“Safety needs team work, let us work together”,

Presentation of Material Handling

“Safety needs team work, let us work together”,

Safe Material Handling

“Safety needs team work, let us work together”,

Safe Material Handling

Introduction:
• 40% of accidents in an Industry are due to
Unsafe material handling practices

Objective:
• Outline the hazards
• Develop systems and procedures
• Minimize the untoward incident/accident
“Safety needs team work, let us work together”,

Scope :

Applicable to all AIL sites irrespective of location and activities

Definitions :

• Competent Person
• Safe Working Load
• Lifting Machine
• Lifting Tackle
• Hoists and Lifts
• Initial Load Test
• Operational Test
• Rated Load Test
“Safety needs team work, let us work together”,

Legal Requirements :

• The Factories Act 1948 –

• Section 28 Lift & Hoist ,
Examination in 6 Months by competent Person– GFR Form
No.9
• Section 29 Lifting machines, chains etc
Examination in 12 Months by competent Person – GFR Form
No.10
• The Gujarat Factories Rules 1963 - Sec 58,60, 60 A, 62,
“Safety needs team work, let us work together”,

Manual Handling

• Hazards:
Strains, Sprains, Fractures, cut,
bruiceslumber Pain
• Methods:
Foot position , Knee bent, back
straight, head ,
• Accessories :
Hook , crowbar , jack, hand
truck etc
“Safety needs team work, let us work together”,
Means
Safe Lifting using
your
Use Your Head and Save Your Back! head!
• Bend •Let
your your
•STAND
knees - legs do
close to
not your the
the load
back! lifting

Get Help Use the

with heavy right
or awkward tools!
loads!
“Safety needs team work, let us work together”,
“Safety needs team work, let us work together”,

Safe Lifting

Carrying the load…

• Hold the load close so you can see over it.

• Keep the load balanced.
• Avoid twisting the body
• Watch out for pinch points -- doorways, etc.
• Face the way you will be moving.
“Safety needs team work, let us work together”,

CRANES:
General Safety Guidelines

Points to be consider while planning

lift
• Weight of the Eqpt.
• Radius
• Elevation to which Eqpt. Should be
lifted
• SWL and Dimension of tools and
tackles
Cranes to be equipped with
• Skilled crane operator
• All controls and brakes in good
condition
• Boom angle indicators
• Rear view
• Spirit level
“Safety needs team work, let us work together”,

Cranes - General Safety Guidelines

• Check slings and hooks for any defects

• Enclose moving plants
• Guide the hook / handle
• Limit switches – boom ,lifting , lowering etc.
• Minimum three windings of rope on drum
• No man movement under suspended load
• No suspended load to be kept unattended
• Use brakes while parking
• Follow Manufacturers manual
• Lower the boom in adverse weather condition
‘Safety needs team work, let us work together”,

Crane Operators and Signalman

Crane Operator :
• Valid RTO license
• P&M validation for skill and
experience
• Medical examination
• Training

Signal Man :
• Follow signals from authorised
signalman only
• Emergency stop signal
• List of authorised signalman to be
maintain
“Safety needs team work, let us work together”,

Mobile Crane
Major hazards:
Overturning / Contact with electrical cables O/H pipelines / sudden release
of load / damage to UGU

Planning of Lift:
• Ground condition
• Crane Position
• Required boom length / Angle
• Compliance to Traffic safety Rules
• Out rigger fully extended.
“Safety needs team work, let us work together”,

Mobile Crane
Travelling

• Speed not more than 20 KMPH

• No passenger in crane
• Vehicle access permit / Safety inspection Certificates
• Minimum distances from fixed object
• 3 Mt.from O/H electrical lines
• Horn ,reverse horn ,headlight,flashing light etc.

Travelling with Load

• Traveling up gradient derricked out load ,while down derricked in load

• Use of tag line
“Safety needs team work, let us work together”,

Positioning :

• Firm ground
• 0.6 Mt.clearance from fixed object
• 3 Mt. or distance or equal to half depth of Excavation

Attaching the Load :

• Slings of sufficient capacity

• Safety latch
• Use D shackle in case of more than 2 slings used

Slewing of load :
• Smooth / See path / No dragging of load
“Safety needs team work, let us work together”,

Lowering of Load
• Load must be lowered under crane power
Multi Crane Lifts
• Lifting plan
Work Near H.T Over head lines
• Minimum 6 Mt.Distance
Emergency Actions
• Remain in cab
• Do not touch any part of crane
• Jump in case o fire
“Safety needs team work, let us work together”,

