Module 11

Material Handling
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 DISCLAIMER
This material was produced under grant
number SH-22248-1 from the Occupational
Safety and Health Administration, U.S.
Department of Labor. It does not
necessarily reflect the views or policies of
the U.S. Department of Labor, nor does
mention of trade names, commercial
products, or organizations imply
endorsement by the U.S. Government.

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 Objectives
• After this module you should be able to
– identify the most common material handling
hazards
– take the steps necessary to avoid those
hazards

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 Crane Hazards
• Improper loading
• Not using outriggers or leveling crane
• Not calculating load weight correctly
• Lifting on unstable support surface
• Working around powerlines
• Damaged windows and other crane parts
• No barrier around swing radius
• No or poor regular inspections
• No boom angle indicator
• Wind and other side forces
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 Preplanning the Lift
• Level the crane to within 1% and ensure
support surface is firm, able to support
the load
• Know the location and voltage of any
overhead powerlines; stay 10’ away
• Barricade the area within the swing radius
• Determine your pickup and drop locations
• Calculate the weight of the load and
determine how to safely lift that weight
• Inspect the crane
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 Daily Crane Inspection
• Some items to inspect include
– tires properly inflated
– clearance for tail swing
– wire rope wear
– physical damage to crane
– loose or missing hardware
– fluid leaks
• Inspection must be done by a competent person
• If it needs fixed, don’t use it until it is repaired

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 Load Weight
• Refer to the shipping ticket or other
documentation
• Ensure load is within the load chart rating
for the boom length and load radius the
operator is using
– remember that the crane is rated by the
maximum weight it will lift at minimum boom
length and minimum radius
– the further from the crane’s center point the
load is, the less the crane will handle safely

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 Load Limiting Factors
• An operator must also consider the
following when calculating for a safe lift
– wind
– side loads
– on wheels or outriggers
– lifting over the side
– use of extensions, jibs, or other attachments
– the limits of rigging
– the actual weight of the rigging must be
considered
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the results of an improperly
loaded crane are obvious

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the crane operator must have reference to and be familiar with
rated load capacities, operating speeds, and special hazard warnings

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an illustration of the hand signals used in your company’s
crane operations must be posted at the job site

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do not stand under a suspended load at
any time; use tag lines to guide the load

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a warning barrier must be placed so that a worker
will not enter the swing radius of the crane

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 this crane’s window is badly cracked

Corrective Action: this crane must be taken

out of service until the window is replaced 14
this crane’s outriggers are fully extended
and the crane is level; therefore, it is stable

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a boom angle indicator must be installed on
every crane with variable angle booms

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 these sheaves are damaged which
causes excessive wear on the wire rope

Corrective Action: replace the sheaves when they are worn or

broken or when their damage will cause damage to the wire rope 17
 a thorough, annual inspection of the hoisting
machinery must be made by a competent person

the employer shall maintain a record of

the dates and results of the inspections
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 Working Safely Around Rigging
• General safety guidelines
– keep at least 10’ away from powerlines
– never hoist loads over workers
– never stand too close or under a load
– never ride a load
– use sling angles greater than 45°
– attach tag lines to control loads while lifting
– test lift the rigging
– use proper equipment (make sure it is marked,
not homemade, and in good condition)
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 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

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 Sling Angle
• The safest sling angles are greater than
45° from the horizontal
• The ideal sling angle is 60° from horizontal

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 this pipe is about to be lifted with a makeshift chain sling; the chain is
not lifting grade, has no markings, and is too short for a safe sling angle

Corrective Action: use proper rigging and sling angle

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 all slings whether nylon, wire rope, or chain must
have permanently affixed durable identification

information includes the size, grade, capacities, and manufacturer;

if you can’t read it, the sling should be pulled from service 23
knowing the sling’s capacity is important; capacity changes depending
on how we rig the load; the same goes for wire rope and chain slings

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 makeshift slings and other rigging
devices are unacceptable

