MATERIAL HANDLING

1. MATERIAL HANDLING

2. Safe Rigging Practices Know How to Do It Right! Then Do It Right!

3. THE NEED FOR MATERIALS HANDLING • Required to handle materials in office, home, site, etc. • 25% of total accidents are due to materials handling • Materials handling from Prehistoric times

4. PRE-HISTORIC TIME MATERIALS HANDLING The gigantic pyramid at Giza near Cairo (Egypt) built about 2700 B.C. which is 764 ft square at the base and 480 ft. high. About 2(1/3) million stones from 2 to 30 tons in weight each were transported from the quarry to the Nile River at the flood season, ferried across the river on rafts, dragged from river to the site of the pyramid and piled up on each other to a height of a 40 storied building. It is believed that a ramp was built up on one side of the pyramid and the stones were dragged up the slope by slaves working in teams.

5. MATERIAL HANDLING WE SHALL DISCUSS ABOUT • Material Handling Problems. • Ropes. • Rigging and safe rigging practice. • “D” Shakle. • Case Study.

6. MATERIAL HANDLING PROBLEMS LEAD TO INJURIES DURING THE COURSE OF MATERIALS HANDLING e.g. • CUT INJURIES • BRUISES • SPRAIN & STRAIN • CRUSH INJURIES • FRACTURE

7. MATERIAL HANDLING PROBLEMS…. THESE INJURIES ARE DUE TO • UNSAFE WORKING PRACTICES • IMPROPER LIFTING • CARRYING TOO HEAVY LOADS MANUALLY • INCORRECT GRIPPING • NOT USING PPE • FAILING TO HAVE PROPER FOOT AND HAND CLEARANCES, ETC.

8. ROPES

9. ROPES…. COMMONLY USE OF • FIBRE ROPES • WIRE ROPES

10. FIBRE ROPES USAGE • For light loads • For construction • Painting Jobs • Marine Works

11. FIBRE ROPES TYPES • Coconut Coir Rope • Cotton Rope • Jute Rope • Manila Rope

12. FIBRE ROPES 10 USEFULL TIPS ON HANDLING CARE & USE OF FIBRE ROPE • It should be hung up in loose coils on large diameter wooden pegs. • It should be kept away from heat sources. • It should be kept away from acid fumes. • For opening a new coil of rope, the end of the rope should be at the bottom of the core or eye and the end should be pulled out through the core. If this is not followed kinks will be formed which will damage the rope.

13. 10 USEFULL TIPS …. • When used as slings should not be passed over sharp edges. Proper padding should be used. • Strength of Fibre Ropes • At 60 ° -- 86 % of their strength when vertical • At 45 ° -- 71% of their strength when vertical • At 30 ° -- 50% of their strength when vertical • Rope should not be dragged on ground to avoid abrasive action. • Fibre rope should be inspected thoroughly before and after use.

14. 10 USEFULL TIPS …. • When a rope is condemned, it should be destroyed at once to cut up into short hand lines so that it cannot again be used for hoisting. • If the rope is used for lifting loads with pulley blocks, it is advisable to reverse the ends periodically so that the rope is worn out more or less uniformly through-out.

15. WIRE ROPES A Wire Rope is usually made up of a number of wires laid left or right handed into a strand and number of wires laid left or right handed into a strand and number of strands, usually 6 or 8, laid right or left handed round a hemp rope center to form the wire rope, or steel cable as it is generally called.

16. WIRE ROPES CONSTRUCTION OF WIRE ROPES

17. WIRE ROPES • There are 4 different ways of laying the wire rope. • Right-lay, regular-lay • Left-lay, regular-lay • Right-lay, lang-lay • Left-lay, lang-lay

18. WIRE ROPES CONSTRUCTION OF WIRE ROPES: There are a different possible constructions of wire rope. (Number of Strands) X (Number of Wires in a Strand) Example: 6X7  6 Strands and 7 Wires in each strand 6X19  6 Strands and 19 Wires in each strand 6X37  6 Strands and 37 Wires in each strand

19. WIRE ROPES COMMON USE OF VARIOUS CONSTRUCTION OF WIRE ROPES 6X7 (Regular Lay)  Guys, Suspension Ropes, etc. 6X19 (Regular lay with hemp core)  Slings, elevators, etc. 6X19 (Regular lay with steel core)  Blast furnace bell hoist 6X37 (Regular lay with hemp core)  Overhead Cranes, Mill Hoist, etc. 6X37 (Regular lay with steel core)  Hot Metal Cranes, Blast Furnace bell, etc.

