103.

(II) MANUALHANDLING OF MATERIALS

A.MAHANTI

Hazards in manual handling. Avoidance of excessive muscular effort. Kinetic methods of correct lifting and handling of
materials. Maximum loads that may be carried. Lifting and carrying of object of different shapes, size and weight. Safe use
of accessories for manual handling. Storage of materials.

1.0 INTRODUCTION:
Kinetic handling, or manual handling, involves safely lifting and carrying heavy loads while using correct muscles and
movement. Many organizations use kinetic handling training to teach their employees how to safely lift loads. There are
many advantages to kinetic handling, and organisations can save themselves money if they provide the correct training to
their employees. Kinetic handling isn't just about using correct lifting and carrying techniques; it's also understanding
when a load is too heavy and when you may need a cart to transport something.
Injury Prevention
The biggest reason to use kinetic handling is to prevent injuries. Carrying heavy loads without the correct technique can
result in lower back pain, torn and pulled muscles and knee injuries. By being taught the correct way to lift, what muscles
to use and other preventive measures, many of these injuries will never occur.

Increased Production
Employees who do not have pain or injuries can get a lot more done in a day than ones who are suffering through severe
back pain or have bad knees. Increased production is another advantage employers will see with kinetic handling
techniques. By using kinetic handling, employees will be able to carry more and be more efficient in the work they are
conducting.

Reduced Worker's Compensation Claims

If having employees who are not injured and who are being more productive isn't reason enough to promote kinetic
handling, organizations can also save thousands of dollars each year on worker's compensation claims. With the
amount of worker's compensation claims being reduced each year, you will also save money on lower insurance costs
and deductibles.

Safety Compliance
By having your employees complete a kinetic handling training course, you can become compliant with all safety laws.
With a safety compliant certificate, you meet safety standards set by the state in which you live. This certification will save
you money by lowering insurance costs, reducing worker's compensation costs, and promoting goodwill to your
employees. The goodwill will ensure that you care about their safety and make them more likely to continue working for
you.

1.1 HAZARDS IN MANUAL HANDLING:

The operation of lifting, placing or carrying of material with muscle power by hands of person or by other hand tools is
termed as manual handling of material. The principal hazards are as under:

a) Struck against-rough or sharp object, running or bumping into

b) Struck by (Hit by moving object
c) Fall to lower level
d) Fall on same level (slip and fall)
d) Caught in (pinch and nip point)
e) Caught on (snagged or hung)
f) Caught between-crushed
g) Over stress
h) Over exertion
i) Over load
j) Physical strain
 2.0 AVOIDANCE OF EXCESSIVE MUSCULAR EFFORT:

Excessive muscular effort with improper ergonomical posture might lead to muscle contraction. Supply of blood along with oxygen
and sugar is reduced and fatigue sets in very soon. The physical efficiency of worker is on the decline after the age of 30. The
women are having weaker muscle than man and the max physical capacity of woman is 2/3 rd of a man of equal age.
In order to avoid excessive muscular effort the following points should be considered:
a) No person should lift or carry load beyond his capacity or max permissible as per rules-which is less
b) The lifted load should not be held for unnecessary longer duration.
c) The age, sex, constitution and training to be considered for selecting the load to be lifted manually.
d) Adopt kinetic method of manual handling when loads have to be transferred from one place to other which needs altering of
foot position.
e) Loads should not be lifted with bent back.
f) Body should not assume un balanced posture any time during manual handling.

3.0 KINECTIC METHOD OF MANUAL HANDLING/BASIC PRINCIPLES:

The following principles are essential to reduce the risk of injury from manual handling:

i) Correct position of feet: In the kinetic method, feet should be positioned with one placed in the proposed direction of
movement and the other in a position where it can give thrust to the body. The worker can decide whether he prefers the
forward foot to be his left or right.

ii) Straight back and bent knee: The back is often inclined particularly when weight is lifted from ground. But the
inclination should be from the hips so that the normal curvature is maintained. This normally curved spine is called straight
back.
With the straight back lifting, the spine is fairly rigid (non medically speaking) and pressure in the lumber inter vertebral disc is
evenly distributed. Rigid and straight spine coupled with bent knee position allows the centre line of gravity of the body to be
over the load and reduces strain. The position of the feet and the flexion of the knee are the key factors for maintaining a
straight back.

iii) Arms close to the body: When lifting and carrying weights, arms should be close to the body and remain straight
whenever possible. This is because flexing elbows and raising the shoulders imposes unnecessary strain on the muscles of
the upper arms and chest. If the arms are closer the centre of gravity of the body of the lifter will be nearer to the load.
Carrying involves a static posture of the arms and any assistance given by the body in supporting the load will lessen the
tension in the muscles. Carrying with arms straight enables the weight to rest against the thighs.

