAR KUMAR ADHYA (SR.
a l i APPROVED BY
Name and Designation: Mr. NALIN KUMAR (HEAD MM-HSM)

V
AREA MGR)
Signature with Date: 20.11.2025 Signature with Date: 20.11.2025 Signature with Date: 20.11.2025
Printed By -QR Scanned Copy Print valid till - 18-Feb-2026 Printed on - 08-Feb-2026 SOP Valid Till - 04-Nov-2026
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel Meramandali
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/HSM/MM/CRS/SOP/02 Effective Date 23-11-2025 REV. No. 01
SOP DESCRIPTION MATERIAL HANDLING SECTION HSM-MM
DEPARTMENT HOT STRIP MILL PAGE Page 6 of 7

3. Ensure material stability and

alignment at final placement.
4. Follow approved lifting plan and
maintain documentation for
traceability.
5. Always use tested and certified
slings/tackles.
SAFETY:
1. Load slippage if not secured 1. J-Hook – Used for lifting and transporting coils,
properly, risk of crushing or injury cylindrical drums, or pipe-shaped components.
to personnel. Ensures a secure grip around the load’s outer
2. Coil can tilt or fall if not aligned, edge to prevent slippage during lifting.

P
risk of operator injury during lift.
3. Overloading or uneven rigging 2. C-Hook – Designed to lift coils through their
Special Tools Used For
Material Handling
can lead to beam failure or load
drop.

S
4. Drum may slip or tip if clamp is
O inner bore safely, commonly used in rolling
mills for vertical or horizontal movement of
heavy coils.

7. of hand injuries.
i d
worn or incorrectly attached, risk

l
Crane Operator/
TSTSL 3. Lifting Beam / Spreader Beam – Distributes

V a
5. Sudden drop if magnetic strength
is insufficient or load exceeds
SWL.
6. Coil may swing or slip if not
Technician/
Supervisor
the load evenly when lifting long, wide, or
irregularly shaped materials to prevent bending
or stress concentration.

properly secured, risk of crushing 4. Drum Lifting Clamp – Specifically designed

personnel. for safely handling oil or grease drums; prevents
7. Heavy mill rolls can fall, serious tipping, spilling, or uncontrolled rotation during

P
injury risk. lifting.

ENVIORNMENT:
1. Dropped loads can damage
flooring or cause spillage of
5. Magnetic Lifter – Lifts ferrous materials like

S
steel plates, billets, or sheets without slings,O
PREPARED BY
oil/grease from drums.

REVIEWED BY
l i d
reducing risk of surface scratches and speeding

APPROVED BY
Name and Designation: Mr. PRUTHIRAJ MOHAPATRA (MGR)
Signature with Date: 20.11.2025
Printed By -QR Scanned Copy
Name and Designation: MR. AMAR KUMAR ADHYA (SR.
AREA MGR)
Signature with Date: 20.11.2025
Print valid till - 18-Feb-2026 Printed on - 08-Feb-2026
a
Name and Designation: Mr. NALIN KUMAR (HEAD MM-HSM)

V
Signature with Date: 20.11.2025
SOP Valid Till - 04-Nov-2026
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel Meramandali
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/HSM/MM/CRS/SOP/02 Effective Date 23-11-2025 REV. No. 01
SOP DESCRIPTION MATERIAL HANDLING SECTION HSM-MM
DEPARTMENT HOT STRIP MILL PAGE Page 7 of 7

2. Falling heavy materials can up handling operations.

damage equipment
3. Falling plates or billets may 6. Coil Grab / Tong – Allows safe vertical or
damage flooring or nearby
horizontal lifting of coils; grips the coil securely,
equipment.
minimizing movement during transport.
7. Roll Lifting Tackles – For lifting heavy mill
rolls safely; ensures proper alignment during
QUALITY:
installation or shifting, reducing risk of
1. Ensure no impact or dent occurs
on the material surface during equipment damage.
handling. 8. Always ensure that when using EOT crane for
2. Always use tested and certified material handling only one person gives signals
tools/ tackles.

P
to the crane operator, and it is mandatory to use
walkie-talkie for effective communication with

SAFETY:

S
1. Risk of manual handling injuries.
O the crane operator.

l i d
2. Tripping hazards from tools and
equipment placed in walkways.

Cleaning Of Working Area And

V
during transport.
ENVIRONMENT: NA
a
3. Potential for tools to fall and
cause injury if improperly secured

TSTSL
Technician/
1. Remove all used tools and equipment and
ensure that all personnel involved in the job are
accounted for and removed from the area. .
8. Normalize The Isolation 2. Then, normalize the system by eliminating any
QUALITY: Supervisor
1. Ensure all tools and tackles are isolation. (If required)
inspected for functionality.
2. Confirm that tools are stored
properly in the working area to
prevent loss or damage.

O P
d S
PREPARED BY
Name and Designation: Mr. PRUTHIRAJ MOHAPATRA (MGR)
REVIEWED BY
Name and Designation: MR. AMAR KUMAR ADHYA (SR.
a l i APPROVED BY
Name and Designation: Mr. NALIN KUMAR (HEAD MM-HSM)

V
AREA MGR)
Signature with Date: 20.11.2025 Signature with Date: 20.11.2025 Signature with Date: 20.11.2025
Printed By -QR Scanned Copy Print valid till - 18-Feb-2026 Printed on - 08-Feb-2026 SOP Valid Till - 04-Nov-2026