1. INTRODUCTION TO MATERIAL HANDLING

3. Have you ever been hurt while lifting material?

4. Have you ever been involved in a crane or forklift accident, or rigging failure???

5. Do you know how to safely store and dispose of material?

6. Training Objectives After completing this course, 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.

7. STATISTICS
In 2002, accidents resulting from manual material handling resulted in more than $10 Billion in losses!!!!
In 2002, injuries associated with repetitive motion, and improper lifting technique cost $2.4 Billion!!!

8. WHAT IS MATERIAL HANDLING?
Material handling is the art and science of moving, storing, protecting and controlling material.
Includes both Mechanical and Manual methods

9. DANGERS OF MATERIAL HANDLING
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.

10. SAFETY SLOGAN
“Is better to lose one minute in life... than to lose life in a minute. “

11. Back Safety and Safe Lifting

12. Anatomy of the Back Why do injuries occur?
Knowing what causes back injuries can help you prevent them.

13. The Forces Involved
* The amount of force you place on your body during lifting may surprise you.
Think of your back as a lever
With the fulcrum
in the center, it only
takes ten pounds of
pressure to lift a ten
pound object.

14. The Forces Involved Lifting a ten pound object puts 100 pounds
If you shift the fulcrum to one side, it takes much more force
to lift the same object. Your waist acts like the fulcrum in a
lever system, on a 10:1 ratio.
Lifting a
ten pound
object puts
100 pounds
of pressure
on your
lower back.

15. The Forces Involved * When you add in the 105 pounds of the
average human upper
torso, you see that
lifting a ten pound
object actually puts
1,150 pounds of
pressure on the
lower back.

16. 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!

17. Common Causes of Back Injuries
Lifting too much weight. Especially
repetitively
Twisting at the waist while holding
a heavy load
Reaching and lifting overhead, or
away from the body
Lifting and carrying objects that have
awkward shapes
Working in awkward, uncomfortable positions
Sitting or standing too long in one position
Slip / Trip / Fall

18. Things you can do to help your back
You can minimize problems with your back by exercises that tone the muscles in your back, hips and thighs.
Before beginning any exercise program, you should check with your doctor and follow his/her advice concerning any exercise program. With his/her approval you should:
Exercise regularly, every other day.
Warm up slowly walking is a good way to warm up.
Inhale deeply before each repetition of an exercise and exhale when performing each repetition.

19. How to prevent back injuries 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!

20. PROPER LIFTING TECHNIQUES
Use proper lift procedures follow these steps when lifting . .
1. Know where you are going. Is the path clear?
2. Size up the load. (Is it too heavy? Do I need gloves?)
3. Take a balanced stance,
feet shoulder-width
apart.
4. Squat down to lift, get
as close as you can.

21. PROPER LIFTING TECHNIQUES
5. Get a secure grip,
hug the load.
6. Lift gradually using
your legs, keep load
close to you, keep back
and neck straight.

22. PROPER LIFTING TECHNIQUES
7. Once standing, change
directions by pointing
your feet and turn your
whole body. Avoid
twisting at your waist.
8. To put load down, use
these guidelines in
reverse.

23. Take care of your back… And it will take care of you Exercise daily
Avoid Heavy Lifting
Get Help with heavy or bulky objects
If you must bend over, do it properly
Avoid twisting at the waist when carrying objects
Always watch where you’re going

24. 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 class if any of them have ever worn a back belt.

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

26. Job Site Considerations
The person authorized and qualified to do rigging must always pay close attention to details. One careless moment or act can result in serious injury or death and tremendous property damage. Proper rigging is an art and should never be left to the inexperienced. If you don’t know how to do it properly, then don’t attempt it.

27. Objectives Be familiar with OSHA’s regulations regarding slings.
Understand safe sling use.
Be able to identify and describe conditions necessitating sling’s replacement.
Understand how load angle effects rigging capacity.

28. 29 CFR Slings
Sling: An assembly which connects the load to the material handling (lifting) equipment.

29. Three Types of Slings Chain Slings Wire Rope Slings
Synthetic Web Slings

30. Frequency of Sling Inspections
– Rigging equipment for material handling shall be inspected prior to use on each shift and as necessary during its use to ensure that it is safe. Defective rigging equipment shall be removed from service.

31. Chain Sling Inspection Items
Cracks, stretches, severe nicks, gouges, welding splattered or deformed master links, coupling links, chains or other components. 
One leg of a double or triple chain sling is longer than the others.  
Hooks have been opened more than 25% of the normal throat opening measured at the narrowest point or twisted more than 10 degrees from the plane of the unbent hook.   
Documented Inspections must be performed and maintained for each chain sling. Inspection data must be compared with previous inspections.