20. WIRE ROPES INSPECTION OF WIRE ROPES • BROKEN WIRES • WORN OUT WIRES • REDUCTION IN ROPE DIA. • ROPE STRETCH • BIRD CAGE • KINKS • CORE PROTRUSION

21. WIRE ROPES BROKEN WIRES • 6 OR MORE BROKEN WIRES IN ONE LAY • 3 OR MORE BROKEN WIRES IN ONE STRAND IN ONE LAY • MORE THAN 5% IN ANY LENGTH OF 10 DIAMETERS

22. WIRE ROPES REDUCTION IN ROPE DIA. REPLACE THE WIRE ROPE IF THE DIA REDUCES BY • 1mm FOR ROPE DIA UPTO 19mm • 1.5mm FOR ROPE DIA UPTO 22-28mm • 2mm FOR ROPE DIA UPTO 32-38mm ROPE STRETCH 150 mm PER 30m LENGTH OF SIX STRANDED ROPE

23. WIRE ROPES BIRD CAGES

24. WIRE ROPES CORE PROTRUSION L&T-HSE

25. INSPECTION PROCEDURE • Coding • Once in a month • Coloring • Announce • Record

26. ‘U’ CLAMPS

27. DISTANCE BETWEEN THE ROPE CLIPS = 6 X Dia. CLIPS AND SPACING FOR SAFE APPLICATION

28. RIGGING

29. SLINGS TENSION ON SLINGS T = W x L H x N T = TENSION W = WEIGHT OF THE LOAD L = LENGTH OF SLING N = NO. OF SLING LEGS

30. SLINGS TENSION ON SLINGS If L is greater than S then sling angle is OK

31. SLINGS - HITCHES BASKET HITCH

32. SLINGS - HITCHES CHOKER HITCH

33. RIGGING PRECAUTIONS • Weight of ALL loads • Allowances for unknown factor • Capacity of equipment & marked

34. RIGGING PRECAUTIONS • Rapid swinging increases the stress • Avoid bending splice/ eye section around the corners. • Avoid dragging of sling beneath loads

35. RIGGING PRECAUTIONS • Sharp Bends , Pinching & crushing –avoid for slings –provide packing- curve 7 lays • Never wrap a wire rope around a hook.

36. RIGGING PRECAUTIONS LIFTING • Suspended loads –securely slung & properly balanced • Tag Line • Safely landed & blocked • Lifting beams –SWL marked. • Hoist rope – don’t wrap it around the load. • Multiple part lines –don’t twist • Slack rope condition –ensure it is seated properly on the drum • Stand clear of the load

37. "D" SHACKLE

38. SHACKLES INSPECTION OF D-SHACKLES DEFECTS: • SAFE WORKING LOAD MISSING • OR UNREADABLE • IDENTIFICATION MISSING • OR UNREADABLE • INCORRECT PIN • DAMAGED THREAD ON PIN OR IN • TAPPED EYE • DISTORTED BODY • WORN OUT BODY OR PIN • NICKS, GOUGES, CRACKS, • CORROSION

39. Shackle L&T-HSE

40. Case Studies

41. L&T-HSE

42. Observation • Alignment of the boom top and the centre of the load was not proper during lifting operation which causedswinging of the load Remedy • Before lifting of load the top of the boom and the centre of the load to be aligned properly to avoid swinging. • Experienced Signal man should facilitate the same L&T-HSE

43. L&T-HSE

44. L&T-HSE

45. Observation • Defective storing. Plates were kept in vertically inclined position by means of make shift arrangement • Work method / Job Safety analysis not prepared Remedy • Suitable stands to be used for keeping plates vertically • Work method statement / Job Safety analysis to be prepared and implemented L&T-HSE

46. L&T-HSE

47. Observation • Used worn threaded D-shackle • Checking of casing pipe and operation of the rig were simultaneous • The rig is operated inside the excavation. No space to run off • Routine checkup not made before starting fresh pile • Over confidence / carelessness of both rigger as well as rig operator • Though the pin of D-shackle released from its position is happened repeatedly none has given solution to avoid its recurrence L&T-HSE

48. Remedy • Routine visual check-up should be made before starting each pile by job engineer • While checking welded joints of the casing pipe, the rig hammering should be paused • Worn threaded D-shackle shall be discarded by means of lifting tools n tackles check, colour code etc. • Frequent pep talk and toolbox meeting to be conducted L&T-HSE

49. L&T-HSE

50. Observation • Use of improper sling • Tag line / guiding ropes were not used for guiding the load from a safe distance, from crane • The plate was tied with a single sling. In order to compensate the sling length, plate width and ground clearance the boom of Hydra was lifted to almost full, leading to just a gap of approx. 1 foot between the rear end of plate and front wheel of Hydra • The victim was walking in front of crane holding the rear end in very close proximity to the wheel, at the left side of the road L&T-HSE