Material Hand l ing - PowerPoint Presentation

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

Material Handling and StorageModule 21OSHA Grant InformationThis material was produced under 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 Planning, Design and Construction at Michigan State University in conjunction withthe American Institute of Steel Construction - SafetyCommittee and the University of Puerto RicoMarch 2015 2

Material Handling and StorageModule 23Learning Outcomes: Participants shall be able to: Identify key materi a l ha n dl ing hazardsRecognize hazards associated with material handlingequipmentIdentify methods to abate, avoid, and preventaccidents when moving material

Material Handling Equipment4Module 2Material Handling Equipment Addre s s e d: Workers and ergonomicsOverhead cranesMobile cranesTrucks for receiving and shippingPowered Industrial Trucks (Forklifts)CartsIndustrial magnetic lifting devicesSlings, wire ropes, and all oy chai nsLifting hardware Lo a di 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 the job easier can lead to certain injuriesUse proper lifting techniquesto avoid injury (Module 5)5Workers working on fabrication

Material Handling Equipment6Module 2WorkersObtain training on each piece of e quipment you use Use equ i pment 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 w i th sharp or rough edge s, wear 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 7

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

Material Handling and StorageModule 2Topics addressed in Modules 2 a nd 3 ♦ ♦ ♦♦♦♦♦♦♦ ♦ 9

Material Handling and StorageModule 2Receiving and Shipping♦ ♦ 10

Receiving and Shipping-Key TopicsRailTrucksRemoving strappi ng PPE Lo a di n g Docks11Material Handling and StorageModule 2

Material Handling and StorageModule 212Receiving 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 13

Material Handling EquipmentModule 2Trucks for Receiving and Shipping Receiving m aterial 14 F ab ricated shapes loaded for shipping

Material Handling and StorageModule 2Loaded for shippingFabricated shapes loaded and ready for shippingLoads must be secured15

Material Handling and Storage16Module 2Potential Hazard: Moving vehicle/equipment acc 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 personn el do ors rather th an doors intended for vehicl e s U s e ba c ki 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 vehicles Do not stand between vehicles and obstructionsMaintain cl earances

Material Handling and StorageModule 217Potential Hazard: Moving vehicle/equipment accidents Struc k -by and caught-between accidentsHazard AvoidanceSet brakes of trucks to prevent trucks from moving during loading and unloadingBlock/chock wheels to prevent movementFol low company po licy on wh ether drivers can remain in t rucks d u ring 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 ards that you use?

Material Handling EquipmentModule 2Rail for Receiving and Shipping 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 unloading18Rail cars used for delivery of steel

Material Handling and StorageModule 2Use of Spottershttps://www.osha.go v/ d oc/topics/ b ack o ver/spotter.html

Module 2 Use of Spotters - Backing Safety Solutions“Spotters are a proven method of protec ting employe e s on foot be h ind vehicles with an obstructed view, but spotters themselves can be at risk for injury or even death.”20Material Handling and Storagehttps://www.osha.gov/doc/topics/backover/spott er.ht ml

Module 2 Use of Spotters - Backing Safety SolutionsSpotters and drivers agree on hand signals before backing S 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 shou ld n ot to use perso n al mob i le p h o n es, 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 activitiesSpotters should wear high-visibility clothing, especi ally during night operationshttps://www. osha.gov/doc/topics/backover/sp otter.html21Mate rial Handling and Storage

Material Handling EquipmentModule 2Hand SignalsUse hand signals to direct drivers https : / / www .osha.gov/doc/topics/backover/spotter.html22

Material Handling EquipmentModule 2Hand signalshttps://www.osha.go v/doc/ t o pi c s /backover/spotter.html23

Material Handling Equipmenthttps://www.osha.gov/doc/topics/back ov er/ s p o t ter.html24Module 2Truck Hand SignalsIn-class activity - Instructor to demonstrate with student proper hand signalsEach attendee to de monstrate one hand signal

Material Handling and StorageModule 225Hazard Potential: Slips, falls and 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:Clea r surfaces of ice and snow Use proper foot-w a re 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 protection from falls when working on platforms abo ve 4 feet

Material Handling and StorageModule 226Potential 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 arrival and duri ngu nloa d i n g 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, pinche s and co n tact injuries from material sharp edges and being caught between materialsFabricated material and material from the millwill have sharp edges. Always w ear proper clothing and PPE. 27

