STORAGE AND HANDLING OF MATERIALS-

INTRODUCTION:
Handling and storing materials involve diverse operations such as hoisting tons of steel with
a crane; driving a truck loaded with concrete blocks; carrying bags or materials manually;
and stacking palletized bricks or other materials such as drums, barrels, kegs, and lumber.
The efficient handling and storing of materials are vital to industry. In addition to raw
materials, these operations provide a continuous flow of parts and assemblies through the
workplace and ensure that materials are available when needed. Unfortunately, the
improper handling and storing of materials often result in costly injuries.
STORAGE OF MATERIALS-
Site storage involves the provision of adequate space, protection and control
for materials, components and equipment that are to be kept on a construction site during
the building process.

There are several factors to be considered when deciding on the amount and nature of
storage required.

 Physical properties: The size, shape, weight and mode of delivery.

 Organisation: The planning process to ensure unloading is available and storage space has
been allocated.
 Control: Processes for checking the quality and quantity of materials on delivery, and
monitoring stock holdings.
 Protection: The necessary protection for durable and non-
durable materials and components from damage.
 Security: Guarding against theft and vandalism.
 Costs: Costs associated with handling, transporting and stacking requirements, the
workforce required, heating and/or lighting that may be required, facilities to be provided
for subcontractors, and so on.

SITE ALLOCATION:

The location and size of space to be allocated should be planned carefully as part of an
overall site layout plan and each site will present its own problems. Failure to adequately plan
for storage space can result in congestion, or having more materials on site than
storage space allows for.

The most appropriate position on site in terms of handling, storage and convenience should
be determined. Unloading deliveries should take place in a clearly marked designated area,
away from other site operations, supervised by a competent person.

The distance between storage areas and the area materials are to be used should be reduced
as much as possible to keep the time and cost required to transport them
from place to place at a minimum. Alternatively, storage areas could be positioned within the
reach of a tower crane which can then be used to move materials as required.

THEFT:

Materials and equipment may need protection from theft and vandalism, particularly when
left out in the open where they have the potential to be removed late at night by
opportunistic thieves. Tradespeople often have heavy duty lockable compartments or vans
for storing tools, but where it is more practical to leave equipment and materials on
site, security may need to be provided. This can be in the form of a lockable fenced compound
on site, perhaps with CCTV, alarms and patrols.

Close boarded fences are often used which are similar to hoarding, or chain
link fencing with precast concrete posts, sometimes incorporating a 45° crank which faces
out.

HEALTH AND SAFETY:

There are certain health and safety issues to consider when storing items on site. Items which
are stacked must be stable to ensure they will not fall onto workers. Workers should not climb
or walk on top of materials which are stacked as they could shift and cause them to fall.

Stored items should not block or obstruct escape routes.

The type of material being stored also needs to be taken into account. If it is hazardous, it
may require specific precautions and control measures such as bunds for toxic substances or
it may need to be kept separate from other substances to prevent a reaction.

To reduce the risk of an accident, special containers are required to store hazardous
chemicals and dangerous goods. These types of containers may have special provisions for
things like natural ventilation, special compartments, electrical earthing, and warning signs.

MATERIALS STORAGE:

Different types of material will have different storage requirements, in particular depending on whether
they are durable or non-durable.

 BRICKS-

Bricks may be delivered to site loose or strapped in unit loads and stored on timber pallets to
be transported using a forklift. Bricks should be stacked on edge in rows to a maximum height
of 2.4 m. It is important that they are stored on level, well-drained ground and covered with
a polythene sheet to protect against efflorescence and other issues. When calculating
the area required for storage, allowance of around 5 m should be given for
the forklift approach.

 BLOCKS-

Blocks may be delivered to site loose or strapped in unit loads on timber pallets. They
should be stacked in columns, to a maximum height of 8 courses, and covered with a
protective sheet.

