SAFE MATERIAL HANDLING

SAIKAT SENGUPTA
AHUJA TOWER PROJECT,
PRABHADEVI, MUMBAI
Contact No.: 9820396503
Mail ID: saikat1237@lntecc.com
1

MATERIAL HANDLING
Material Handling means moving things by

lifting, lowering,

pushing, pulling or

carrying.

MATERIAL HANDLING
Manual Material
Handling

Mechanical Material Handling.

Manual Material Handling Principles

1
4

Manual Material Handling Principles

3
5

Manual Material Handling Principles

6

5
6

Lifting heavy bags

Lift heavy and large sacks in two stages using an
intermediate platform.
Recommended procedure is..

Lowering heavy bags

Depends on size, weight, distance to be covered.
Recommended procedure is..

Handling Cylinders

Use Cylinder Trolleys to

shift Cylinders

Avoid twisting with load

Ensure that there is enough room to turn around to

prevent twisting

10

SAFE MANUAL LIFTING TIPS

SAFE MANUAL LIFTING TIPS

MECHANICAL
MATERIAL HANDLING

13

Hazards in Mechanical
Handling
General
Using mechanical equipment to move and store
materials increases the potential for employee injuries:
Workmen training on safe operating techniques.
All materials handling equipment has rated
capacities.
Employers to display Safe Working Load (SWL)
Employees not to overload the lifting equipment

14

Shackles

15

SHACKLES
Thumb Rule
Safe load in tons is the diameter of the
pin in inches, squared and divided by 3
Example
Shackle with 1 pin 4*4/3 = 5.33 ~ 5 Tons
Shackle with 1 1/4 inch pin 5*5/3 = 8.33
~ 8 Tons
16

Shackles usage

17

SHACKLES
INSPECTION OF D-SHACKLES
DEFECTS:
IDENTIFICATION MISSING
OR UNREADABLE
INCORRECT PIN
DAMAGED THREAD ON PIN OR IN
TAPPED EYE
DISTORTED BODY
WORN OUT BODY OR PIN
CORROSION
18

EYE BOLTS

19

Eye Bolts

Thumb rule for standard eye hook

Safe load in tons is the diameter of the
eye in inches squared
Example
2 dia eye 2*2 = 4 Tons
4 dia eye 4*4 = 16Tons

20

WIRE ROPE
21

WIRE ROPES
CONSTRUCTION OF WIRE ROPES

22

TYPES OF WIRE ROPE

The core forms the heart of the rope and
is the component around which the main
rope strands are laid.
1. FIBRE CORE
2. WIRE ROPE CORE (IWRC)

(IWRC : Independent Wire Rope Core)

23

WIRE ROPES
CONSTRUCTION OF WIRE ROPES

24

TYPES OF LAY

25

LAY OF WIRE ROPE

LAY: The term lay signifies the direction of
rotation is either to right (Clockwise) or left
(Anticlockwise).
REGULAR LAY: The wires in the stands are laid
in one direction while the strands in the rope
are laid in other direction.
LANG LAY: The wires in the strands and the
strands in the ropes are laid in the same
direction.
26

WIRE ROPES
MEASURING THE WIRE ROPE

INCORRECT

CORRECT
27

WIRE ROPES
INSPECTION OF WIRE ROPES
BROKEN WIRES
WORN OUT WIRES
REDUCTION IN ROPE DIA.
ROPE STRETCH
BIRD CAGE
KINKS
CORE PROTRUSION
28

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

29

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 22-32mm
2mm FOR ROPE DIA UPTO 32-38mm

150 mm PER 30m LENGTH OF SIX STRANDED ROPE

30

WIRE ROPES
WORN AND ABRADED WIRES

31

WIRE ROPES
BIRD CAGES

32

Kink

Kink

The defect Kink is caused by improper handling and uncoiling

of wire rope. The rope should be replaced if kink is found.
33

WIRE ROPES
CORE PROTRUSION

34

THUMB RULES FOR FINDING SWL

Wire Rope:
SWL = 8*D*D
D = dia. of the rope
eg: 1/2 rope dia = 8 *1/2 *1/2 = 2MTons.
Note: Dia is in inches & result in Tons.

35

STRENGTH OF WIRE ROPE

SWL OF
MECH.
WIRE ROPE SPLICED

100%

95%

HAND
SPLICED

80%

BULLDOG
GRIPS

80%

CHOKER
HITCH

80%

36

Thumb Rules For Fiber Ropes

Manila Rope
Safe Load in Pounds Change Rope Diameter Into Eights of
an Inch Square the Numerator and Multiply by 20*
Example
Inch Rope = 4/8; SWL = 4*4*20=320 Lbs
5/8 Inch Rope = 5/8 ; SWL = 5*5*20=500 Lbs
1 Inch Rope = 8/8 ; SWL = 8*8*20 = 1280 Lbs
( 01 lbs = 453.6 grams )
Nylon rope multiply by 60
Polypropylene multiply by 40
Polyester

multiply by 60

Polyethylene multiply by 35

37

SAFE WORKING LOAD

Safe Working Load (SWL) = Breaking
Strength / Factor Safety.
Factor of Safety : Factor of Safety of Rope
is defined as the ratio between Ultimate
Strength of the rope and safe working
load.
Min. acceptable factor of safety for rigging
ropes is 6 where for carrying personnel is
10.
38

WIRE ROPES
CORE PROTRUSION
Preferred
method since
rope opens up
over sheave
allowing oil to
penetrate

Temporary
Winding
Drum

Air Blast
Application

Drum

Brush
Application
Dip and Swab Application

39

SLINGS
40

CLAMPING OF WIRE ROPE

41

DISTANCE BETWEEN THE ROPE CLIPS

= 6 X Dia.

