Material Hand l ing and Storage Module 2 Sp e cial War - PowerPoint Presentation

Material Handling and StorageModule 2 Special Warehouse Worker Hazardsin Structural Steel Fabricating and Supply Companies 0

Material Handling and StorageModule 2Material Handling and Storage – OSHA Grant Information1OSHA Grant InformationThis material was produced un d er grant n u m ber SH - 26316 -S H 4 f r om t he Occupation a l S a fety and H e alth A d m i n istrati o n, U.S. D e part m ent of L ab o r. I t do e s not nec e ssari l y reflect the vie w s or p ol i ci e s of the U.S. D e part m ent of L ab o r, nor do e s m enti o n of trades na m es, co m m ercial prod u cts, or orga n iz a tio n s i m p l y e n d o rse m e n t by the U.S. Govern m ent.

Material Handling and StorageModule 2Program DevelopmentThis program was developed by faculty and students in the Sch o ol of P lanning, Design and Construction at Michigan State University in conjunction withthe American Institute of Steel Construction - SafetyCommittee and the University of Puerto RicoMarch 2015 Material Handling and Storage – Program Development 2

Material Handling and StorageModule 2Material Handling and Storage – Learning Outcomes3Learning Outcomes: Participants shall be able t o : Identify key materi a l ha n dling hazardsRecognize hazards associated with material handlingequipmentIdentify methods to abate, avoid, and preventaccidents when moving material

Material Handling EquipmentMaterial Handling and Storage Addressed4Module 2Material Handling Equipme nt A d dre s s e d: Workers and ergonomicsOverhead cranesMobile cranesTrucks for receiving and shippingPowered Industrial Trucks (Forklifts)CartsIndustrial magnetic lifting devicesSlings, wire ropes, and alloy chai nsLifting hardware Loadi n g docks

Material Handling EquipmentModule 2 WorkersWorkers are a key part of the material handling chainUse of equi pment to h e lp make t he job easier can lead to certain injuriesUse proper lifting techniquesto avoid injury (Module 5)5Workers working on fabricationMaterial Handling Equipment - Workers

Material Handling EquipmentMaterial Handling Equipment – Workers Continued6Module 2WorkersObtain training on each pie ce of equi pment you use Use equ ipment properlyPay attention to what you and others around you are doingUse Personal Protective Equipment (PPE) specifically required for the task you are performing

Material Handling EquipmentModule 2Personal Protective EquipmentFor l oads with sharp or rough edge s, w ear gloves or other hand and forearm protectionSteel-toed or composite toed safety shoes to prevent foot injuries if work is dropped Wear a hard hat with a good suspension system Eye Protection Hearing protection Material Handling Equipment – Personal Protective Equipment 7

Material Handling and Storage8Module 2Equipment Use-Identifying Points of Risk ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦♦Material Handling and Storage – Equipment Use – Identifying Points of Risk

Material Handling and StorageModule 2Topics addressed in Modules 2 and 3 ♦ ♦ ♦ ♦ ♦♦♦♦♦ ♦ Material Handling and Storage – Topics addressed in Module 2 and 3 9

Material Handling and StorageModule 2Receiving and Shipping♦ ♦ Material Handling and Storage – Receiving and Shipping 10

Receiving and Shipping-Key TopicsRailTrucksRemoving strappi ngPPE Lo a di n g DocksMaterial Handling and Storage – Receiving and Shipping – Key Topics11Material Handling and StorageModule 2

Material Handling and StorageModule 2Material Handling and Storage – Receiving Material At The Shop12Receiving material at the shopMaterial typically delivered by rail or trucks Of f l o a d ed with overhead cranes or mobile cranesSmaller items may be offloaded with Powered Industrial Trucks (Forklifts)Smaller items may be off loaded to loading docks

Material Handling and StorageModule 2Receiving material at the shopSteel arriving from the mill Material Handling and Storage – Receiving Material At The Shop Continued 13

Material Handling EquipmentModule 2Trucks for Receiving and Shipping Recei v ing m aterial Material Handling Equipment – Trucks For Receiving and Shipping 14 Fabricated shapes loaded for shipping

Material Handling and StorageModule 2Loaded for shipping Fabricated shapes loaded and ready for shippingLoads must be securedMaterial Handling and Storage – Loaded for Shipping15