Iv) Correct hold: An insecure grip may be due to taking the load on the finger tips, thus creating undue pressure at the ends
of the digits and strain to certain muscles and tendons of the arms. Greasy substances often prevent a secure hold
whenever possible such surfaces should be wiped out. The use of suitable gloves should be used. A full palm grip will reduce
local muscle stress in the arms and decreases the possibility of weight slipping.

v) Chin in: Any faulty head position will lead to incorrect spinal position. If the chin is licked in the fore head moves forward
giving rounded shoulder. If the chin is drawn the head is extended upward and this adds to rigidity of spine which is desirable
for a lift. Besides, it is essential that the centre of gravity of the load and the lifter is as close as possible. This reduces strain
and likely hood of loss of balance during course of life.

vi) Use of body weigh: With the correct position of feet and the flexion and extension of knees and weight of the body can
be effectively utilized to push and pull objects and to initiate a forward movement such as placing on a shelf or walking.
When lifting an object from the ground the thrust from the back foot combined with the extension of knee-joints will move the
body forward and up ward and for a brief period it will be off balance. This is immediately countered by bringing the back leg
forward, as in walking. But by this time the lift is completed. The forward movement of the body results in a smooth transition
from lifting to carrying.

6 STEPS OF SAFE LIFTING:

i) Keep feet parted-one along side and other behind the object.
ii) Keep back straight, nearly vertical.
iii) Tuck your chick-in.
iv) Grip the object with the whole hand.
v) Tuck elbows and arms in.
vi) Keep body weight directly over feet
X
PROPER WAY OF LIFT: If lifting which is a part of every day jobs, is not done as per procedure may result in pulled muscles,
disc lesions or painful hernia

TEAM LIFTING AND CARRYING:

When two or more men must carry a single object, they should adjust the load so that it rides level and each
carries an equal part of the load. Test lift can be made before proceeding.
When two men carry long sections of pipe or lumber, they should carry them on the same shoulder and walk on
step. Shoulder pad will prevent cutting of the shoulder and helps to reduce fatigue.
When a gang of men carries a heavy object the supervisor should direct the work and special tools such as tongs
should be used.
It may however be noted that the total load that can be lifted is not the sum of each persons capacity.
Lifting capacity reduces markedly as the number of persons in the team increases. As per r.JP DASHIEL it
is called co ordination loss.

4.0 MAXIMUM LOAD PERMISSIBLE FOR LIFTING/CARRYING:

( Ref- Rule-57 of WB Factories Rules,1958 framed under Section 34 of Factories Act,1948)

SL NO Category of lifter Max load in KG

1 Adult male 55
2 Adult female 30
3 Adolescent male 30
4 Adolescent female 20
5 Male Child 16
6 Female Child 14
It may be noted hat the Occupational Safety and Health Administration does not have a set requirement limiting the
amount of weight a person can be required to lift in the performance of his job. They do have guidelines specifying the
general duty guidelines of jobs and do expect employers to set safe lifting limits for employees. OSHA suggests that
employers follow the lifting guidelines of the National Institute for Occupational Safety and Health.
Recommended Weight Limit
NIOSH has come up with a formula to calculate the recommended weight limit.
RWL=LC x HM x VM x DM x AM x FM X CM , where,
LC is the load constant or the fixed weight to be lifted.
HM is the horizontal multiplier or the distance the weight will be moved from left to right.
VM is the vertical multiplier or the height the weight will be lifted.
DM is the distance multiplier and is taken from a table provided by NIOSH.
AM is asymmetric multiplier and is based on how close the load is to the center of the body. It is also taken from a table
supplied by NIOSH.
FM is the frequency multiplier and based on the number of times the lift is performed per minute and the length of time the
lift takes and is also taken from a NIOSH table.
CM is the coupling multiplier and is based on the type of grip the person doing the lifting can get on the package and is
taken from a NIOSH table.
(NIOSH-National Institute of Occupational Safety and Health,USA)
Analyzing the Task
NIOSH provides worksheets allowing managers to input the measurements necessary to calculate the recommended
weight limit for a task. The same worksheets include calculations for the lifting index. This is the actual weight of the
object divided by the recommended weight limit. Similar worksheets can be completed for the entire task the worker is
asked to perform or the individual lifting components of the task. If the lift index exceeds 1.0, meaning the actual weight
lifted exceeds the recommended weight limit, changes to the task may be necessary.
Meeting Guidelines
Because the formula for the calculation of the recommended weight limit includes the distance the weight is moved as
well as how the load is carried, changes in these areas can bring a task within the guidelines while still moving the same
weight. Managers should also follow all OSHA record-keeping requirements concerning lifting tasks and back-related
injuries.
5.0 LIFTING AND CARRYING OF MATERIALS OF DIFFERENT SHAPE &SIZE