 ROOFING TILES-

Tiles may be delivered to site loose, in plastic-wrapped packs or in unit loads on timber pallets. They
should be stacked vertically in rows, to a maximum of 6 in height. The tiles at the end of the row
should be laid flat and staggered. Ridge tiles should be stored vertically on end.

 DRAINAGE PIPES-

These are usually supplied loose or strapped together on timber pallets. They should be stacked
horizontally with ends reversed in alternate rows. A driven-in timber stack or column of
loose bricks can be used to form end restraints.

Corrugated and similar sheet materials

These should be stored flat on a level surface and covered with a protective polythene sheet.

 TIMBER-

Timber and other joinery items should be stored horizontally and covered in a scaffold rack, although
provision should be made for free air flow, usually by the rack having open ends and sides, while
having a top that is covered. It is advisable for different timber sizes to be kept separate.

 CEMENT-

Since any contact with direct or airborne moisture can cause cement to set, it must be kept dry. In
terms of organisation, it is advisable for a rotational system to be used, whereby the first batch
of cement delivered is the first to be used.

Small quantities of bagged cement should be stacked to a height no more than 1 m, on a raised dry
platform such as a timber pallet. A polythene sheet should be used as cover, with care being made to
ensure that it is weighted down around the edges.

Medium quantities of bagged cement may need to be stored in a watertight and fireproof shed, with
galvanized steel sides and adjustable legs on bearing plates.
Large quantities of loose cement should be stored in a cement storage silo.

 AGGREGATES-

It is essential for different aggregate types and sizes to be kept separate. They should be stored on a
clean, hard, free-draining surface, surrounded by retaining and separating walls of bulk timbers.
Stored aggregates should be regularly monitored for moisture content.

PRECAUTIONS WORKERS MUST TAKE TO AVOID STORAGE HAZARDS-

Stored materials must not create a hazard for employees. Employers should make workers
aware of such factors as the materials’ height and weight, how accessible the stored materials
are to the user, and the condition of the containers where the materials are being stored
when stacking and piling materials.

To prevent creating hazards when storing materials, employers must do the following:

■ Keep storage areas free from accumulated materials that cause tripping, fires, or
explosions, or that may contribute to the harboring of rats and other pests.

■ Place stored materials inside buildings that are under construction and at least 6 feet from
hoist ways, or inside floor openings and at least 10 feet away from exterior walls.

■ Separate noncompatible material.

■ Equip employees who work on stored grain in silos, hoppers, or tanks, with lifelines and
safety belts. In addition, workers should consider placing bound material on racks, and secure
it by stacking, blocking, or interlocking to prevent it from sliding, falling, or collapsing.

SAFEGUARDS ONE MUST FOLLOW WHEN STACKING MATERIALS-

Stacking materials can be dangerous if workers do not follow safety guidelines. Falling materials and
collapsing loads can crush or pin workers, causing injuries or death. To help prevent injuries when
stacking materials, workers must do the following:

■ Stack lumber no more than 16 feet high if it is handled manually, and no more than 20 feet if using
a forklift.

■ Remove all nails from used lumber before stacking.

■ Stack and level lumber on solidly supported bracing.

■ Ensure that stacks are stable and self-supporting.

■ Do not store pipes and bars in racks that face main aisles to avoid creating a hazard to passersby
when removing supplies.

■ Stack bags and bundles in interlocking rows to keep them secure.

■ Stack bagged material by stepping back the layers and cross-keying the bags at least every ten layers
(to remove bags from the stack, start from the top row first). 6 During materials stacking activities,
workers must also do the following:

■ Store baled paper and rags inside a building no closer than 18 inches to the walls, partitions, or
sprinkler heads.

■ Band boxed materials or secure them with cross-ties or shrink plastic fiber.

■ Stack drums, barrels, and kegs symmetrically.

■ Block the bottom tiers of drums, barrels, and kegs to keep them from rolling if stored on their sides;
■ Place planks, sheets of plywood dunnage, or pallets between each tier of drums, barrels, and kegs
to make a firm, flat, stacking surface when stacking on end.