Material Handling and StorageMaterial Handling and Storage – Potential Hazard – Moving Vehicle16Module 2Potential Hazard: Moving vehicle/equipment ac c idents Struc k -by and caught-between accidentsHazard AvoidanceClear surfaces of ice and snowDirect traffic movement and drivers with hand signalsUse trained “spotters”Personnel should use personnel do ors rather than doors i ntended for vehicl esU se backi n g -up a u d i b l e w a rni n gs, l i g h ts a n d flas h ers Stand cl e ar of mov i ng veh i cl e s Do not s t and between veh i cl es and obstructionsMaintain clearances

Material Handling and StorageModule 2Material Handling and Storage – Poterntial Hazard – Moving Vehicle Continued17Potential Hazard: Moving vehicle/equipment ac c idents Struc k -by and caught-between accidentsHazard AvoidanceSet brakes of trucks to prevent trucks from moving during loading and unloadingBlock/chock wheels to prevent mov ementFol low company policy on whe ther drivers can remain in trucks during l o ad i ng and off l o ad i ng Maintain gu a rds at d ropped l o ad i ng areas O t her methods to a void haz a rds that y ou us e ?

Material Handling EquipmentModule 2Rail for Receiving and S hipping OS H A 1 9 1 0.178 (k) requires wheel stops or other recognized positive protection to prevent rail cars from moving during loading or unloadingMaterial Handling Equipment – Rail for Receiving and Shipping18Rail cars used for delivery of steel

Material Handling and StorageModule 2Use of SpottersLink to Preventing Backovers on OSHA Website Material Handling and Storage – Use of Spotters

Module 2 Use of Spotters - Backing Safety Solutions“Spotters are a proven method of protec ting employees on foot be h i n d vehicles with an obstructed view, but spotters themselves can be at risk for injury or even death.”Material Handling and Storage – Use of Spotters – Backing Safety Solutions20Material Handling and StorageLink to Spotters on OSHA Website

Module 2 Use of Spotters - Backing Safety SolutionsSpotters and drivers agree on hand signals before backingS potters sho u ld maintain visual contact with the driverDrivers should stop backing immediately if they lose sight ofthe spotterSpotters should not have additional duties while they are acting as spottersSpotters sho uld no t to use personal mobi le pho nes, p e rson a l headphones , o r o t he r ite ms whic h coul d pos e a d is tr ac t ion duri n g spotting activiti e s S potters sho u ld w e ar high-vis i bi l ity clothing, especially during night operationsLink to Spotter Web Page on OSHA Website Material Handling and Storage – Backing Safety Solutions21Mate rial Handling and Storage

Material Handling EquipmentModule 2Hand SignalsUse hand signals to direct drivers link to spotter web page on OSHA Website Material Handling Equipment – Hand Signals 22

Material Handling EquipmentModule 2Hand signalsLink to Spotter Web page on OSHA WebsiteMaterial Handling Equipment – Hand Signals 2 23

Material Handling EquipmentLink to Spotter web page on OSHA websiteMaterial Handling Equipment – Truck Hand Signals24Module 2Truck Hand Sign als I n -cl a ss activ i ty - Instructor to demonstrate with student proper hand signalsEach attendee to demonstrate one hand signal

Material Handling and StorageModule 2Material Handling and Storage – Hazard Potential: Slips, Falls and Trips25Hazard Potential: Slips, fal ls an d trips from eq u ipment or in storage yardSlips, falls and trips may occur from equipment or in the storage yard due to slippery surfaces from inclement weather or obstructed walking pathsHazard Avoidance: Clear surfaces of ice and snow Use proper foot-ware w i th t r ea d ed so l es K e ep w a lk w ays cl e ar of d ebris Do not w o rk fati g ued Use pro t ection f r om fal l s when working on platforms above 4 feet

Material Handling and StorageModule 2Material Handling and Storage – Potential Hazard – Unstable loads26Potential Hazard-Unstable loads due t o shif t ing during transportLoads may shift or otherwise become unstable duringtransport or during unloadingHazard AvoidanceObserve and evaluate load upon arriv al and duri ngunl oadi ng Stab i l i ze and r e - secure lo a ds Stand cl e ar of u nstab l e l o ads

Material Handling and StorageModule 2Potential Hazard - Cuts, scrapes, bumps, pinches and co n tact injuries from material sharp edges and being caught between materialsFabricated material and material from the millwill have sharp edges. Alw ays wear proper clothing and PPE.Material Handling and Storage – Potential Hazard – Cuts, Scrapes, Bumps, Pinches and Contact Injuries 27