Material Handling and StorageModule 2Potential Hazard-Cuts and scrapes from material sh arp edges H a zard A voidance:Wear appropriate personal protective clothingHandle materials properlyUse tools properly28

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 a pted 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 datevisited Dece mber 8, 2014

Material Handling and Storage30Module 2Hazard Avoidance - remov ing metal material 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 after cutt ing the straps , 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 ping.pdf date visited D ecember 8, 2014,

Material Handling EquipmentModule 2Potential Hazard-Loading docksInjuries happen when for k lifts 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 trucks with hand signalsD r i v e for k li f ts 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 fork lifts to dock edgeAvoid dock edge sSource OSHA 3220-10N 2004 Careful use of forklifts in areas of loading docks is needed to prevent fall-offs31

Material Handling Equipment32Module 2Potential Hazard-Loading doc ks 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”Use non -slip su rfaces and ke ep surfa c 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 guardrails Source OSHA 3220-10N 2004

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

Movem ent Overhead - Key TopicsOverhead CranesMobile CranesSlings 34 Mate r ial Handli ng and StorageModule 2

Material Handling and StorageModule 2Cranes - Moving material in the yardTypi cally by ov e rhead crane or mobile craneOverhead crane in material yard35

Material Handling and StorageModule 2Cranes - Moving material within the sh op Ty p ic a l ly material is moved within the shop with overhead, gantry or jib cranesOverhead crane for moving material in shop36

Material Handling EquipmentModule 2Overhead Cranes1910.179 Overhead and gantry cranes Photo from OS H A 3341-03N 200837

Material Handling and StorageModule 238Potential Hazard: Dropped loads Loads 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 being movedoverhead Use only t rained op e rato r s 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 239Potential Hazard: Dropped loads Loads carri e d by overhead cranes can be droppedHazard Avoidance:Maintain crane equipmentConduct required safety inspections of lifting equipmentUse proper rigging hardware, slings, al loy cha ins and wire ropes free of d e fects 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. Discard if damage d.

Material Handling and StorageModule 2https://www.osha.gov/Publications/OS HA2 2 36 / o s ha2236.html40Safety measures for cranes:Know the weight of the material that is being liftedAlways check the crane's rated capacity to make sure that the crane wi ll not be overloaded Pla n l i fts b e fore starting th e m to make sure that th e y are safe.  K n ow the “ w e akest” l i nk in t he l i f t , often rigg i ng. Plan the path of travel, clear landing area, notify others in the area, etc.

Material Handling and StorageModule 2Safety measures employers should take w ith cra n e s : Inspected 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 op e rating mechan i sms, 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 djustment, deterioration, leakage, deformation , or other damage.”41 https://www.osha.gov/Publicat ions/OSHA2236/osh a2236.html

Material Handling EquipmentModule 2Mobile Cranes1910.180 Crawler, locomotive, and t r uck cranes in yard to load trucks42Mobile crane being used

Material Handling and Storagehttps://www.osha.gov/Publications/OSHA2236 /o s h a2 2 3 6.html43Module 2Safety measures with mobile cranes:Only thoroughly trained and competent workers shouldoperate cranes Cranes operato rs must be National C o m m iss i on of the C e r t ific a tion of Crane Operato r s (NC C CO) certifi e d if op e rating cranes on a const r uction jobsite, alth o ugh it is not mandated for work in the shop Operators should know what they are lifting and what it weighs. Rated capacity of mobile cranes vary with boom length and radius

Material Handling and Storagehttps://www.osha.gov/Publications/OSHA2236 /o s h a2 2 3 6.html44Module 2Safety measures with mobile cranes:To minimize the risks of crane use, employers shalltake the following precautions:Eq uip all cranes with boom angle i n dic a tors  “Provide cranes w i th telesc o pi n g bo o ms with some means to d e ter m i n e b o om len g ths u n l e ss the l o ad rating is independent of the boom length.”“Post load rating charts in the cab of cab-operated cranes. (All cranes do not have uniform capacitie s for the same boom length and radius in all directions around the chassis of the vehicle.)”