i) Boxes and cartoon- Grasp them at opposite top and bottom corners. Draw a corner between legs
ii) Barrels and drums- Two men stand on the opposite side-grasp both chimes near high point up and pressing
down the drum.
iii) Handling on incline-Use of rope and tackle to control motion. Pass a rope around a drum one end of the
rope fastened to the platform at higher workers keep a firm grip on the free end; then gradually lower or
raise the drum.
iv) Sheet metal- Handle with leather /gloves with metal insets.
v) Sheet glass- handle with gloves, cover wrist and fore arm with long leather sleeves or canvas apron and
guard for the feet and ankle. Carry the glass sheet with the bottom edge resting on palm, with other hand
holding the top edge.
vi) Long object- Carried over shoulders, held as high as possible.
vii) Metal scrap: Wear goggles, gloves, shoes- mechanical handling is preferred.

6.0 SAFE USE OF ACCESSORIES:

All the tools and accessories should be kept in good repair and used for the jobs for which they are designed.

i) Hooks: Sharp point of hooks necessary for handling of logs, crates, boxes etc.

Hazards: Glancing of hard objects

Remedies: Sharp points to be carried in belts, workers are to be trained to use hand or packing
hooks so that they will not glance off hard objects, handles are to be made from hard wood and in good
condition.
ii) Crow bar: Hazard: Main hazard is slipping, fall of person

Remedies:
Point/edge should have god bite,
Proper position of hand and body to minimize chance of hand pinching,
Never work astride a crow bar,
When not in use keep crow bar in rack,
Ordinary crow bar should not be used to move cars on steel rails,
Use non slippery bar, when two bars are required to be used two bars are to be used.
iii) Rollers: Heavy and bulky objects are often moved on rollers
Hazards:
Finger/toes getting pinched or crushed between the roller and floor or roller
and object when direction of roller is changed.
Remedies:
Sledge or bar is to be used to move a roller.
Never use hand to move rollers
Rollers should extend beyond the load to be moved
Rollers should be sufficiently strong to carry the load.

iv) Hand Trucks and Wheel Barrows: Two wheelers and Four wheelers-

Hazards:
 - Jamming of hands against door-frames or other obstructions
- Injuries on toes from wheels
-Injuries on foot while loading the truck.
- Over turning of trucks due to improper loading
Remedies:
-Knuckle guards are to be provided to prevent jamming
-Wheels should be under truck, otherwise wheel guards have to be provided
-Brakes are to be provided to avoid holding the truck with foot
-Daily inspection of trucks has to be ensured
-The trucks are to be properly maintained
-Specific materials are to be handled only
-Loader should keep their feet clear of wheels
-Load should be so placed that it will not shift
-On two wheelers the centre of gravity of load should be well forward
-Four wheelers should be pushed not pulled and should be evenly loaded to prevent tipping
-Avoid collision especially at blind corners
-Do not park trucks in aisles so as to obstruct traffic or causing stumbling hazards
-Four wheeler trucks should be so loaded that the drivers view is not obstructed
-Truck content should be so arranged that they will not fall or be damaged in case the truck is bumped

v) Car buoy truck:

Carbuoy truck or carbuoy trolley is two wheeled, long handled truck/trolley that transports carbuoys containing acids, oils
and other liquid chemicals. The handles are long enough to keep the man handling them away from splashes, in case the
carbuoys are dropped or broken. The truck has a bed curved to fit the carbuoy and a hook to catch the chime.
Hazards:
- Jamming of hands against door-frames or other obstructions
- Injuries on toes from wheels

-Injuries on foot while loading the truck.