Material Handling and StorageModule 2Potential Hazard-Cuts and scrapes from material sh arp edgesH a zard A v oidan ce:Wear appropriate personal protective clothingHandle materials properlyUse tools properlyMaterial Handling and Storage – Potential Hazard – Cuts and Scrapes from Material Sharp Edges28

Material Handling and StorageModule 2Potential Hazard-Injuries from removing metal b anding C u ts and eye injuries Hazard Avoidance-removing metal material bandingWear appropriate personal protective clothing:Use the right tools such as longhandled shearsDo not us e tools like crowbars or claw hammers 29 Ad apted from wy o m ing w ork f orce.or g /D o c u m e n t s / O S H A / . .. / S t e e lSt r a p pin g . pdf date v isited D ece m ber 8, 2014 Material Handling and Storage – Potential Hazard – Injuries From Removing Metal Banding

Material Handling and StorageMaterial Handling and Storage – Hazard Avoidance – Removing Metal Material Banding30Module 2Hazard Avoidance - removing metal m a terial b a n d ing Plan the job. Cut the band farthest away first.Other personnel should stand clearMake cuts squarelyStay away from the area that straps springs to when cutClean up straps af ter cut ting the str aps, do not leave them laying around Adapted from wy o m ing w orkforce.org /D o c u m e n t s / OS H A / . .. / S t e e lSt r a p pin g . pdf date v isited D ece m ber 8, 2014,

Material Handling EquipmentModule 2Potential Hazard-Loading docksInjuries happen when for k li f ts run off the dock, products fall on employees or equipment strikes a person.Hazard Avoidance:Do not stand between a truck and a fixed surfaceBlock/chock wheels of trucks Guide truck s with hand signalsDr ive for klifts slowly around do c ks C he c k if do c k plates c a n s a fely s u ppo r t loads Do not back up f or k li f ts to dock edge A v oid dock edgesSource OSHA 3220-10N 2004Careful use of forklifts in areas of loading docks is needed to prev ent fall-offsMaterial Handling Equipment – Potential Hazard – Loading Docks31

Material Handling EquipmentMaterial Handling Equipment – Potential Hazard – Loading Docks Continued32Module 2Potential Hazard-Loa ding docks In j uries hap p en when forklifts run off the dock, products fall on employees or equipment strikes a person.Hazard Avoidance:“Provide visual warnings near dock edges”“Prohibit “ dock jumping ” by employees”Us e non-slip surfaces and keep surfac es clean P aint the edges of the loading dock to impro v e v isibili t y M eet OSHA standards for do c k ladder s , stairs, and gua r drails Source OS H A 3220-10N 2004

Material Handling and StorageModule 2Movement Overhead♦♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ Material Handling and Storage – Movement Overhead 33

Movem ent Overhead - Key TopicsOverhead CranesMobile CranesSlingsMaterial Handling and Storage – Movement Overhead – Key Topics 34 Mate r ial Handli n g and StorageModule 2

Material Handling and StorageModule 2Cranes - Moving material in the yardTypi cally by ov e rhead crane or mobi le craneOverhead crane in material yardMaterial Handling and Storage – Cranes 35

Material Handling and StorageModule 2Cranes - Moving material within the sh op Ty p ic a l l y material is moved within the shop with overhead, gantry or jib cranesOverhead crane for moving material in shopMaterial Handling and Storage – Cranes – Moving Material36

Material Handling EquipmentModule 2Overhead Cranes1910.179 Overhead and gantry cranes Photo from OS H A 3341-03N 2008Material Handling Equipment – Overhead Cranes37

Material Handling and StorageModule 2Material Handling and Storage – Potential Hazard: Dropped Loads38Potential Hazard: Dropped loadsLo a ds carri e d by overhead cranes can be dropped or workers can be struck or caught between objectsHazard Avoidance:Do not work under loads being moved or suspended overheadMaintain safe distances from loads b eing moved overhead Use only tr ained op erators Use “ S p otters” w hen op e rator cannot see the l o ad and a clear path Operate cranes w i thin l o ad rating l i mits

Material Handling and StorageModule 2Material Handling and Storage – Potential Hazard: Dropped Loads Continued39Potential Hazard: Dropped loadsLo a ds carri e d by overhead cranes can be droppedHazard Avoidance:Maintain crane equipmentConduct required safety inspections of lifting equipmentUse proper rigging hardware, sl ings, all oy chains and wire ropes free of defects a nd prop e rly si z ed Inspect s l i n gs, cha i ns, w i re ropes and hardware for defects, corrosi o n and de g radation. D i scard if damage d .