■ Chock the bottom tier of drums, barrels, and kegs on each side to prevent shifting in either direction
when stacking two or more tiers high.

■ Stack and block poles as well as structural steel, bar stock, and other cylindrical materials to prevent
spreading or tilting unless they are in racks.

In addition, workers should do the following:

■ Paint walls or posts with stripes to indicate maximum stacking heights for quick reference.

■ Observe height limitations when stacking materials.

■ Consider the need for availability of the material.

■ Stack loose bricks no more than 7 feet in height. (When these stacks reach a height of 4 feet, taper
them back 2 inches for every foot of height above the 4-foot level. When masonry blocks are stacked
higher than 6 feet, taper the stacks back one-half block for each tier above the 6-foot level).
HANDLING OF MATERIALS-

Handling and storing materials involves many different activities such as hoisting steel beams,
driving a truck loaded with raw material, manually carrying bags or material and stacking
supplies. Employees can be injured by improperly lifting materials (manually and by machine),
falling objects and improperly stacked supplies. It is critical that you make proper materials
storage and handling a priority.

As a process, material handling incorporates a wide range of manual, semi-automated

and automated equipment and systems that support logistics and make the supply chain
work. Their application helps with:

 Forecasting
 Resource allocation
 Production planning
 Flow and process management
 Inventory management and control
 Customer delivery
 After-sales support and service
A company’s material handling system and processes are put in place to improve customer
service, reduce inventory, shorten delivery time, and lower overall handling costs in
manufacturing, distribution and transportation.

GENERAL REQUIREMENTS FOR CONSTRUCTION MATERIALS HANDLING:

Proper materials handling practices help prevent injury and property damage. Segregating
noncompatible materials during storage goes a long way in preventing fires. For example,
keep all solvent waste, oily rags and flammable liquids in fire resistant covered containers
until removed from the worksite.

Also, all materials stored in tiers must be stacked, racked, blocked, interlocked or otherwise
secured. Structural steel, poles, pipe, bar stock and other cylindrical materials, unless
racked, must be stacked and blocked to prevent spreading or tilting. If this isn't done, the
materials may slide around and could injure employees.

When working in a building, make sure you know the maximum safe load limits of floors
used as storage areas within the buildings and structures. If the building is under
construction, maximum safe load limits (in pounds per square foot) should be posted for
floors used as storage areas. Never exceed maximum safe loads.
 Keep aisles and passageways clear and in good repair to provide for the free and safe
movement of material handling equipment and employees.

Build a ramp or provide a graded surface when work areas are not on the same level. This
will help prevent vehicle accidents and spillage of material.

SYSTEM FOR FAST PACE CONSTRUCTION-

Modern construction methods (MMC) are methods that are developed in construction
industry with proper planning and design so that each project reduces the construction time,
cost and maintain overall sustainability.

TYPES OF MODERN METHODS OF CONSTRUCTION-

1. Precast Flat Panel System

2. 3D Volumetric Modules

3. Flat Slab Construction

4. Precast Cladding Panels

5. Concrete Wall and Floors

6. Twin Wall Technology

7. Precast Concrete Foundation

8. Concrete Formwork Insulation

 PRECAST FLAT PANEL SYSTEM

This method of construction involves the procedure of making floor and wall units off site.
For this, separate factory outlets and facilities is required.

Once the panel units are made as per the design specification and requirements, they are
brought to the site and placed. This method is best suited for repetitive construction project
activities.
The panels manufactured has the services of windows, doors and the finishes. This method
also brings building envelope panels which are provided with insulation and decorative
cladding that is fitted by the factory which can also be used as load – bearing elements.

 3D VOLUMETRIC CONSTRUCTION-
As the name implies, the 3D volumetric construction involves the manufacture of 3D units in
the form of modules in off site. At the time of installation, they are brought to the site and
assembled module by module.

Each modular unit manufactured are 3D units, hence this construction is called as 3D
volumetric construction or modular construction.

