DEFINITION

“Material Handling embraces all of the basic

operations involve in movement of bulk,
packaged and individual products in
semisolid or solid state by means of
machinery and within the limits of place of
business”
(Material Handling Institute)
 OBJECTIVES
1. To increase efficiency of material flow by
ensuring availability of materials when and
where they needed.
2. To reduce MH cost.
3. To improve facilities utilization.
4. To improve safety & working conditions.
5. To facilitate manufacturing processes.
6. To increase productivity.
MH Equipment and Types
All Equipments in MH are classified in three main
types,
Conveyors
Crane &Hoist
Trucks
 1. Conveyors
 Conveyors are used for moving materials
continuously over a fixed path.
 Eg. roller, belt and chute conveyors.
TYPES
Belt Conveyor

Conveyor Machines

Roller Conveyor
Chute Conveyor
Advantages
1. Permits high capacity for moving large number of items.
2. Their speed is adjustable.
3. Handling combined with other activities such as
processing & inspection is possible.
4. They are versatile & can be on floor or overhead.
5. Temporary storage of loads b/w work station is possible
(particularly overhead conveyors).
6. Load transfer is automatic & does not require the
assistance of many operators.
7. Straight line paths or aisles are not required.
8. Utilization of the cube is feasible through the use of
overhead conveyors.
Disadvantages
1. They allow a fixed path, serving only limited
areas.
2. Bottlenecks can develop in the system.
3. A breakdown in any part of the conveyor stops
the entire line.
4. Since conveyors are fixed in position, they
hinder the movement of mobile equipment on
the floor.
 2. Cranes & Hoists
 Cranes & Hoists are items of overhead
equipment for moving loads intermittently
within a limited area.
 Bridge cranes, monorail cranes, & hoists are
examples of this basic equipment type.
Bridge Crane
Jib Cranes
Monorail Cranes & Hoists
Advantages
1. Lifting as well as transferring of material is
possible.
2. Interference with the work on the floor is
minimized.
3. Valuable floor space is saved for truck rather than
being utilized for installation of handling equipment.
4. Such equipment is capable of handling heavy
loads. Eg. Shipyards & heavy equipment production
facilities.
5. Such equipment can be used for loading &
unloading of materials.
Disadvantages
1. They require heavy investment (especially bridge
cranes).
2. They serve a limited area.
3. Some cranes move only in straight line & thus can not
make turns.
4. Utilization may not be as high as desirable since
cranes are used only for a short time during daily work.
5. An operator has to be available for operating some
types, such as bridge cranes.
 3. Trucks
 Hand or Powered Trucks move loads over varying
paths.
 Examples of such Trucks include Lift Trucks, Fork
Trucks, Trailer Trains and Automated Guided
Vehicles.
Lift Trucks
Hand Trucks
Fork Trucks
Trailer
Automated Guided Vehicles
(AGVs)
Advantages
 They are not require to follow a fixed path of
movement and therefore can be used any where on
the floor where space permits.
 They are capable of loading, unloading, &
lifting, in addition to transferring material.
 Because of their unrestricted mobility, which
allows them to serve different areas, trucks can
achieve high utilization.
Disadvantages
 They cannot handle heavy loads.
 They limited capacity per trip.
 Aisles are required; other wise the trucks will
interfere with the work on the floor.
 Most trucks have to be driven by an operator.
 Trucks do not allow handling to be combined
with processing and inspection, as other type of
equipment do.
Degree of Mechanization of MH
 A MH System can be completely manual or fully
automated.
 Different degrees of mechanization also exist
between these two extremes.
 Level of Mechanization in MH System is classified
with respect of Source of power for handling,
degree of human involvement & computers in
operating the equipment.
CLASSIFICATION
1. Manual & Dependent on Physical Effort
This level also includes manually driven
equipment such as hand truck
2. Mechanized
 Power instead of physical effort is used for
driving the equipment.
 Some trucks, conveyors, & cranes fall into this
level.
 Here operators are needed for operating the
equipment as opposed providing the power.
3. Mechanized with Computers
It is an extension mechanized systems. The function of
the computers is to generate documents specifying
the transportation.
4. Automated:
 Minimum human intervention is used for driving and
operating the equipment, and most of these functions
are performed by computers. The equipment usually
receives instructions form key boards 0r pushbuttons.
Eg. Conveyors, AGVs.
5. Fully Automated:
This level is similar to the 4th level, but computers
perform the additional task of on-line control, thus
eliminating the need for human intervention.
Principles of Material Handling
 There are no definite rules that can be followed
for achieving a successful material handling
system.
 There are, however, several guidelines that can
result in reducing the system cost and in
enhancing efficiency.
 These guidelines are known as Principles of
Material Handling.
 There are 20 Principle of Material Handling.
1. Planning: Plan all MH and Storage
activities to obtain maximum overall
operating efficiency.
2. System Flow: Integrate as many
handling activities as is practical into
a coordinated system of operations.
 These operations covering vendor,
receiving, storage, production,
inspection, packaging, warehousing,
shipping, transportation and delivery to
customer.
3. Material Flow: Provide an operation sequence
and equipment layout optimizing material flow.
4. Simplification: Simplify handling by reducing,
eliminating or combining unnecessary
movements /equipment.
5. Gravity: Use gravity to material handling
whenever practical.
6. Space Utilization: Make optimum utilization of
the building cube.
7. Unit Size: Increase the quantity, size or weight of
unit loads or flow rate.
8. Mechanization: Mechanize handling operations.
9. Automation: Provide automation to include
production, handling and storage functions.
10. Equipment Selection: In selecting handling
equipment, consider all aspects of the material
handled, the movement and the method to be
used.
11. Standardization: Standardize handling
methods as well as type and sizes of handling
equipment.
12. Adaptability: Use methods and equipment that
can best perform a variety of tasks and
applications when special-purpose equipment is
not justified
13. Dead Weight: Reduce the ratio of dead
weight of mobile handling equipment to load
carried.
14. Utilization: Plan for optimum utilization of
handling equipment and manpower.
15. Maintenance: Plan for preventive
maintenance and schedule repairs of all
handling equipment.
16. Obsolescence: Replace obsolete handling
methods and equipment when more efficient
methods of equipment will improve operations.
17. Control: Use material Handling activities to
improve control of production, inventory and
order handling.
18. Capacity: Use handling equipment to help
achieve the desired production capacity.
19. Performance: Determine the effectiveness of
handling performance in terms of expense per unit
handled.
20. Safety: Provide suitable methods and equipment
for safe handling.
Unit Load Concept in MH
“It is defined as number of items arranged
such that they can be handled as a single
object”
1. Palletization: It is assembling and
Securing of individual items on a Pallet
platform that can be moved by a truck
or a crane.
2. Unitization: It is also the assembling of
goods, but as one compact load. Unlike
Palletization additional materials are
used for packaging and wrapping the Cargo unit
items as a complete unit.
3. Containerization: It is assembling of
items in a box or a bin. It is most suitable
for use with conveyors, especially for
small items.
In general, the factors that influence the
solution of the unit load type are
 The weight, size and shape of the material. Containers
 Compatibility with the material handling
equipment.
 Cost of the unit load.
 The additional functions provided by the
unit load stacking and protection of
material.
THANKS
Transporting Devices in Materials Handling
 ROPES
 Fibre Ropes
 Wire Ropes
 SLINGS
 Wire Rope Slings
 Metal Mesh Slings
 Chain Slings
 Fibre Slings
 HOOKS