32. Chain Slings
Only chain slings purchased from the manufacturer are allowed No homemade
slings allowed!!

33. Wire Rope Sling Inspection Items
 Three randomly distributed broken wires in one strand, in one rope lay.
Wear or scraping of 1/3 the original diameter of outside individual wires.
Kinking, crushing or any damage resulting in distortion of the wire rope.
End attachments that are cracked, worn or deformed.
Corrosion of the rope or end attachments.

34. Synthetic Web Sling Inspection Items
Acid or caustic burns on the sling.
Melting or charring of any part of the sling’s surface.
Snags, punctures, tears, or cuts.
Stitching is broken or worn.
The sling is stretched. To assist operators in determining if a sling is stretched, manufacturers incorporate a colored wear cord inside of the sling. When this red wear cord can be readily seen upon inspecting the sling, the sling has been stretched and is to be removed. The web sling may need to be removed from service before the wear indicator is showing.

35. 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.

37. 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.

38. 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.

39. OSHA Rigging Requirements
All slings and hardware must be:
Manufactured to meet demanding specifications.
Clearly stamped, marked, or labeled.
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.

40. Knowing Safe Working Loads
Trainer's Notes:
Explain that OSHA provides tables for riggers showing rated capacities for all rigging equipment. Have students 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.

41. Definitions
Hitch “Basket” - loading with the sling passed under the load and both ends on the hook or a single master link.

42. Definitions
Hitch “Choker” – loading with the sling passed through one eye and suspended by the other.

43. Definitions
Hitch “Vertical” – loading with the the load suspended vertically on a single part or leg of the sling.

44. Sling Capacities
60 degrees
45 degrees
30 degrees
A sling capable of lifting 1000 lbs in a vertical basket hitch, can only lift 866 lbs at a 60 degree angle, and 707 lbs at a 45 degree angle, and 500 lbs at a 30 degree angle. 60 30

45. Wire Rope Sling Capacities

46. Working Safely Around Rigging
General safety guidelines:
Keep at least ten feet away from power lines.
Never hoist loads over workers.
Never stand too close or under a load.
Never ride a load.
Use sling angles greater than 45 degrees.
Attach 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 class.
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!

47. Rigging the Load Sling angles <450, load unstable, receiver not
protected.
Balanced load; sling angle >600

48. Safe Usage Practices Never shock load slings.
Keep loads balanced to prevent overloading slings.
Always lift loads straight up.
Never rest a load on a sling, or pinch a sling between the load and the floor.
Slings should be stored off of the floor and hung on racks whenever possible in a clean, dry environment.
Never drag slings across the floor. 
A sling should not be pulled from under a load when the load is resting on the sling.
Make sure the hook is always over the center of gravity of the load before lifting it.
Do not apply a load to a twisted, knotted or kinked chain.
Do not force or hammer hooks or chains into position.
Always hook with a “closed hook” arrangement (hooks facing out).

49. Safe Usage Practices (Cont.)
Hands and Fingers shall not be placed between the sling and the load while the sling is being tightened around the load.
Clean chains regularly as dirt and grit can cause excessive wear at the link bearing points.
Never shorten a sling with knots, bolts or other makeshift devices. Knots in slings reduce the capacity by as much as 50%!!
Protect the chain’s surface from contact with sharp corners, which can cause permanent damage through gouging or abnormal stress and wear.

50. Softeners, padding or use of blocking..
Rigging Protection From Cutting or Slipping
Softeners, padding or use of blocking..

51. In Conclusion Select the right sling for the job.
Only trained personnel can perform rigging operations
Inspect slings prior to use, removing from service any in question.
Remember the effect of sling angles on load capacities.
Properly store slings when finished to avoid damage.

53. MECHANICAL EQUIPMENT (MOVIE)

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

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

56. 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 IAW the manufacturer AND COMMON SENSE.
Make sure all understand 6 ft/10 ft. rule about approach to the edge. Use OSHA interpretation for reference.

57. 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 materials.

58. 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.

59. 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”.

60. Using Conveyors to Move Materials

61. 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?
No riders on conveyor!
.555(a) Means for stopping motor at
operator’s station + start up warning.
.555(a)(5) Protection for workers below.
.555(a)(7)Lockout/Tagout for maintenance.

62. Skid Steer Loader
What do we
need to know
about this
operator?

63. 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.
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 OEM or if you install one, it must be working.
Local regulations may require license, eg. Massachusetts does require one.

64. 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 Class C Hydraulics License.
OSHA requires certification that the operator has been trained.

66. MATERIAL STORAGE, AND DISPOSAL OF WASTE MATERIAL

67. Material Storage Five basic rules for safe storage:
SUBPARTS
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.

68. 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.

69. 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?

70. 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 class if they can think of any others.

71. Disposal of Waste Material
OSHA requirements:
Scrap lumber, waste and trash must be regularly removed from the work area.
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.

72. Debris Chutes Objectives in using a chute: material control,
dust control and protection of workers and
bystanders – note the differences here….
Material Chutes must be entirely enclosed, and
designed of such strength as to eliminate
failure.

73. THE END