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8/3/2019 Training Module of Material Handling Equipment
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Material Handling EquipmentMaterial Handling Equipment
Safety Standard No.Safety Standard No. ::
Revision No.Revision No. ::
Effective DateEffective Date ::
Date of TrainingDate of Training ::ByBy ::
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Material Handling EquipmentMaterial Handling Equipment
To provide guidelinesTo provide guidelines
Handling Materials manuallyHandling Materials manually
Using moving machinery likeUsing moving machinery like
Fork Lift TrucksFork Lift Trucks
ConveyorsConveyors
Cranes and DerricksCranes and Derricks
Tower CranesTower Cranes
Overhead and Gantry CranesOverhead and Gantry Cranes
Mobile CranesMobile Cranes
Passenger Lifts and Material HoistsPassenger Lifts and Material Hoists
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Material Handling EquipmentMaterial Handling Equipment
Associated Hazards
Poor site layouts
Falls from Vehicle
Height Restriction
Overturning
Collisions
Striking people and equipment
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Material Handling EquipmentMaterial Handling Equipment
Responsibility
Departments
Drivers
Consultants
Contractors
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Material Handling EquipmentMaterial Handling Equipment
Manual Lifting
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
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Material Handling EquipmentMaterial Handling Equipment
Safe lifting posturesSafe lifting postures
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Material Handling EquipmentMaterial Handling Equipment
Mechanical Lifting
Trained Drivers and Operators
Adequately skilled
No persons below 18 years of age
Who should use ?
Suitable sticker to be pasted on the helmet on trained
driver/operator - for easy identification
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Material Handling EquipmentMaterial Handling Equipment
Which one to use ?
All lifting machines and lifting tackles bearing
Identification mark
Safe Working Load
Date of Last test
ANDAND
Fit for Use
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Material Handling EquipmentMaterial Handling Equipment
General Precautions
The Load is safe and securedwhile 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 unattendedwhen 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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Material Handling EquipmentMaterial Handling Equipment
Fork Lift Trucks
Be provided with Overhead ProtectionBe provided with Overhead Protection
Must be fully insideMust be fully inside Must notMust not
UNSAFEUNSAFE
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Material Handling EquipmentMaterial Handling Equipment
Fork Lift Trucks
No attachment shall be incorporated, without taking necessary precautionsNo attachment shall be incorporated, without taking necessary precautions
ForkFork--lift should be stablelift should be stable
If Load is obstructing, drive in reverse gearIf Load is obstructing, drive in reverse gear
Fork must be kept 15Fork must be kept 15--20 cm above floor20 cm above floor
Drive at a slow and safe speed, avoid sudden start and stopDrive at a slow and safe speed, avoid sudden start and stop
Avoid driving over any object lying of the pathAvoid driving over any object lying of the path
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Material Handling EquipmentMaterial Handling Equipment
Conveyors
11
22
33
Starting Sequence = 3 - 2 - 1
Stopping Sequence = 1 - 2 - 3
Design
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Material Handling EquipmentMaterial Handling Equipment
Conveyors
Stop switch at operators station and near motor
Emergency Switch pull chord must be operative all time
Proper interlock to start
Screw conveyors to be guarded to prevent contact
Proper guard to be provided, if required to work below conveyor
Riding or crossing-over a conveyor is not allowed
All pulleys, belt nips, idlers are to be guarded
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SAFETY DEVICESSAFETY DEVICES
HOOK LATCHHOOK LATCH
BOOM LIMIT SWITCHBOOM LIMIT SWITCH
BOOM ANGLE INDICATORBOOM ANGLE INDICATOR
OVER HOIST LIMIT SWITCHOVER HOIST LIMIT SWITCH
Boom Limit Switch
Over Hoist Limit switch
Hook Latch
Boom angle indicator
Material Handling EquipmentMaterial Handling Equipment
Cranes and Derricks
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Unsafe Practices
Non-Use of Hook Latch
Remedial Measures
Use Hook latch to
avoid slings fromgetting removed
from hook
Material Handling EquipmentMaterial Handling Equipment
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A is a point in the Tipping of Crane
To achieve the stability of Crane the
following equation should be satisfied
Moment about point A
W1 X L1 + W2 X L2 W3 X L3
Tipping Axis
STABILITY
L2L1 L3
A
W3W
1
W2
Material Handling EquipmentMaterial Handling Equipment
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Must comply with the manufacturers specification and limitations
Rated capacity, operating speed and hazard warning shall be pasted clearly
Standard Hand Signals from authorised person are to be used
A minimum one distance clearance between swing radius of greatest extension.