Material Handling and StorageModule 2Link to OSHA Publication 2236Material Handling and Storage – Safety Measures for Cranes40Safety measures for cran es:  K n o w the weight of the material that is being liftedAlways check the crane's rated capacity to make sure that the crane will not be overloadedPlan lifts before starting them to make sure that theyare safe.Know the “weakest” li nk in the l ift, often rigging. Plan the path of travel, cl ear la nd i ng area, n o tify others in the area, etc.

Material Handling and StorageModule 2Safety measures employers should take w ith cra n e s :  Insp ected at least quarterly “by persons thoroughly familiar with the crane, the methods of inspecting the crane, and what can make the crane unserviceable.Crane activity, the severity of use, and environmental conditions determine more frequent inspection schedule s.” “Ensure that the critical parts of a crane—such as crane operating mechanisms, hooks, air, o r hy d raul i c system comp o n e nts a n d other l o a d -carrying comp o n e nts — are i n spected da i ly for any mala d justment, deteri o ration, l e aka g e, deformatio n , or o t her d amage.”41Link to OSHA Publication 2236Material Handling and Storage – Safety Measures Employers Should Take With Cranes

Material Handling EquipmentModule 2Mobile Cranes1910.180 Crawle r, locomotive, and t r uck cranes in yard to load trucksMaterial Handling Equipment – Mobile Cranes42Mobile crane being used

Material Handling and StorageLink to OSHA Publication 2236Material Handling and Storage – safety Measures with Mobile Cranes43Module 2Safety measures with mobile crane s :  On l y thoroughly trained and competent workers shouldoperate cranesCranes operators must be National Commission of the Certification of Crane Operators (NCCCO) certified if operating cranes on a construction jobsite, although it is not mandated for work in the shop Operators sho u ld know w h at they are lifting and what it w e i g hs. R ated ca p ac i ty of mob i le cran e s vary w i th bo o m l e ngth and radi u s

Material Handling and StorageLink to OSHA Publication 2236Material Handling and Storage – Safety Measures with Mobile Cranes Continued44Module 2Safety measures with mobile crane s :  To minimize the risks of crane use, employers shalltake the following precautions:Equip all cranes with boom angle indicators“Provide cranes with telescoping booms with some means to determine b oom lengths u nless the load rating is indep endent of the boom l e ngt h .”  “Post l o ad rating charts i n the cab of cab-op e rated cranes. (A l l cranes do not h ave un i form c ap a citi e s for the s a me bo o m l e ngth and radius in all directions around the chassis of the vehi cle.)”

Material Handling and StorageModule 2Link to OSHA Publication 2236Safety Measures with Mobile Cranes Continued45Safety measures with mobile cranes :  K n ow that there are regulations and limitations that operators need to know before working close to power linesOutriggers if used must rest on firm ground, timbers, or cribbing to spread the crane weight and load over a large enough area

Cranes Reminders*Check the load chart in the cabFrequently inspectLift people on l y w h en permitted by OSHA StandardsCheck overhead power lines if outdoorsEnsure area of travel is clear46Material Handling EquipmentModule 2Material Handling Equipment – Cranes Reminders

Material Handling EquipmentModule 2Mobile CranesUse hand signals wh en necessary to g ui d e l o ad placementLink to Hand Signals for Crane Operations Web pageMaterial Handling Equipment – Mobile Cranes – Hand Signals47

Material Handling EquipmentModule 2Mobile CranesHand signals contin ued Link to Hand Signals for Crane Operations Web Page Material Handling Equipment – Mobile Cranes Continued 48

Material Handling EquipmentLink to Hand Signals for Crane Operations Web PageMaterial Handling Equipment – Crane Hand Signals49Module 2Crane Han d Signals I n -cl a ss activ i ty - Instructor to demonstrate with student proper crane signals used by spottersEach attendee to demonstrate one hand signal

Material Handling EquipmentModule 2Mobile CranesAISC has a sample daily inspection check list avai l a ble on its safety channelLink to AISC Mobile Cranes Daily Inspection FormMaterial Handling Equipment – Mobile Cranes – Inspection Form50

