1 Material Handling Module 11 2Objectives After this module you should be able to identify the most common material handling hazards take the steps necessary to avoid those hazards 3 Material Handling Hazards Back injuries (the number one cause of worker compensation claims) Workers being struck by or crushed by falling loads due to improper rigging and sling failures Workers being electrocuted due to power line contact Workers being struck by falling materials which are improperly stored Workers slipping, tripping, and falling 4 Manual Lifting and Storage 5 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 dollars each year 6 back strains are one of the most common injuries at any workplace use proper lifting techniques and dont try to lift, by yourself, an object that is too heavy or bulky 7 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 8 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; dont twist your back keep the load close to your body avoid lifting above shoulder height 9 Material Storage 5 basic rules for safe material storage 1.keep total weight within the safe loading limits of the buildings 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 10 correct use of pipe chocks to keep pipe from rolling off rack 11 this placement of the slips presents a tripping hazard Corrective Action: move and store slips out of the way to prevent a trip 12 neat and proper storage is a big part of safety 13 neatly stacked materials that are level, plum, and maintained at a safe height 14 Rigging and Slings 15 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) 16 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 17 Sling Angle The safest sling angles are greater than 45 from the horizontal The ideal sling angle is 60 from horizontal 18 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 19 all slings whether nylon, wire rope, or chain must have permanently affixed durable identification information includes the size, grade, capacities, and manufacturer; if you cant read it, the sling should be pulled from service 20 knowing the slings capacity is important; capacity changes depending on how we rig the load; the same goes for wire rope and chain slings 21 Corrective Actions: never try to repair a broken or badly damaged rigging device; use only approved rigging devices makeshift slings and other rigging devices are unacceptable 22 Homemade Hooks Job or shop hooks and links, or makeshift fasteners made from bolts, rods, etc., or other such attachments cannot be used 23 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 24 the shackle has an improper pin and the hook has a broken safety latch Corrective Action: replace both safety latch and shackle pin 25 Material Handling Equipment 26 equipment should have a functioning, audible backup alarm equipment with defective alarms should be pulled from service and repaired 27 a rollover protective system (ROPS), guarding of moving parts, and warning labels must be in place 28 seat belts, in combination with rollover protection, save lives wear your seat belt at all times while operating material handling equipment 29 keep the load reasonably low; also, if the load is too high to see over, tram in reverse a load that is kept low to the ground will be more stable and easier to control 30 material handling equipment has blind spots make eye contact with the operator when possible and always work defensively 31 certify the competency of operators of machinery by classroom and hands-on training Certified Forklift Operator Cards an employee must be trained on the specific piece of machinery before approval can be given for operation 32 Applicable Standards 1910 Subpart N Materials Handling and Storage Rigging Equipment for Material Handling 1926 Subpart W Rollover Protective Structures; Overhead Protection 33 Your Employer Is Responsible For Providing training to operators of material handling equipment Ensuring that equipment is properly maintained and repaired when damaged Providing replacement rigging devices when damaged or deemed inadequate Responding to and correcting hazards pointed out by you, the worker 34 You Are Responsible For Using proper manual lifting and storage techniques Inspecting the equipment and rigging devices you use daily Wearing a seat belt while operating material handling equipment Correcting the hazards you are able to correct Reporting to your supervisor the hazards you are unable to correct 35 Case Study A forklift operator was moving a pallet containing bags of materials. When the forklift hit a bump, several of the bags fell from the pallet onto an employee. 36 Case Study A worker was attempting to lift an adapter flange without aid. He suffered severe back sprain and was taken to the hospital. 37 Always Remember Proper lifting techniques will prevent most back a injuries Inspect your material handling tools, materials, and machines before each use Stay at least 10 from overhead powerlines Use and operate material handling equipment according to the manufacture Aisles, passageways, and steps should not be used for storage 38 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 39 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 40 Memory Check 3.When should forklift operators wear their seat belts? a.when operating near drop-offs b.when backing up c.only when learning to operate d.at all times 41 Memory Check 4.Which of the following is the safest sling angle? a.5 b.10 c.30 d.60