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 FIBRE ROPE
 Fibre rope is a commonly used tool which has many
applications in daily hoisting and rigging operations.
 Readily available in a wide variety of synthetic and
natural fibre materials, these ropes may be used as
FIBRE SLING
 slings for hoisting materials

 hand-lines for lifting light loads

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 The fibres in these ropes are either natural or synthetic.
Natural fibre ropes
 Strength is more variable than that of synthetic fibre ropes
and are much more subject to deterioration from rot,
chemicals etc.
Synthetic fibre ropes
 Polypropylene is the most common fibre rope used in
rigging.
 Nylon, Polyester etc. are also used.

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 WIRE ROPE
Wire Rope consists of three components.
 Centre Core: The centre of the wire rope. The
core serves as the foundation to hold the rope
together.
 Wire: The basic building block. Mostly, the
wire is High Carbon steel, but other material
types are also available .
 Strand : Collection of wires in a particular lay.
It is made up of a specific number of wires, laid
helically around a wire core.
5
Features...
 All wire rope must be:
 steel wire rope of the type, size, grade, and construction
recommended by the manufacturer of the crane.
 compatible with the sheaves and drum of the crane.

 lubricated to prevent corrosion and wear.

 The rope must have its end connections securely fastened

and kept with at least three full turns on the drum.

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Classification
 Ordinary: all wires are the same size.

