INTRODUCTION TO

MATERIAL HANDLING
Have you ever been hurt while
lifting material?
Have you ever been involved
in a crane or forklift accident,
or rigging failure???
 Do you know how to safely
store and dispose of material?
 Training Objectives
 After
completing this course,
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.
WHAT IS MATERIAL HANDLING?

 Material handling is the art and

science of moving, storing,
protecting and controlling material.
 Includes both Mechanical and Manual
methods
 DANGERS OF MATERIAL
HANDLING
 Unsafe storage and
materials movement
can lead to:
 Back injuries .
 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.
 SAFETY SLOGAN

“Is better to lose one minute in

life... than to lose life in a
minute. “
Back Safety and Safe
Lifting
 Anatomy of the Back

 Why do injuries
occur?
 Knowing what
causes back injuries
can help you
prevent them.
 The Forces Involved
* The amount of force you place on your
body during lifting may surprise you.

• Think of your back as a lever

• With the fulcrum
in the center, it only
takes ten pounds of
pressure to lift a ten
pound object.
 The Forces Involved

• If you shift the fulcrum to one side, it takes much more

force
to lift the same object. Your waist acts like the
fulcrum in a
lever system, on a 10:1 ratio.
Lifting a
ten pound
object puts
100 pounds
of pressure
on your
lower back.
 The Forces Involved

* When you add in the

105 pounds of the
average human upper
torso, you see that
lifting a ten pound
object actually puts
1,150 pounds of
pressure on the
lower back.
 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!
 Common Causes of Back
Injuries
 Lifting too much weight. Especially
repetitively
 Twisting at the waist while holding
a heavy load
 Reaching and lifting overhead, or
away from the body
 Lifting and carrying objects that have
awkward shapes
 Working in awkward, uncomfortable
positions
 Sitting or standing too long in one position
 Slip / Trip / Fall
Things you can do to help your
back
 You can minimize problems with your back
by exercises that tone the muscles in your
back, hips and thighs.
 Before beginning any exercise program, you
should check with your doctor and follow
his/her advice concerning any exercise
program. With his/her approval you should:
 Exercise regularly, every other day.
 Warm up slowly . . . walking is a good way to warm
up.
 Inhale deeply before each repetition of an exercise
and exhale when performing each repetition.
 How to prevent back injuries
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.
 Talkto your team-mate!
 Coordinate your lift!
 PROPER LIFTING
TECHNIQUES
 Use proper lift procedures . . . follow
these steps when lifting . .
1. Know where you are going. Is the path clear?

2. Size up the load. (Is it too heavy? Do I need gloves?)

3. Take a balanced stance,

feet shoulder-width
apart.

4. Squat down to lift, get

as close as you can.
 PROPER LIFTING
TECHNIQUES
5. Get a secure grip,
hug the load.

6. Lift gradually using

your legs, keep load
close to you, keep back
and neck straight.
 PROPER LIFTING
TECHNIQUES
7. Once standing, change
directions by pointing
your feet and turn your
whole body. Avoid
twisting at your waist.

8. To put load down, use

these guidelines in
reverse.
 Take care of your back…
 And it will take care of you
 Exercise daily
 Avoid Heavy Lifting
 Get Help with heavy or bulky objects
 If you must bend over, do it properly
 Avoid twisting at the waist when
carrying objects
 Always watch where you’re going
 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.
Safe Rigging Practices

Know How to Do It Right!

Then Do It Right!
 Job Site Considerations

The person authorized and qualified to do

rigging must always pay close attention to
details. One careless moment or act can
result in serious injury or death and
tremendous property damage. Proper
rigging is an art and should never be left to
the inexperienced. If you don’t know how to
do it properly, then don’t attempt it.
 Objectives
 Be familiar with OSHA’s regulations
regarding slings.
 Understand safe sling use.
 Be able to identify and describe
conditions necessitating sling’s
replacement.
 Understand how load angle effects
rigging capacity.
Sling: An assembly which connects
the load to the material handling
(lifting) equipment.
 Three Types of Slings

1. Chain Slings

2. Wire Rope Slings

3. Synthetic Web Slings

 Frequency of Sling
Inspections
1926.251 – Rigging equipment for material
handling shall be inspected prior to use on
each shift and as necessary during its use to
ensure that it is safe. Defective rigging
equipment shall be removed from service.
Chain Sling Inspection Items
 Cracks, stretches, severe nicks, gouges, welding
splattered or deformed master links, coupling links,
chains or other components.