Material Handling EquipmentModule 2Mobile CranesAISC has two useful crane webinars available f or v i ewing at its safety channel site for additional informationLink to AISC's crane safety webinarsMaterial Handling Equipment – Mobile Cranes Webinars51

Material Handling EquipmentModule 2Industrial Magnetic Lifting De vices Link to Walker Magnet Material Handling Equipment – Industrial Magnetic Lifting Devices 52

Material Handling EquipmentModule 2Industrial Magnetic Lifting Devices Per m anent m agnet Material Handling Equipment – Industrial Magnetic Lifting Devices Continued 53Using magnet to lift plate

Material Handling EquipmentMaterial Handling Equipment – Magnet Defined54Module 2Industrial Magnetic Lifting Devices 1910.179 ( a)(47 ) "Mag n et" means an electromagnetic device carried on a crane hook to pick up loads magnetically.

Material Handling EquipmentMaterial Handling Equipment – Below-the-Hook Lifting Devices55Module 2Industrial Magnetic Lifting Devices The Americ a n Society of Mechanical Engineers has developed the ASME B30.20-20-3 Below-the-Hook Lifting Devices- Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Sli ngs which add resses permanent and electric-rated lifting magn ets and thei r operatio n . Link to Understanding Lift Magent Compliance

Material Handling EquipmentMaterial Handling Equipment – Industrial Magnetic Lifting Devices Safety56Module 2Industrial Magnetic Lifting Devices A S ME B30.2 0 - 20 -3 addresses safety of magnetic lifting devices including:User qualificationsTrainingOperation practicesLink to Understanding Lift Magnet Compliance

Material Handling EquipmentMaterial Handling Equipment – Main Types of Magnets57Module 2Industrial Magnetic Lifting Devices Three main types of magnets:ElectromagnetsPermanent magnetsElectro-permanent magnetsAll three can be used to lift ferrous metals such asplate, structural shapes, coils etc.Link to magnetics 101 on Walker Magnet Website

Material Handling EquipmentIndustrial Magnetic Lifting Devices Continued58Module 2Industrial Magnetic Lifting Devices P e r m an e nt magnets typically will have “on” position and “off” position. The operator engages the magnet using the “on” positionSafety pins are engaged to protect against accidental switching to the “off” positi on and di sengagi ng the magnet May a l so i n cl u de safety l i f t i n g features that can be used to test the l oad before a l i ft

Material Handling and StorageModule 2Material Handling and Storage – Potential Hazard Magnets: Dropped Loads59Potential Hazard Magnets: Dropped loads“Caught between” injuries can range f r om p i nching, crushing to amputations (caught between) due to:Dropped loads“Struck by” caused by material being movedAttracting unintended surrounding tools, material etc. dueto magn etic forceHa zard Avoidanc e:N ever work un d er t he path of the load Maintain safe distances f r om l o ads be i ng moved overhead N e ver put your f i n gers under the l o ad w h en gu i di n g l o adsUse same precautions as crane hazard avoidance discussed previously

Material Handling EquipmentMaterial Handling Equipment – Dropped Loads Causes60Module 2Industrial Magnetic Lifting Devices Drop p ed l o ads can occur from factors such asInstantaneous loss of powerLoss of magnetism of permanent magnetsIrregular surfaces which may prevent the magnet from being fully engaged with the material being movedLink to Understanding Lift Magnet Compliance

Material Handling EquipmentLink to Understanding Lift Magnet ComplianceMaterial Handling Equipment – Industrial Magnetic Lifting Devices Cont61Module 2Industrial Mag netic Lifting D e vices Fo llow Manufacturer's instruction for safe operationMagnets should have legible labels showing magnet lifting capacityLifting charts can be hard to read on magnets, and hard to keep legible. These charts can be enlarged and posted in the facility (as long as employees know w here to find the inform ation) R e move f r om service defective equ i pment or w hen missing tags.

Material Handling EquipmentLink to Understanding Lift Magnet ComplianceMaterial Handling Equipment – Strong Magnet Warnings62Module 2Industrial Magn etic Lifting D e vices “ Strong magnet w arnings” should be placed in areas when lifting magnets are usedStrong magnets can attract unwanted materials such as tools, adjacent materials, table etc.Remember magnets depending on their design can l ift from several hundred lbs to 10,000 lbs

Material Handling EquipmentModule 263Module 2Q and A

Material Handling EquipmentModule 264Take a Break!