Lifting of Personnel by Cranes :

• In case of inevitable condition only

• Obtain special Permit
• Not more than 6 persons
• Factor safety of 5
• Clearly marking of empty weight and capacity
• Standard railing
• Th’ inspection of tackles and attachment
• Use of 50% of cranes capacity
• Incase of Emergency Operator will first lowered the cage
“Safety needs team work, let us work together”,

Safe Material Handling

“Safety needs team work, let us work together”,

Safe Material Handling

3 Meters

3 Meters
“Safety needs team work, let us work together”,

Lift Categories
• Definitions of Lift Categories:
– Standard Lift
– Standard Lift in Hazardous Area
– Complex Lift
– Complex Lift in Hazardous Area
– Heavy Complex Lift
“Safety needs team work, let us work together”,

• Standard Lift:

– Criteria : Load to be lifted weighs less than 15 T.

– Requirement : Mobile crane planning and risk assessment

check sheet.
“Safety needs team work, let us work together”,

• Standard Lift in Hazardous Area:

– Criteria : Load to be lifted weighs less than 15 T and is carried

out in area with charged HC and utilities lines or equipment
( except water & plant air ).

– Requirement : Mobile crane planning and risk assessment

check sheet, Task risk assessment.
“Safety needs team work, let us work together”,

• Standard Lift in Hazardous Area:

– Criteria : Load to be lifted weighs less than 15 T and is carried

out in area with charged HC and utilities lines or equipment
( except water & plant air ).

– Requirement : Mobile crane planning and risk assessment

check sheet, Task risk assessment.
“Safety needs team work, let us work together”,

• Complex Lift :
– Criteria : Load to be lifted weighs between 15 - 30 T or boom
length above 55 m or capacity loading above 85% and lift is
carried out in non hazardous area.
– Requirement : Mobile crane planning and risk assessment check
sheet, Lifting Plan.
“Safety needs team work, let us work together”,

Complex Lift in Hazardous Area:

Criteria : Load to be lifted weighs between 15 - 30 T or boom length
above 55 m or capacity loading above 85% and lift is carried out in
hazardous area.

Requirement : Mobile crane planning and risk assessment check sheet,

Lifting Plan, Task Risk Assessment.
“Safety needs team work, let us work together”,

Lifting Tools And Tackles

• Fibre rope slings

• Wire rope slings
• chains
• Shackles
• Hooks
“Safety needs team work, let us work together”,

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

“Safety needs team work, let us work together”,

Markings Alloy Steel Chain

It must be marked with grade or manufacturer's mark

“Safety needs team work, let us work together”,

Wire Rope Slings

Wire
Core
Selection considerations : Center

• Strength

 Ability to bend without cracking

Strand
 Ability to withstand abrasive
wear Wire rope

 Ability to withstand abuse

“Safety needs team work, let us work together”,

  Sling Inspection
 Each day before use.
 Where service conditions
warrant
 Remove them from service if
damaged or defective
“Safety needs team work, let us work together”,

Remove From Service

Immediately remove damaged or defective slings from service

“Safety needs team work, let us work together”,

Remove The Sling From Service if these happens :

Kinking

Bird Caging Crushing

“Safety needs team work, let us work together”,

Wire Rope Slings Eye Splices

• Eye splices made in

any wire rope must
have at least three full
tuck
“Safety needs team work, let us work together”,

Protruding Ends :

Cover or blunt protruding ends of strands

“Safety needs team work, let us work together”,

Synthetic Web Sling

Mark or code :

• Name or trademark of
manufacturer
• Rated capacities for the type
of hitch
• Type of material
“Safety needs team work, let us work together”,

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
“Safety needs team work, let us work together”,

Synthetic Web Sling Stitching

Stitching is the only

method allowed to attach Stitching
end fittings to webbing,
or to form eyes
“Safety needs team work, let us work together”,

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
– Distortion of fittings

Heat Damage
“Safety needs team work, let us work together”,

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
“Safety needs team work, let us work together”,
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
“Safety needs team work, let us work together”,

Hitches
• Vertical
• Basket
• Choker
Sling Angle

• 45 DEG TO 90 DEG
• Capacity of the sling
“Safety needs team work, let us work together”,

1000 Kg
“Safety needs team work, let us work together”,

Kg

T
=
7

76
76

7
=

K
T

g
0
45

1000 lBS
“Safety needs team work, let us work together”,

1000 Kgs
“Safety needs team work, let us work together”,

1000 Kg
“Safety needs team work, let us work together”,

Safe Use of Chain Pulley Block

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a nk
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