CLIPS AND SPACING FOR SAFE APPLICATION

Rope Diam.
In.

Minimum No. Clips

for Each Rope End

Spacing of Drop
Forged Clips
in.

1/2
5/8
3/4
7/8
1
1.1/8
1.1/4
1.1/2

3
3
4
4
5
6
6
7

3
3.3/4
4.1/2
5.1/4
6
6.3/4
7.1/2
9
42

WEDGE SOCKET

Wedge Sockets are among the simplest devices for anchoring a wire
rope for any purpose. They are intended for "on the job" attachment
and for quick rope replacement. The efficiency of a wedge socket is
70% of the strength of the rope. The dead or short end of the wire
rope should be looped back and secured to itself by a clip as shown
in the above sketch.
43

Swaged Socket
Wire rope end fittings with Swaged Socket provide an efficiency of
100%. These fittings are made by compressing a steel sleeve over the
rope with hydraulic press.
Careful inspection of the wires leading into these socketed terminals
is more important. On visual inspection, one broken wire is sufficient
to cause it to be condemned.
44

Mechanical Splice

Eye with mechanical splice has strength of 90% of the

breaking strength of the wire rope.

45

RIGGING
46

SLINGS - HITCHES

47

Do not permit bending near

any splice or attached fitting

48

Ensure that slings are protected at

all sharp corners on heavy items

For heavy
structural
members

Radius of
contact
should be
equal to 1
rope lay
49

RIGGING PRECAUTIONS
Sharp Bends , Pinching & crushing
avoid for slings provide packing

Never wrap a wire rope around a

hook.

50

Single vertical hitch

SWL of Single Vertical Hitch shown in the above sketch shall be

the same embossed on the sling itself. Otherwise, it can be derived
by dividing the Breaking Strength with the Factor of Safety, 6.
SWL

Breaking of the Sling / Factor of Safety

51

Two Leg Bridle Hitch

Safe Working Load (SWL) of Two Leg Bridle Hitch:

SWL

=
=

(SWL of single vertical Hitch) X (H/L) X (N)

(SWL of single vertical Hitch) X (H/L) X 2

Note: When Sling legs are of not equal length the smallest H/L ratio
should be taken for calculation.
52

Bridle Hitch

Safe Working Load (SWL) of Bridle Hitch:

SWL =
=

(SWL of single vertical Hitch) X (H/L) X (N)

(SWL of single vertical Hitch) X (H/L) X 2
53

Single Basket Hitch

SWL

=
=

(SWL of single vertical Hitch) X (H/L) X (N)

(SWL of single vertical Hitch) X (H/L) X (2)
54

Double Basket Hitch

SWL

=
=

(SWL of single vertical Hitch) X (H/L)

X (N)
(SWL of single vertical Hitch) X (H/L)
X (4)

55

Single Choker Hitch

SWL

=
(SWL of single vertical Hitch) X (A/B) X (N)
=
(SWL of single vertical Hitch) X (A/B) X (1)
Note: When Choker angle is greater than 450 A/B can be taken
as 3/4
56

Double Choker Hitch

SWL
X (N)

(SWL of single vertical Hitch) X (H/L) X (A/B)

(SWL of single vertical Hitch) X (H/L) X (A/B)

X (2)
Note: When Choker angle is greater than 450 A/B can be taken
as .

57

SLINGS
TENSION ON SLINGS

If L is greater than S
then sling angle is OK
58

SLINGS
TENSION ON SLINGS
S=WxL
HxN
S = TENSION
W = WEIGHT OF THE LOAD
L = LENGTH OF SLING
N = NO. OF SLING LEGS
H = VERTICAL HEIGHT
59

EFFECT OF INCLUDED ANGLE ON SLING TENSION

57
8

kg

60

70

g
7k

kg
0
0
10
kg
1
2
19
5747 kg

90

120
150
170

1000kg
60

EFFECT OF INCLUDED ANGLE ON SLING TENSION

5747 kg

150
120

70
7

kg

kg
8
57

192
1 kg
100
0k
g

170

90

60

1000 kg

61

Whenever 2 or more ropes

are to be placed over a hook use a Bowshackle

Use of tag lines to control swing of loads

62

RIGGING PROCEDURES
Planning

Skill gang - Leader

Rigging equipments
Inspection procedure
Once in a month color code

63

RIGGING PRECAUTIONS
Weight of ALL loads
Allowances for unknown factor
Capacity of equipment & marked
Lifting equipment & slings shall
not be overloaded
Erection shall be carried out
during daylight