Corrective Actions: never try to repair a broken or badly

damaged rigging device; use only approved rigging devices
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 Homemade Hooks
• Job or shop hooks and links, or makeshift
fasteners made from bolts, rods, etc., or
other such attachments cannot be used

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 this heavily worn sling is a
dangerous situation

Corrective Action: inspections of rigging devices should be performed daily;

defective rigging should be pulled from service and tagged, then destroyed
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the shackle has an improper pin and
the hook has a broken safety latch

Corrective Action: replace both safety latch and shackle pin

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 Material Handling Hazards
• Back injuries (the number one cause of
worker compensation claims)
• Struck by or crushed by falling loads due
to improper rigging and sling failures
• Electrocution due to power line contact
• Struck by falling materials which are
improperly stored
• Slipping, tripping, and falling due to
improper materials storage

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 Manual Lifting Back Facts
• 8 out of every 10 Americans will have a
back injury during their lifetime
• Approximately 1 out of 3 injuries at work
are back injuries
• Personal pain and inconvenience cannot
be measured
• Back injuries cost employers an estimated
$10 billion each year

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 back strains are one of the most
common injuries at any workplace

use proper lifting techniques and don’t try to lift,

by yourself, an object that is too heavy or bulky
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 Preventing Back Injuries
• You can avoid back injuries by
– using proper lifting techniques
– keeping in lifting shape
– using mechanical aids
– working as a team while lifting
– knowing the truth about back belts

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 Proper Lifting Technique
• Basic moves of a proper lift
– plan your lift
– use a wide-balanced stance
– get close to the load
– tighten your stomach muscles
– keep you back straight and use your legs
– turn with your feet; don’t twist your back
– keep the load close to your body
– avoid lifting above shoulder height

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 Material Storage
• 5 basic rules for safe material storage
1. keep total weight within the safe loading
limits of the structure’s floors
2. keep passageways clear
3. control materials so that they do not slide,
fall, roll, or collapse
4. provide cribbing for heavy loads on unstable
surfaces
5. store materials away from traffic

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correct use of pipe chocks to
keep pipe from rolling off rack

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 this placement of the slips
presents a tripping hazard

Corrective Action: move and store

slips out of the way to prevent a trip 36
neat and proper storage is a big part of safety

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neatly stacked materials that are level,
plum, and maintained at a safe height

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 Applicable Standards
• 1910 Subpart N Materials Handling and
Storage
• 1926.251 Rigging Equipment for Material
Handling
• 1926 Subpart W Rollover Protective
Structures; Overhead Protection
• 1926 Subpart CC Cranes and Derricks in
Construction

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 Your Employer Is Responsible For
• Providing training to operators of material
handling equipment
• Ensuring that equipment is properly
inspected, maintained, and repaired when
damaged
• Providing proper and replacement rigging
devices when damaged

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 You Are Responsible For
• Using proper manual lifting and storage
techniques
• Inspecting the equipment and rigging
devices you use daily
• Preplanning all crane lifts

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 Case Study
A worker was attempting to lift an adapter
flange without aid. He suffered severe back
sprain and was taken to the hospital.

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 Always Remember
• Proper lifting techniques will prevent most
back a injuries
• Inspect cranes and rigging before each use
• Operate and use cranes and rigging
according to the manufacturer
• Stay at least 10’ from overhead
powerlines
• Aisles, passageways, and steps should not
be used for storage

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 Memory Check
1. What material handling-related injury is
known to be the number one cause of
workers compensation claims?
a. workers being struck by falling materials
b. equipment contacting powerlines
c. back injuries
d. none of the above

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 Memory Check
2. Slings that have no labels or labels too
worn to read must be
a. used with extreme caution
b. used on only lightweight loads
c. pulled from service, tagged, and destroyed
d. none of the above

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 Memory Check
3. Which of the following is NOT a factor
that affects the load calculation of a
crane lift?
a. the limits of the rigging
b. the weight of the rigging
c. the wind speed
d. all of the above must be considered

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 Memory Check
4. Which of the following is the safest sling
angle?
a. 5°
b. 10°
c. 30°
d. 60°

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