Material Handling and StorageModule 2https://www.osha.gov/Publications/OSH A22 36 / o s h a2236.html45Safety measures with mobile cranes:Know that there are regulations and limitations that operators need to know before working close to po wer lines O utriggers if used m ust rest on firm groun d , timber s , or cribb i ng to s p read the crane we i ght and load over a l a rge en o ugh area

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

Material Handling EquipmentModule 2Mobile CranesUse hand signals wh en necessary to g ui d e load placementhttps://www.osha.gov/dte/grant_materials/fy10/sh-21009-10/Hand_Signals_Cranes.pd 47

Material Handling EquipmentModule 2Mobile CranesHand signals contin ued https:/ / www . o sha.gov/dte/grant_materials/fy10/sh-21009-10/Hand_Signals_Cranes.pd48

Material Handling Equipmenthttps://www.osha.gov/dte/grant_m ater ia ls/f y 10/s h -21009-10/Hand_Signals_Cranes.pd49Module 2Crane Hand SignalsIn-class activity - Instructor to de monstrate with student proper crane sign als used by spotters E a ch at t en d ee to d e m onstrate one ha n d si g nal

Material Handling EquipmentModule 2Mobile CranesAISC has a sample daily inspection check list ava i l a ble on its safety channelhttp://www.aisc.org/content.aspx?id=3182850

Material Handling EquipmentModule 2Mobile CranesAISC has two useful crane webinars available f or v iewing at its safety channel site for additional informationhttp://www.aisc.org/content.aspx?id=3182851

Material Handling EquipmentModule 2Industrial Magnetic Lifting Devices http: / / www . w alkermagnet.com52

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

Material Handling Equipment54Module 2Industrial Magnetic Lifting De vices 1910.179 ( a)(47 ) "Mag net" means an electromagnetic device carried on a crane hook to pick up loads magnetically.

Material Handling Equipment55Module 2Industrial Magnetic Lifting De vices 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 Slings which addresses permanent and electr ic-rated lifting magnets and the i r o p e ratio n . http: / / www .the f ab r i cat o r.com/ a rtic le /mat e r ia ls h a nd l i ng / u nde rsta n d i n g - l i f t-magnet-complia nce

Material Handling Equipment56Module 2Industrial Magnetic Lifting De vices A S ME B30.2 0 - 20-3 addresses safety of magnetic lifting devices including:User qualificationsTrainingOperation practiceshttp://www.thefabricator.com/article/materialsha ndl ing /unde rstan d i n g - l i f t - m agne t - co m pl i a n ce

Material Handling Equipment57Module 2Industrial Magnetic Lifting De vices Three main types of magnets:ElectromagnetsPermanent magnetsElectro-permanent magnetsAll three can be used to lift ferrous metals such asplate, structural shapes, coils etc.http://www.walkermagnet.com/res our ce s-m ag ne t i c s - 1 0 1 . h t m

Material Handling Equipment58Module 2Industrial Magnetic Lifting De vices P e r m an ent 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” posit ion and di senga ging 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 259Potential Hazard Magnets: Dropped loads“Caught between” injuries can range f r om p i n ching, crushing to amputations (caught between) due to:Dropped loads“Struck by” caused by material being movedAttracting unintended surrounding tools, material etc. dueto magnetic forceH azard A voidance :N ever w o rk 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 hen guidi ng loadsUse same precautions as crane hazard avoidance discussed previously

Material Handling Equipment60Module 2Industrial Magnetic Lifting De vices Drop p ed l oads 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 movedhttp://www.thefab ri cato r.com/artic le/mat e r ia ls h a nd l i ng / u nde rsta n d i n g - l i f t - m agne t - co m pl i a n ce

Material Handling Equipmenthttp://www.thefabricator.com/article/materials hand l i ng / u nderstanding-lift-magnet-compliance61Module 2Industrial Magnetic Lifting DevicesFollow Manufacturer's instruction for safe operation Magnets should have legi ble la be l s sho w i n g magnet l i f t i n g cap a city Lifting charts can be hard to read on magnets, a n d hard to keep l e gi b l e . These charts can be en l arged a n d p o sted in the facility ( as long as employees know where to find the i nformation)Remove from service defective equipment or when missing tags.

Material Handling Equipmenthttp://www.thefabricator.com/article/materials hand l i ng / u nderstanding-lift-magnet-compliance62Module 2Industrial Magnetic Lifting Devices“Strong magnet warnings” sho uld be p laced in areas when lif t i n g magnets are used Strong magnets can attract un w anted materia l s such as too l s, a d jace n t materia l s, tab l e etc. R e member magnets depen d i n g on their des i gn can lift from several hundred lbs to 10,000 lbs

Material Handling EquipmentModule 263Module 2Q and A

Material Handling EquipmentModule 264Take a Break!