Crane shall be stationed on firm ground when operating
Cranes must not be operated between sun-set and sun-rise, without adequate
lighting arrangements
Suitable horns, head lights, side lamps, rear & stop lights and flashing
direction indicator
Tyre pressure to be maintained correctly always
Material Handling EquipmentMaterial Handling Equipment
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Material Handling EquipmentMaterial Handling Equipment
When traveling up a gradient, the
load shall be derricked out
When traveling down a gradient,
the load shall be derricked into
Position shall be corrected on reaching the level ground
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Material Handling EquipmentMaterial Handling Equipment
When leaving crane, operator must
Lower any suspended load to the ground
Disengage the clutch
Engage all safety locks
Secure boom againsth
igh
winds
When parking over night, in addition to the above
Release the load
Lower the boom to ground
Provide wheel locks and wheel blocks
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Material Handling EquipmentMaterial Handling Equipment
Except where Electrical Lines are de-energised
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
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
A person shall be designated to observe clearance of the equipment
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Material Handling EquipmentMaterial Handling Equipment
While working under HT cables
1. Electrical department Representative and Job SupervisorMUST
be present through out
2. Written clearance MUST be obtained from
Electrical Department
Mechanical Department
Safety Officer
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.
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Material Handling EquipmentMaterial Handling Equipment
Tower Cranes
Tower cranes shall be erected, jumped or dismantled under the direct
supervision of a competent person, in accordance with the
manufacturers specification.
A Professional engineer shall certify that the crane foundation and
underlying soil are adequate to support
Tower cranes shall be positioned whereby they can swing 360
Suitable limit switch is to be installed, if it strikes an object.
Direct voice communication between the operator and the signal man.
Operating controls shall be properly marked.
In installed on existing building or new construction, structural
engineer shall certify that the building is designed to withstand the
torque and loads.
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Material Handling EquipmentMaterial Handling Equipment
Tower Cranes
Capacity chart shall be furnished by crane manufacturer and shall be
pasted in operators cabin. Chart shall be visible and readable to the
operator at the normal operating position.
shall have adequate overhead protection to the operator
Access to operators cab shall be safe and approved by competentauthority.
For inspection and maintenance, ladders, walkways with railing and
fall protection devices must be provided.
slewing brake must be able to hold the boom and load
Tower cranes shall not be erected or raised when wind velocity exceed
20 kmph
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Material Handling EquipmentMaterial Handling Equipment
Overhead and Gantry Cranes
The rated load shall be plainly marked on each side of the crane
Bridge trucks shall be equipped with sweeps, which extend below the top of
the rail and project in front of the truck wheel
Effective audible signal
An unobstructed passageway of 600 mm width shall be maintained between
any part of the lifting appliance and any guard rail, fencing or other nearby
fixtures.
Platforms for crane drivers and signalers shall be sufficient area providedwith safe means of access
Cabins for drivers shall have unrestricted visibility, safe access and weather
protected.
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Material Handling EquipmentMaterial Handling Equipment
Stability of Lifting Appliances
Adequate precaution to ensure stability of lifting appliance used on a soft
or uneven surface or on a slope
Cranes shall be
Anchored to the ground or other foundations. Rail Tracks shall not be
used as anchorage.
Securely counter-weighted to prevent over turning
A diagram of the counter weight indicating the position shall be affixed on
the crane
Anchorage shall be examined by a competent person by applying 1.25times the rated load. Report of this test shall be maintained at the
construction site by the contractor.
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