1. Materials Handling, Rigging, & Cranes
New England Roofing Industry Partnership
Materials Handling, Rigging, & Cranes
Trainer's Notes:
Duration: One and One-Half Hours
Training Aids:
1. Back Belt.
2. Box for lifting demonstration.
3. Various new and proper slings.
4. Various damaged rigging equipment.
5. Operator’s manuals for various mechanical equipment.
6. Crane or other equipment models.
7. Video options:
“Crane Safety for Site Supervisors” [Nat’l Audio Visual]

2. Training Objectives After completing this unit, you will:
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Training Objectives
After completing this unit, you will:
Know the basic OSHA requirements for the storage and disposal of materials.
Know hazards in both mechanical and manual material handling.
Understand hazards of rigging and crane operations and how to minimize them.
Be aware of proper lifting techniques.
Trainer's Notes:
This Training module is designed to help you recognize and control some of the more common hazards associated with materials handling when doing construction work.
If you spot problems on your site, or unsure of what to do, notify your supervisor. Awareness of basic aspects of material movement is critical, whether it’s equipment inspection or operation, rigging a load, or lifting something by hand.

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References
29 CFR ; Subpart H, Materials Handling, Storage, Use, and Disposal
29CFR , Subpart N – Cranes, Derricks, Hoists, Elevators, and Conveyors
29CFR , Subpart O – Motor Vehicles, Mechanized Equipment, and Marine Operations
ANSI and ASME Standards
Trainer's Notes:
The law requires your employer to be in compliance in addition to exercising due diligence and recognize good practice.
ANSI – American national Standards Institute
ASME – American Society of Mechanical Engineers

4. Materials Handling Dangers
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Materials Handling Dangers
Unsafe storage and materials movement
can lead to:
Back injuries (the number one cause of worker compensation claims).
Struck-by or crushed by falling loads due to rigging failures.
Electrocutions due to power line contact.
Injury from falling materials.
Injury from slipping, tripping and falling.
Trainer's Notes:
Review the dangers.
Emphasize the fact that materials handling occurs from the beginning of the job to the end and whether mechanical or manual, holds a potential for many injuries.

5. Moving Materials by Hand: Back Facts
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Moving Materials by Hand: Back Facts
8 out of 10 Americans will have a back injury during their life.
Approximately 1 out of 3 injuries at work are back injuries.
Personal pain and inconvenience can not be measured.
Back injuries cost employers an estimated 10 billion dollars each year!
Trainer's Notes:
Review the facts with the participants.
Ask for a show of hands concerning back problems.

6. Preventing Back Injuries
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Preventing Back Injuries
You can avoid back injuries by:
Using mechanical aids.
Using proper lifting techniques.
Keeping in lifting shape.
Working as a team when lifting.
Knowing the truth about back belts.
Trainer's Notes:
Review the components with the participants.

7. Proper Lifting Technique
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Proper Lifting Technique
Basic moves of a proper lift:
Plan your lift.
Use a wide-balanced stance.
Get close to the load and keep it close to your body.
Tighten your stomach muscles.
Keep your back straight and use your legs.
Turn with with your feet don’t twist your back.
Avoid lifting above shoulder height.
Trainer's Notes:
Review the components with the participants.

8. A Proper Lift Materials Handling, Rigging & Cranes H, N, O 7
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A Proper Lift
Trainer's Notes:
Review the steps a second time while you demonstrate with the box.
Stress the importance of using the leg muscles, keeping the back straight, and keeping the load close to the body.

9. Keeping in Lifting Shape
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Keeping in Lifting Shape
Keeping your stomach and back muscles strong can help prevent back injuries.
Even if you don’t work out in a gym, you can prevent back injuries.
Strength and flexibility exercises should be done at least every other day.
Trainer's Notes:
Review the components with the participants.
Stress how much of a difference strong stomach muscles can make when trying to prevent back injuries.