- Over turning of trucks due to improper loading
Remedies:
-Knuckle guards are to be provided to prevent jamming
-Wheels should be under truck, otherwise wheel guards have to be provided
-Brakes are to be provided to avoid holding the truck with foot
-Daily inspection of trucks has to be ensured
-The trucks are to be properly maintained
-Specific materials are to be handled only
-Loader should keep their feet clear of wheels
-Load should be so placed that it will not shift
-On two wheelers the centre of gravity of load should be well forward
-Four wheelers should be pushed not pulled and should be evenly loaded to prevent tipping
-Avoid collision especially at blind corners
-Do not park trucks in aisles so as to obstruct traffic or causing stumbling hazards
-Four wheeler trucks should be so loaded that the drivers view is not obstructed
-Truck content should be so arranged that they will not fall or be damaged in case the truck is bumped
vi) Jacks: Heavy loads are lifted and supported to a small height by jacks

Hazard:
- Slip of load / failure are to over load
- Capacity plates to be checked for capacity plates
- Capacity to be determined first if not marked and then painted
- Heavy jacks may be moved on a slowly
- During manual moving of jacks, handles should be provided
- Lubrication of jack has to be done properly
- Broken teeth or holding fixtures should be checked prior to use
- Jacks should not be dropped upon floor
 - Jacks should be placed on level surface
- Hard load blocking has to be used if jack is place on earth
- To prevent load from slipping no meatal to metal contact is allosd
- A hard wood shin longer and wider then the jack head should be placed between jack head and contact
surface of the load
- When jack is released worker should keep all parts of the body clear of the movement.
- PPEs like safety shoes, helmet and in step guard protection are required
- Oil that has collected on the box of the equipment of machine to jacked should be removed prior to job
start
- When jack develops any defect it should be removed from service, repaired, got tested under load before
being returned to service.
Safe procedure for handling acid carbuoys

Acid carbuoys are portable containers having rectangular or cylindrical shape. The capacity is around 20 litres. They have
a handle and a threaded cap on the top. They are made of acid resistant and not easily breakable material

Safe procedure:

-They should be suitably marked for the kind of acid stored

-They should be handled carefully and stored in a room having impervious walls and floors and walls for safe disposal of
spillage.
-Acid carbuoys should not be stored along with in compatible chemicals e.g. nitrites, glycerine, copper, brass, gasoline
etc.
-They are to be transported on car buoy trucks/trolley.
-Vacuum pump/siphoning are to be used to empty
-Acid should be poured in to acid car buoys through siphoning/funnelling.
-While handling empty acid carbuoys, they should be washed thoroughly, made harmless by neutralising and stoppers
replaced before piling.
-Protect carbuoys from damage by mechanical parts
-Eye fountain and wash showers are to be provided near store room.
-Suitable PPEs e.g rubber/PVC hand gloves, apron suit and face shield, gum boot etc should be used.

7.0 STORAGE AND HANDLING OF SPECIFIC MATERIALS

i) Bagged materials:
-Cross ties with mouths in side
-When pile is 5 ft high step back by one row for each additional three feet
-Do not remove a bag from a lower row, first
-Automatic sprinklers should provided in ware house
-Aisles should be more than 3 feet wider than the widest vehicle

ii) Pipes and bar stock:

-Strength of the floor is to be considered.
-Pipes are to be stacked in layers with strips of wood/iron.
-Bar stocks are to be in racks inclining towards the back.

-Before stacking, at least four stopper bars should be fixed at two sides of the place of stacking in such a way that two
stoppers must be at each side at a suitable distance.
-For pipes or bar lengths of 10 to 12, the distance should be 2 to 2.5from the ends of the pipes or bars.
-Fixing of stoppers should be strong enough to hold the load.
-stacking height should not be more than the height of the stopper bar.
-Pipes should not be kept in triangular form, keeping directly over the lines of two adjacent pipes of lower layer, making
rectangular shape.
-Stacking in triangular shape has a chance of rolling of pipes.

iii) Barrels and Kegs:

 -Pyramid shape is safer
-Bottom row should be blocked.
-If piled on ends, planks should be laid between rows.
- Piles of barrels should be symmetrical and stable.

iv) Liquid Chemicals:

-Portable containers of liquid chemicals e.g. drums, barrels and car buoys etc should be stored and carefully handled.
-Store room should have impervious walls, floors and provision of safe disposal of spillage. -For transporting of carbuoys, use
carbuoy trolley.
-Use of vacuum pump or siphoning is to be made to empty carbuoy.
-Empty carbuoys should be washed thoroughly and stoppers replaced before piling.

v) GAS CYLINDERS:

-Gas cylinders may be rolled on bottom edge but never dragged.