64

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

65

Before being unhooked all loads

must be safely landed and
properly blocked

Stay away from slings when

they are being pulled out from
under loads

66

Rigging Safety Rules

Know the weight of the load

Know the center of gravity of the load
Make load attachment above center of gravity or stabilize
Select hitch that will hold and control load
Know rated capacities of slings and rigging hardware
Select sling best suited for load
Inspect all rigging gear prior to use
Protect sling from sharp surfaces
Protect load from rigging if necessary
Allow for increased tension caused by sling angles
Equalize loading on multiple leg sling
Allow for reduction when using choker hitches
Allow for sling angles when forcing choker
Attach tag lines prior to lift if required
67

Rigging Safety Rules

Keep personnel clear of lift area
Lift load few inches and check rigging
Know limitations of hoisting device
Start and stop slowly
Watch for obstruction and power lines
Use proper hand signals
Maintain load control
Do not forget the law of gravity

68

SHEAVES
69

SHEAVES
Matching of Ropes and
Sheaves
Properly
matched
rope and
sheave

Rope is
too large will pinch

Rope is
too small
- will
flatten

70

SHEAVES
Frictional Force

Plain Bore sheave =

10%

Bronze bushing

3%

Roller bearing

1.5%

Sheave dia shall be 10- 12 times the dia. of the

rope
71

WINCHES
FLEET ANGLE

FOR SMOOTH DRUM UP TO 1 1/20

FOR GROOVED DRUM UPTO 20

72

Material Handling By Equipments

73

Precautions while Using Tower Crane

1.

Ensure Ground leveling, rail alignment , Erection procedure/sequence.

2.

Inspection of all Mechanical components, wire ropes, mast guy ropes, drives
conditions,Safety Devices, ladders, Electrical Limit switches , Electrical panels
and cable conditions.

3.

Load testing by Third party and certification. (1.25 Times Load tested)

4.

Inspection of all lifting gears and its certification.

5.

Designated Operator and Signal Man for the Tower Crane Functions

6.

Correct slinging Method and trained Riggers to do Handle the load.

7.

Ensure proper access to the operator cabin.

8.

Ensure proper locking of the rails at both the ends.

9.

Never over load the Tower crane even for a short period.

10. Never by pass limit switches

74

Reduce Crane Rating - While

Un leveled Ground
Traveling on slope
Load away from the pulley
center line

75

Reduce Crane Rating Reason for side loading

Un level
Rapid swinging
Dragging the load
Wind velocity

76

Crane Safety Devices

Over Hoist Limit switch

Boom Limit Switch

Hook Latch

Angle Plate
Pointer

77

Tipping
Axis

STABILITY OF CRANE
A is a point in the Tipping of Crane
L1is Distance between Point A and
CG of Counter Weight
L2 is Distance between Point A and
CG of Crane Assembly
L3 is Distance between Point A and
CG of Load
W1 is weight of counter weight
W2 is weight of Crane Assembly
W3 is weight of Load

Moment about point A

L2
L1

To achieve the stability of Crane the

following equation should be satisfied

L3

78
W1 X L1 + W2 X L2 >= W3 X
L3

Unsafe Practices

Non-Use of Hook Latch

Remedial Measures

Use Hook latch to avoid

slings from getting removed
from hook
79

ABSENSE OF BOOM LIMIT SWITCH

No Boom Limit Switch

Boom Limit Switch

Over Hoist
Limit switch

Hook Latch

Angle Plate
Pointer

80

ABSENCE OF OVER HOIST LIMIT SWITCH

No Limit Switch

Limit Switch

81

Working principle of a Crane

W1 Weight of the
Load
W2
W1

W3

Tipping
Fulcrum

B
C

W2 Weight of the
Boom
W3 Weight of the
Crane

Over turning moment <

Crane resisting moment
about Tipping Fulcrum
about Tipping Fulcrum
W2 X B + W1 X L <
W3 X C
82

Conditions when a crane gets destabilised?

Unequal Tyre Pressure

Tandem Lifting

84

Crane boom collide with Power cable

Distance not maintained
Safe distance:
11kV & below =1.4 M
>11kV & <33kV=3.6M
>33kV & <132kV=4.7M
>132kV&<275kV=5.7M
>275kV&<400kV=6.5M

85

CRANE
SIGNALS

86

Alloy Steel Chains

Adapts to shape of the load
Can damage by sudden
shocks
Best choice for hoisting very
hot materials
Must have an affixed tag
stating size, grade, rated
capacity, and sling
manufacturer
87

Markings
Alloy Steel Chain

It must be marked with grade or manufacturer's mark

88

Alloy Steel Chain Attachments

Rated Capacity
Hooks, rings, oblong
links, or other
attachments, when used
with alloy steel chains,
must have a rated
capacity at least equal
to that of the chain

89

Unsuitable Alloy Steel Chain

Attachments

Right

Wrong

Job or shop hooks and links, or makeshift

fasteners, formed from bolts, rods, etc., or other
such attachments, cant be used
90

Chain Wear
When a chain shows
excessive wear, or is
cracked or pitted,
remove it from
service
Repair links can not
be used

91

92