10. For Strength and Flexibility
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For Strength and Flexibility
Trainer's Notes:
Review the exercises with the participants.
1. Knee to Chest Raise: Hold ten seconds repeat ten times.
2.Wall Slide: Slide to a sitting position, hold for minutes.
3. Press-up: Hold for ten seconds, repeat ten times.
4. Round and Arch: round your back up and touch your chin to your knees.
5. Lower back Stretch: Hold for ten seconds.
6. Back Stretch: Press your lower back to the floor.

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Mechanical Aids
Use hand trucks, dollies, carts, wheel barrows, and wagons whenever possible.
Encourage management to include mechanical aids whenever possible.
Trainer's Notes:
Ask the participants to name some of the more common mechanical aids they see around the work site.

12. Mechanical Aids Slab carrying rig here has eliminated bending over and
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Mechanical Aids
Slab carrying rig
here has eliminated
bending over and
has provided secure
non-abrasive hand-
holds.
Trainer's Notes:
Ask the participants to name some of the more common mechanical aids they see around the work site.

13. Team Lifting Use team lifting for: Talk to your team-mate!
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Team Lifting
Use team lifting for:
Loads too heavy for one person.
Loads too bulky for one person.
Long loads such as pipes and rolls of material.
Talk to your team-mate!
Coordinate your lift!
Trainer's Notes:
Ask them for examples of the type of materials they might team lift.

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What About Back Belts?
The National Institute for Occupational Safety and Health (NIOSH) says:
Back belts may not reduce stress on the back.
May increase blood pressure and heart rate.
May make you think you can lift heavier loads with a belt on and you could get hurt trying to.
If you want to wear a belt; don’t wear it too tight and don’t lift more than you usually would.
Trainer's Notes:
Review the NIOSH findings concerning back belts.
Ask the participants if any of them have ever worn a back belt.

15. Material Storage Five basic rules for safe storage:
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Material Storage
Five basic rules for safe storage:
Keep total weight within the safe loading limits of the building’s floors.
Keep passageways clear.
Control materials so they do not slide, fall, or collapse.
Provide cribbing for heavy loads on unstable surfaces.
Store materials away from traffic.
Trainer's Notes:
Ask the participants which one of the five they think causes the most problems on their work site.

16. What Does OSHA Require? Basic requirements:
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What Does OSHA Require?
Basic requirements:
Don’t put materials within 10 feet of roof edge.
Don’t store materials on scaffolds or runways.
Keep materials at least 6 feet from floor openings and hoistways.
Keep aisles clear.
Keep work area free from tripping, fire, explosion, pest and vegetation hazards.
Trainer's Notes:
Ask the participants for stories concerning materials blowing or falling off of roof edges.

17. OSHA Also Requires Specific requirements:
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OSHA Also Requires
Specific requirements:
Stack bagged materials by stepping back the layers and cross-keying the bags at least every 10 bags high.
Stack bricks no higher than 7 feet.
Taper masonry blocks back one-half block per tier for stacks above 6 feet.
Stack lumber on sills and on level solid ground - never exceed 16 feet high and always remove nails!
Trainer's Notes:
Review the specific requirements.
Ask the participants if they can think of any others.

18. Setting Materials on the Deck
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Setting Materials on the Deck
Trainer’s Notes:
Use this or similar photographs to emphasize the importance of minimizing both fall hazards and falling material hazards in these situations.
Note also that the flat roof situation does not change the rule. Putting material outside the warning line may seem better as it is out of the way, it is not allowed and would be a citation.
What could happen to these stacked materials?

19. Disposal of Waste Material
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Disposal of Waste Material
OSHA requirements:
Scrap lumber, waste and trash must be regularly removed from the work area.
Burning must meet local regulations.
Materials dropped more than 20 feet require a chute.
Solvent waste, oily rags, and flammables must be kept in fire resistant containers until removed.
If the waste is considered hazardous, your employer will have to follow federal, state, and local regulations.
Trainer's Notes:
Getting rid of the trash is always a problem and “housekeeping” directly or indirectly is said to contribute to one-third of injuries.