-Cylinders should be carried in cradles.
-Do not allow the cylinders to strike each other violently.
-While returning empty cylinders or when they are not in use close the valve and replace the valve protection cap.
-Always consider cylinders full and handle them with care.
-Do not store gas cylinders in the sun or excessive hot environment.
-Follow the provisions of the Gas CylindersRules, 1981 and adhere to IS-5903.
- Pre entry checks: Nozzle guards, test rings, pressure relief devices, valve caps are in position and appropriate colour of
cylinders are adhered to.
- Leakage from valve is to be checked with soap solution.
- Cylinders are to be transported in specially built trolley/carrier with adequate provision of fall protection and
anchorage/bracing of the cylinders being transported.
- Segregated areas should be used for transporting/carrying different type of cylinder contents.
- Separate trolleys are to be used for carrying cylinders containing different gases.
- Cylinders are to be unloaded through incline plane and by tying with rope.
- Cylinders should not be dropped or bumped against hard surface or object.
- Hydras, cranes and two wheelers should not be used for carrying cylinders.
- Cylinders are to be stored in cool well ventilated shed
- Separate sheds are to be used for full and empty cylinders
- Cylinders are to be considered full unless other wise marked
- Store register is maintained regarding their inventory and other related documents
- Cylinder valves are checked by soap solution or other effective method before they are issued for use at site. Document
there of is maintained.
- Leaky cylinders are to be kept in the open area and immediately sent to the vendor
- Cautionary boards and safe handling procedures for gas cylinders are to be displayed at storage area.
- Electrical fittings at shed should be of approved type and quality
- Empty cylinders are to be sent to the licensed vendors for refilling at the earliest.
- Record of receipt, dispatch and issue of gas cylinders is to be maintained and discrepancy in any fittings is noted in the
register
- Mobiles should not be used near the area where gas cylinders are used or stored.

vi) HANDLING OF DANGEROUS SUBSTANCES/CHEMICALS:

-Dangerous substances/chemicals should be handled and stored under the supervision of a competent person who is familiar
with the risks and precautions to be taken.
-In case of doubt as to the nature of risk and precautions to be, the necessary instruction should be obtained from the
competent person.
-When dangerous chemicals are to be stored and handled, the workers should be given adequate information concerning their
nature and special precautions to be taken in handling them.
-Special precautions e.g. provision for sling, nets boxes to prevent damage to the container.
-If containers are damaged or broken to a dangerous extent, work should be stopped and danger is to be eliminated.
-When highly flammable material is being handled, fire protection arrangement should be kept at site.
-When required non sparking tools should be provided and used in explosive atmosphere.
-When corrosive substances are handled or stored special precautions are to be taken to prevent damage to the container and to
render any spillage harmless.
-Workers handling harmful substances should thoroughly wash their hands and face with soap and water before taking any food
or drink. They must proper PPEs.
-Explosives should be stored in magazine of approved fire proof and bullet proof design, located at a safe distance from rail road
and other building.
-Highly toxic substances e.g. cyanide and soluble oxalates should be stored in containers of distinctive shape, if they are handled
manually.

vii) SAFETY PRECAUTIONS FOR HANDLING AND STORING EXPLOSIVES:

- Explosives should be stored in magazine of approved fire proof and bullet proof design,

-Magazines should be located at a safe distance from rail road and other building.
-The Explosive Act and Rules are to be obeyed.
- NFPA standard 495 gives detailed specification for handling and storage of explosives.
- To be consulted and adhered to.
- Explosives are to be kept under lock and key and records are to be maintained of all explosives issued.
- No matches, flammable materials, metal or metal tools should be brought into a magazine containing explosives.
- Floors must be kept clean and free from loose explosives.
- Floors which are usually of wood should be blind nailed.
- No nail or bolt head should be exposed.
- Magazines should be clean, dry and well ventilated.
- Ventilation openings of magazines should not exceed 110 square inches in area and should be screened to prevent sparks
and rodents.
- Only portable light of approved quality are to be allowed in side magazine.
- Fire/sparks are not permitted near magazine.
- Surrounding ground should be kept clear of bush, leaves, grass, debris etc.
- Explosives should not be exposed to direct rays of sun.
- Storage should be arranged so that oldest explosives are used first.
- Ammonium nitrite explosive requires special precautions including stacking limitation, air space and ventilation.
- No oil or hydrocarbons are permitted near ammonium nitrate.
- Packages of explosives should not be opened within at least within 50 ft. from the magazine.
- Only wood wedges, wood, fibre, raw hide, zinc or rubber-mallets should be used to open cases of explosives.
- Explosives and blasting supplies should always be kept in magazines.
- Explosives should never be in any place where animals, unauthorized persons or children can get at them. Many children
have been killed or crippled because they obtained detonators from unwatched or unguarded sources.
- Blasting caps or detonators of any kind should never be kept in the same magazine with other explosives.