The transportation of the modules can be carried out in various forms or methods. This can
involve the transportation of the basic structure or a completed unit with all the internal
and external finishes, services installed within it, that the only part remaining is the
assembly.

The factory construction brings different unit of same product maintaining their quality
throughout. Hence this method is best suited for repetitive projects so that rapid assembly
of the products is possible.
 FLAT SLAB CONSTRUCTION-
The flat slabs are structural elements that are highly versatile in nature. This is this
versatility that it is used widely in construction. The flat slab provides minimum depth and
faster construction. The system also provides column grids that are flexible.

Wherever it is necessary to seal the partitions to the slab soffit as a reason of acoustic and
fire concerns, the flat slabs are a desirable solution. When compared with other forms of
construction, the flat slabs are faster and more economic in nature.

The construction of flat slabs can be completed with good surface finish for the soffit, this
enables to utilize he exposed soffits.

The flat slab construction is also a means of increasing the energy efficiency as this allows
the exploitation of building thermal mass in the design of ventilation, heating and the
cooling requirements.

 PRECAST CONCRETE FOUNDATIONS-

For the rapid construction of foundation, the precast concrete system can be employed.
This method is more suited for a bespoke design.

Here, the elements required for the construction of foundation are constructed separately
in the factory (off site) and brought to the site and assembled. The manufactured product
must have the assured quality as specified by the designer.

The foundation assembled is mainly supported by concrete piles. During assembling, both
the systems are connected together. These foundation systems helps in increasing the
productivity, increase quality, decrease the soil excavation quantity.
 This is best suited for extreme and adverse weather conditions. When the construction is
dealt on a highly contaminated ground, this system of construction is a best choice.

 TWIN WALL TECHNOLOGY-

The twin wall technology is a hybrid solution of wall system that combines the qualities of
erection speed and precast concrete with the structural integrity of in-situ concrete. This
type of wall system guarantees structural integrity and waterproof reliability for the
structure.

The twin wall system has two walls slabs that are separated as shown in the figure-6. The
two slabs are separated by a cast in lattice girders. The procedure involves:

1. The wall units are placed in the site.

2. The twin units are propped temporarily.

3. The wall units are later joined by means of reinforcing.

4. The gap between the wall units are filled by means of concrete.
This system of construction is faster than normal construction methods and economical. The
twin wall system is mainly employed in association with the construction of precast floors.

 INSULATING CONCRETE FORMWORK-

The system of insulating concrete formwork (ICF) have twin walled panels that are either
polystyrene panels or blocks are employed. These are built quickly to create the formwork
as the wall of the buildings.
The formwork that is made is filled with concrete. This concrete is factory produced that
have quality assurance so that a ready – mixed concrete. Mostly the mix is ready mix
concrete.

Higher level of thermal insulation is provided by expanded polystyrene blocks. The concrete
core will provide good robustness and better sound insulation.

 PRECAST CLADDING PANELS-

The cladding system is the installation of a material over another that finally act as a skin or
a layer. This system of layer is not only intended for aesthetics, but it can help in controlling
the infiltration of the weather elements.

No kind of waterproof condition is provided by the cladding. Instead, the cladding is a

control measure against water penetration. This safely help in directing the water or the
wind so that there is control of the runoff. This helps to prevent the infiltration into the
building structure.

 CONCRETE WALLS AND FLOORS-

Concrete walls are mainly applied for seat walls, retaining wall, decorative exterior, and
interior finishes.

The concrete is also used a flooring material. As per the latest technology, the concrete
floors can be provided with good finish to provide smooth and attractive flooring.
When compared with any other material, the concrete floors provide a wide variety of
material for applications like acid-stained painted, radiant floors, overlays, and micro
toppings. The concrete flooring can also be called as cement flooring.

When compared with other flooring types, concrete flooring is affordable and maintenance
is easy. Proper sealing of concrete flooring can be cleaned by a dust mop.