20. Debris Chutes Objectives in using a chute: material control,
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Debris Chutes
Trainer’s Notes:
Objectives in using a chute: material control,
dust control and protection of workers and
bystanders – note the differences here….

21. Mechanical Materials Handling
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Mechanical Materials Handling
Depending on the job, you might use or work around:
Buggies
Roof Hoists
Conveyors
Skid-steers (“Bobcats”)
Rough Terrain Forklifts (“Lulls”)
Cranes
Trainer’s Notes:
Get a discussion going about all the different kinds of equipment that can get involved on a large roof job.

22. Buggies What are the safety concerns while moving
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Buggies
Trainer’s Notes:
What are the safety concerns while moving
materials with these?

23. Mechanical Equipment on Flat Roofs
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Mechanical Equipment on Flat Roofs
Will the deck support the weight of the equipment?
Has the equipment been inspected?
Are all equipment guards in place?
Is the operator trained?
See Subpart C - .20(b)(4)
Are all aware that the equipment is not to be operated outside warning lines due to the fall hazard?
See Subpart M - Fall Protection -.502
Closest approach is 6 feet parallel and 10 feet perpendicular to direction of travel.
Trainer’s Notes:
Discuss use and movement of equipment on roofs beginning with the assessment of load-bearing capacity. Include inspection/maintenance/operation in accordance with the manufacturer (IAW) AND COMMON SENSE.
Make sure all understand 6 ft/10 ft. rule about approach to the edge. Use OSHA interpretation for reference.

24. Roof Hoists What are the manufacturer’s instructions for set up & use?
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Roof Hoists
What are the
manufacturer’s
instructions for set up & use?
What does OSHA say?
Trainer’s Notes:
Use an actual manufacturer’s manual and go over set up procedure and safety precautions along with (again) COMMON SENSE…
It is important to mention the counter weights required on these hoists must be as proscribed by the manufacturer and NOT construction, roofing materials.

25. Roof Hoist Safety Concerns
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Roof Hoist Safety Concerns
.552(a)(1) Compliance with manufacturer’s specifications and limitations.
.552(a)(2) Load capacity, hazard warnings and instructions must be posted.
.552(a)(3)(i-iv) Wire rope replacement
criteria.
.552(a)(4) Hoist rope is to be installed in accordance with manufacturer’s instructions.
.501(b)(3) Fall Protection (Subpart M) in
hoist area.
Trainer’s Notes:

26. Is the Hoist Operator Protected?
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Is the Hoist Operator Protected?
Trainers Notes:
This should be obvious, but maybe it isn’t to the audience at hand. Discussion as necessary, especially if the reaction indicates that being tied off while operating the hoist is a “hassle” and/or “gets in the way”.

27. Using Conveyors to Move Materials
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Using Conveyors to Move Materials
Trainer’s Notes:

28. Safety Concerns In Conveyor Use
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Safety Concerns In Conveyor Use
Set up and used in accordance with the manufacturer’s instructions?
Guards in place on pinch points?
Power line clearances maintained?
Maintenance program in place?
Trainer’s Notes:

29. Safety Concerns In Conveyor Use
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Safety Concerns In Conveyor Use
No riders on conveyor!
.555(a) Means for stopping motor at
operator’s station and start up warning.
.555(a)(5) Protection for workers below against falling objects.
.555(a)(7) Lockout/Tagout for maintenance.
Trainer’s Notes:

30. Using Conveyors to Move Materials
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Using Conveyors to Move Materials
Power line clearance?
Back up alarm or
signal person?
Fall protection for roof workers?
Trainer’s Notes:

31. Using Skid Steers If on the roof – will it take the load?
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Using Skid Steers
If on the roof – will it take the load?
Is the operator qualified?
.20(b)(4) – Again! Training is available from some manufacturers.
Skid Steers are powerful, work in close quarters with people and are very quick, with large areas where the operator cannot see (the “no-zone”).
Is the work area adequately barricaded?
Trainer’s Notes:
Ask who has operated skid steers. Are they aware of the ‘no-zone’? Has anyone ever attempted to climb out of the machine with bucket raised?
Skid steers are (for now) exempt from back up alarm requirement unless original equipment as manufactured (OEM) or, if you install one, it must be working.
Local regulations may require license, eg. Massachusetts does require one.

32. Skid Steer Loader What do we need to know about this operator?
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Skid Steer Loader
What do we
need to know
about this
operator?
Trainer’s Notes:

33. The “NO-ZONE” Vehicle: S-44 Bobcat
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Operator sight distances
from eye level to ground
The “NO-ZONE”
11’ 7”
Eye level 5 ft - 5 in above ground level
11’ 5”
21’ 8”
4’ 10”
6’ 1”
3’ 1”
Trainer’s Notes:
Explain the “No-Zone Concept” as the area around machinery where the operator can’t see a pedestrian on the ground. Anyone in the shadowed area can’t be seen.
Vehicle:
S-44 Bobcat
6’ 3”

34. Using Forklifts to Move Materials
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Using Forklifts to Move Materials
What do we need to know?
Is the operator trained?
See .602(d)
Has the machine been inspected and properly maintained?
Is the backup alarm audible?
Are ground personnel protected?
Is the balanced load within capacity?
Are workers on roof protected from falls?
Trainer’s Notes:
Massachusetts requires a participants C Hydraulics License.
OSHA requires certification that the operator has been trained on the machine he is operating. This requirement is found in 29CFR (General Industry) and is referred to in 29CFR (d).

35. Getting Materials to the Roof
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Getting Materials to the Roof
Trainer’s Notes:
Stress that getting the material off the lift, regardless of what kind, can be a fall hazard situation.
How can we protect against falls in these
situations?

36. Using Forklifts What precautions need to be taken around
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Using Forklifts
Trainer’s Notes:
Emphasize the importance of protecting ground personnel, building occupants, and the visiting public while replacing a roof.
What precautions need to be taken around
the machine’s operating area?

37. Materials Handling, Rigging & Cranes
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Operator sight distances
from eye level to ground
Eye level 7 ft - 3 in above
ground level
85’ 0”
18’ 2”
10’ 9”
7’ 9”
3’ 0”
39’ 0”
Trainer’s Notes:
Same as for the Skid Steer slide – each machine is different, but the operator’s “blind spots” are significant.
The “NO-Zone”
21’ 2”
14’ 10”
Vehicle: R High Reach Fork Lift

38. Platforms on Forklifts
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Platforms on Forklifts
If you work off of some attachment it must:
(1) Be secured to forks (2) Have a guardrail.
(3) Have a Personal Fall Arrest System tie-off.
(4) Used only while the operator is in the seat.
Trainer’s Notes:
If the manufacturer says the machine is NOT to be used to lift personnel, then it is a violation to do so, regardless of the nature of the platform, and OSHA will cite.
Whatever platform is used , it must be approved by a qualified person for use on that machine.

39. Rigging and Crane Safety
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Rigging and Crane Safety
Rigging is the lines or cables used to lift and move materials by hoisting with a crane.
A rigger is a skilled mechanic who prepares heavy equipment or loads of material for movement.
Trainer's Notes:

40. Examples of Rigging Materials Handling, Rigging & Cranes H, N, O 39
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Examples of Rigging
Trainer's Notes:
Ask the participants what is the most common type of rigging equipment is used at their work site.
Ask them if they have ever seen home-made rigging.
Having actual used rigging here works better than pictures…

41. The Hazards of Rigging Possible contact with power lines.
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The Hazards of Rigging
Possible contact with power lines.
Rigging failures due to overloaded, improper, or defective rigging.
Out of control loads.
Being struck by the crane’s swing radius.
Trainer's Notes:
Review the slide with participants.
Ask them if they can think of any other hazards.