 One leg of a double or triple chain sling is longer than

the others.

 Hooks have been opened more than 25% of the normal

throat opening measured at the narrowest point or
twisted more than 10 degrees from the plane of the
unbent hook.

 Documented Inspections must be performed and

maintained for each chain sling. Inspection data
must be compared with previous inspections.
 Chain Slings

Only chain slings purchased

from the manufacturer are
allowed.

No homemade

slings allowed!!
 Wire Rope Sling Inspection
Items
 Three randomly distributed broken
wires in one strand, in one rope lay.

 Wear or scraping of 1/3 the original

diameter of outside individual wires.

 Kinking, crushing or any damage

resulting in distortion of the wire rope.

 End attachments that are cracked,

worn or deformed.

 Corrosion of the rope or end

attachments.
 Synthetic Web Sling
Inspection Items
 Acid or caustic burns on the sling.

 Melting or charring of any part of the sling’s surface.

 Snags, punctures, tears, or cuts.

 Stitching is broken or worn.

 The sling is stretched. To assist operators in

determining if a sling is stretched, manufacturers
incorporate a colored wear cord inside of the sling.
When this red wear cord can be readily seen upon
inspecting the sling, the sling has been stretched and is
to be removed. The web sling may need to be removed
from service before the wear indicator is showing.
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.
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!

The Rigger’s Duties
 The rigger
selects the
rigging.
 The rigger sets-

up the rigging.
 The rigger

directs the lift.

 OSHA Rigging
Requirements
 All slings and hardware must be:
 Manufactured to meet demanding

specifications.
 Clearly stamped, marked, or
labeled.

 OSHA prohibits job-made: slings, hooks,

links, and fasteners formed from bolts.
 Before each use all components must be
inspected by a Competent Person.
 Definitions

Hitch “Basket” - loading with the sling passed under

the load and both ends on the hook or a single
master link.
 Definitions

Hitch “Choker” – loading with the sling passed

through one eye and suspended by the other.
 Definitions

Hitch “Vertical” – loading with the the load

suspended vertically on a single part or leg of the
sling.
 Sling Capacities

60 degrees 45 degrees 30 degrees

A sling capable of lifting 1000 lbs in a vertical basket hitch, can

60
only lift 866 lbs at a 60 degree angle, and 707 lbs at a 45 degree
30
angle, and 500 lbs at a 30 degree angle.
 Working Safely Around
Rigging
 General safety guidelines:
 Keep at least ten feet away from power

lines.
 Never hoist loads over workers.

 Never stand too close or under a load.

 Never ride a load.

 Use sling angles greater than 45 degrees.

 Attach 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.

Rigging the Load
Sling angles <450, load
unstable, receiver not
protected.

Balanced load; sling angle >600

 Safe Usage Practices
 Never shock load slings.  A sling should not be
pulled from under a load
 Keep loads balanced to when the load is resting
prevent overloading slings. on the sling.
 Always lift loads straight up.  Make sure the hook is
always over the center
 Never rest a load on a sling, of gravity of the load
or pinch a sling between the before lifting it.
load and the floor.

 Slings should be stored off

 Do not apply a load to a
of the floor and hung on twisted, knotted or
racks whenever possible in kinked chain.
a clean, dry environment.
 Do not force or hammer
 Never drag slings across the hooks or chains into
floor. position.

 Always hook with a

“closed hook”
 Safe Usage Practices
(Cont.)
 Hands and Fingers shall  Never shorten a sling
not be placed between with knots, bolts or other
the sling and the load makeshift devices. Knots
while the sling is being in slings reduce the
tightened around the capacity by as much as
load. 50%!!

 Clean chains regularly as  Protect the chain’s

dirt and grit can cause surface from contact with
excessive wear at the sharp corners, which can
link bearing points. cause permanent
damage through gouging
or abnormal stress and
wear.
 In Conclusion
Select the right sling for the job.
Only trained personnel can
perform rigging operations
Inspect slings prior to use,
removing from service any in
question.
Remember the effect of sling
angles on load capacities.
Properly store slings when finished
to avoid damage.
MECHANICAL
EQUIPMENT
(MOVIE)
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?

MATERIAL STORAGE, AND
DISPOSAL OF WASTE
MATERIAL
 SUBPARTS

Material Storage
 Fivebasic 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.
 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.
 Disposal of Waste
Material
 OSHA requirements:
 Scrap lumber, waste and trash must be regularly
removed from the work area.

 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.
THE END