Malik Material Handling Presentation

“Safety needs team work, let us work together”,
Presentation of Material Handling

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
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
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,
Manual Handling
• Hazards:
Strains, Sprains, Fractures, cut,
bruiceslumber Pain
• Methods:
Foot position , Knee bent, back
straight, head ,
• Accessories :
Hook , crowbar , jack, hand
truck etc
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!
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.
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
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
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.
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
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
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
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

3 Meters
3 Meters
Lift Categories
• Definitions of Lift Categories:
– Standard Lift
– Standard Lift in Hazardous Area
– Complex Lift
– Complex Lift in Hazardous Area
– Heavy Complex Lift
• Standard Lift:
– Criteria : Load to be lifted weighs less than 15 T.
– Requirement : Mobile crane planning and risk assessment

check sheet.
• 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 ).

check sheet, Task risk assessment.
• 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 ).

check sheet, Task risk assessment.
• 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.
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.
Lifting Tools And Tackles
• Fibre rope slings

• Wire rope slings
• chains
• Shackles
• Hooks
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

Markings Alloy Steel Chain
It must be marked with grade or manufacturer's mark

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

Sling Inspection
 Each day before use.
 Where service conditions
warrant
 Remove them from service if
damaged or defective
Remove From Service
Immediately remove damaged or defective slings from service

Remove The Sling From Service if these happens :
Kinking
Bird Caging Crushing

Wire Rope Slings Eye Splices
• Eye splices made in

any wire rope must
have at least three full
tuck
Protruding Ends :
Cover or blunt protruding ends of strands

Synthetic Web Sling
Mark or code :
• Name or trademark of
manufacturer
• Rated capacities for the type
of hitch
• Type of material
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
Synthetic Web Sling Stitching
Stitching is the only

method allowed to attach Stitching
end fittings to webbing,
or to form eyes
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
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
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
Hitches
• Vertical
• Basket
• Choker
Sling Angle
• 45 DEG TO 90 DEG
• Capacity of the sling
1000 Kg
Kg
T
=
7
76
76
7
=
K
T
g
0
45
1000 lBS
1000 Kgs
1000 Kg
Safe Use of Chain Pulley Block

yo u
a nk
Th

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

Presentation of Material Handling

Safe Material Handling

Safe Material Handling

Applicable to all AIL sites irrespective of location and activities

• The Factories Act 1948 –

Get Help Use the

Carrying the load…

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

Points to be consider while planning

Cranes - General Safety Guidelines

• Check slings and hooks for any defects

Crane Operators and Signalman

• Speed not more than 20 KMPH

Travelling with Load

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

Attaching the Load :

• Slings of sufficient capacity

Lifting of Personnel by Cranes :

• In case of inevitable condition only

Safe Material Handling

Safe Material Handling

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

– Requirement : Mobile crane planning and risk assessment

• Standard Lift in Hazardous Area:

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

– Requirement : Mobile crane planning and risk assessment

• Standard Lift in Hazardous Area:

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

– Requirement : Mobile crane planning and risk assessment

Complex Lift in Hazardous Area:

Requirement : Mobile crane planning and risk assessment check sheet,

Lifting Tools And Tackles

• Fibre rope slings

Rigging Equipment Slings :

Chain Wire rope Metal mesh Synthetic

Markings Alloy Steel Chain

It must be marked with grade or manufacturer's mark

Wire Rope Slings

 Ability to bend without cracking

 Ability to withstand abuse

Remove From Service

Immediately remove damaged or defective slings from service

Remove The Sling From Service if these happens :

Bird Caging Crushing

Wire Rope Slings Eye Splices

• Eye splices made in

Cover or blunt protruding ends of strands

Synthetic Web Sling

Synthetic Web Slings Fittings

• At least as strong as that of

• Free of sharp edges that

Synthetic Web Sling Stitching

Stitching is the only

Synthetic Web Slings

• Remove from service if any of

– Acid or caustic burns

Alloy Steel Chain Attachments Rated Capacity

Hooks, rings, oblong links, or