42. Can Anyone Rig or Lift Loads?
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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!
Trainer's Notes:
Ask them for the definition of a Competent Person.
Review the definition with the participants.
Ask them why rigging must be supervised by a competent person.

43. The Rigger’s Duties The rigger selects the rigging.
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The Rigger’s Duties
The rigger selects the rigging.
The rigger sets-up the rigging.
The rigger directs the lift.
Trainer's Notes:
Review the rigger’s duties with the participants.

44. OSHA Rigging Requirements
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OSHA Rigging Requirements
All slings and hardware must be manufactured to meet demanding specifications which include safety factors.
All web or alloy chain slings must be clearly stamped, marked, or labeled, for capacity.
OSHA prohibits job made: slings, hooks, links, and fasteners formed from bolts.
Before each use all components must be inspected by a Competent Person.
Trainer's Notes:
Ask them why OSHA will not allow job-made slings and other components.
Explain that the competent person must identify slings for a written inspection record and get rid of defective slings right away.

45. Safe Working Load (SWL)
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Safe Working Load (SWL)
The maximum load allowed on rigging is the Safe Working Load (SWL).
The sling may actually be able to hold 5 times the SWL.
A safety factor is the ratio of the ultimate strength to the SWL.
If a rigger exceeds the SWL, then they lose some of the safety factor.
Trainer's Notes:
Explain that the rigger can never exceed the SWL of a given sling.
Explain that safety factors are applied in any situation where you want a margin of safety.

46. Knowing Safe Working Loads
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Knowing Safe Working Loads
Trainer's Notes:
Explain that OSHA provides tables for riggers showing rated capacities for all rigging equipment. Have participants look up chart in standards. Explain that Mechanical Spliced (MS) slings have a higher rating than Hand Tucked Spliced (HT) slings.
On chart: HT = Hand- tucked Splice, MS = Mechanical Splice
The capacities shown must never be exceeded.
Most tables give the safety factor assigned to the specific type of sling.
Have the participants find these tables in the OSHA Standards.

47. Sling Angle The safest sling angles are greater
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Sling Angle
The safest sling angles are greater
than 450 from the horizontal.
Trainer's Notes:
Explain that sling angles are crucial in determining safe working loads.
Explain that they should rarely see sling angles less than 45 degrees.
Remind them that the steeper the angle, the less stress is placed on the rigging.

48. Rigging the Load Materials Handling, Rigging & Cranes
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Rigging the Load
Sling angles <450, load
unstable, worker not
protected.
Trainer’s Notes:
Present the question to your audience: What is wrong here?
Balanced load; sling angle >600

49. Working Safely Around Rigging
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Working Safely Around Rigging
General safety practices:
Keep at least ten feet away from power lines up to 50 kV.
Increase power line clearance distance by .4” per kV >50kV
Never hoist loads over workers.
Never stand too close or under a load.
Never ride a load.
Trainer's Notes:
Review the safety practices with the participants.
Ask the participants of they can think of any other basic safety guidelines.
Emphasize the importance of never working under a suspended load, not even for a few seconds!

50. Working Safely Around Rigging2
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Working Safely Around Rigging2
General safety practices:
Use tag lines to control loads while lifting.
Test lift the rigging.
Use proper equipment, make sure it is marked, not home-made, and in good shape.
Trainer's Notes:
Review the guidelines with the participants.
Ask the participants of they can think of any other basic safety guidelines.
Emphasize the importance of never working under a suspended load, not even for a few seconds!

51. Crane Hand Signals Only a qualified rigger will give hand signals.
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Crane Hand Signals
Trainer’s Notes:
The ANSI Hand Signal Chart should be posted near the crane lift area.
Only a qualified rigger will give hand signals.

52. Basic Crane Safety Do we have the right crane for the job?
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Basic Crane Safety
Do we have the right crane for the job?
Is the operator qualified on that crane?
Has the crane been inspected?
Is the crane set up on solid ground?
Full outriggers with cribbing?
Level, with tires off the ground?
Are power line clearances known?
Do we know the weight of the load?
Is everyone aware that a lift is being made?
Trainer’s Notes:
Even though most roofers would not be involved in crane setup or operation they still should be aware of the basic principles.
Note that power line contact continues to be the number one cause of crane-related fatalities.

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Basic Crane Safety2
Is the load properly rigged for a stable, vertical lift?
Is there a high wind condition?
Is the swing radius barricaded?
Can a tagline be properly used?
Can the crane make the lift and set the load without interference?
Trainer’s Notes:
Ask the participants – Where is the best place to stand during a crane lift?
Best answer: Stand behind the load, closer to the crane and to the side. That way, a swing or sudden load radius change would not result in swinging the load into the person or crush them between the load and the building, between the load and other material or between the load and the crane.

54. Truck-Mounted Cranes/Boom Trucks
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Truck-Mounted Cranes/Boom Trucks
Trainer’s Notes:

55. Case Study: What went wrong?
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Case Study: What went wrong?
Two employees were moving structural steel building beams to a storage area. After setting the fourth beam on the crib, the signal man signaled the crane operator to pull the sling from around a cribbed structural beam which was set on its flange side. The second employee then attempted to remove the shackle from the beam when the swaged fitting of the sling apparently caught and caused the steel beam to roll off the cribbing, crushing the second employee.
Trainer's Notes:
Read the following fire related case study to the participants.
Ask what kind of hazard caused the fatality.
Ask them to name things that should have been done to prevent the fatality.
Make a list of the identified precautions.

56. Materials Handling (1926.250 - 252)
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Materials Handling ( )
Common OSHA Citations:
.251(a)(1) Rigging equipment inspection
and removal from service.
.251(e)(8) Synthetic Web Slings – removal from service.
.252(a) Exterior drop chutes
.251(a)(4) Rigging capacity not marked – not proof- tested.
How can the hazards addressed by these Standards best be corrected, controlled, or eliminated?
Trainer's Notes:
Review the Top Four Serious Citations
Ask the participants how each of the four hazards could be abated.

57. Review Questions True or False?
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Review Questions
True or False?
Back injuries are the number one cause of worker compensation claims.
Using proper lifting techniques, staying in shape, using mechanical aids, and team lifting are the best ways to avoid back injuries.
Using a back belt almost always prevents a back injury.
Anyone can hook-up a sling and be a rigger.
Trainer’s Notes:
Answers:
1. TRUE
2. TRUE
3. FALSE – back belts may cause moe harm than good.
4.FALSE – rigging must be done under supervision of Competent person by a trained rigger.

58. Review Questions True or False?
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Review Questions
True or False?
Job-made slings, hooks, links, and fasteners formed from bolts are allowed if a Competent Person says so.
Proper knots are permitted in web-slings.
Slings should be inspected before each use and pulled from service if found defective.
The safest sling angles are less than 45 degrees from the horizontal.
Trainer’s Notes:
Answers:
5. FALSE – prohibited by OSHA.
6. FALSE
7. TRUE
8. FALSE – safest sling angles are greater than degrees from sling angle.

59. Review Questions True or False?
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Review Questions
True or False?
Cranes and rigging must stay at least 10 feet from power lines.
Materials can be stored within 10 feet of the roof’s edge.
Materials dropped more than 20 feet require a chute.
Materials must be kept at least 2 feet from floor openings and hoistways.
Trainer’s Notes:
Answers:
9. TRUE
10. FALSE
11. TRUE
12. FALSE – 6 feet