 Warrington: outer wires are alternately

larger and smaller.
 Filler: small wires fill spaces between
larger wires.
 Seale: wires of outer layer are larger
diameter than wires of inner layer.

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 WIRE ROPE failures
 Snagging of wires due to
crushing
 Jamming of fibres due to
crushing
 High stranding (causes on
other fibres)
 Bird- cage (multiple high
stranding, due to release of a KINKING

tensile load)
 Kinking (drawing tight loops)
 Rope breaking (excessive Rope breaking
strain)
 Corrosion 8
Precautions for use
 Ensure that the right size and construction of rope is used for the
job.
 Inspect and lubricate rope regularly according to manufacturer’s
guidelines.
 Never overload the rope and minimize shock loading.
 Ensure there is no slack in the rope.
 Use softeners to protect rope from corners and sharp edges.
 Do not drop rope from heights.
 Never use wire rope that has been cut, kinked, or crushed.
 Ensure that rope ends are properly seized.
 Avoid reverse bends.
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 SLINGS
1.Wire rope slings and cable clip
 After the hoist rope/ cable, the sling is the most commonly
used piece of rigging equipment
 The cable clip shall be properly installed according to the
following points:
 The wire rope sling is equipped with thimble.

 There is a minimum of 3 cable clips.

 The direction of installation shall be correct.

 The distance between the cable clips shall be the same.

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2. Metal Mesh Sling
 Designed when the loads are abrasive or
hot or tend to cut the web slings.
3. Chain Sling
 Must be made of Alloy Steel.
 Chain is better suited for lifting rough Chain
Sling
Metal
loads and withstanding high Mesh
temperatures. Sling

11
4. Fibre Sling
 Pliable, flexible and tend to mould themselves
to the shape.
 Minimize twisting and spinning.
 Do not rust and are non-sparking.
 Won't mar or crush the load.
 Are elastic and stretch.

12
SLINGS - precautions
 Never use damaged slings.
 Inspect slings regularly to ensure their safety.
 Check wire rope slings for kinking, wear,
abrasion, broken wires, worn or cracked
fittings, loose seizing and splices, crushing,
flattening, and rust or corrosion.
 Slings should be marked with an
identification number and their maximum
capacity.
 Avoid sharp bends, pinching, and crushing.

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 Avoid dragging slings out from
underneath loads.
 Keep wire rope slings away from
flame cutting and electric welding.
 Before making a lift, check to see that
the sling is properly attached to the
load.
 Never work under a suspended load.
 Secure or remove unused sling legs
of a multi-leg sling before the load is
lifted.

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 HOOKS
 Hooks are a vital part of lifting.
 A variety of them cater for
different lifting purposes.
 All hooks shall be installed with
safety latches (other than the
specially designed hooks).
 Hooks can be installed with
swivels to allow the load to
revolve.
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Guidelines:
 Select hooks of the right size.

 Do not tie or remove the safety latches.

 Maintain the hook in a vertical position.

 If the hook is eccentrically loaded, the Safe Working Load will

be reduced.

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PRECAUTIONS
 Look for distortions such as bending, or twisting exceeding 10
degrees from the plane of the unbent hook.
 Check for an increase in throat opening exceeding 15% of original
throat opening.
 Check for wear in the saddle area of the hook.
 Check for cracks, severe nicks, and gouges.
 Check the hook attachment and securing means for defects.
 Rigging hooks shall be inspected as a part of the slings to which
they are attached.
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Equipment for Material Handling
 Conveyors & Elevators
 Industrial Hoists
 Mobile Cranes
 Fork Lift

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A. CONVEYORS
 A conveyor system is a common piece of mechanical handling
equipment that moves materials from one location to another.
 Conveyors are especially useful in applications involving the
transportation of heavy or bulky materials.
 Conveyor systems allow quick and efficient transportation for a
wide variety of materials, which make them very popular in the
material handling and packaging industries.

20
Composition
 A conveyor belt is composed by two endpoint pulleys and
a closed conveyor belt.
 The pulley that drives conveyor belt rotating is called drive
pulley or transmission drum; the other one–only used to
change its movement direction–is called bend pulley.
 Drive pulley is driven by the motor through reducer, and
conveyor belt dragging relies on the friction drag between
the drive pulley and the belt.

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Belt Conveyor
 A conveyor belt (or belt conveyor) consists of two or
more pulleys, with a continuous loop of material - the
conveyor belt - that rotates about them.
 One or both of the pulleys are powered, moving the
belt and the material on the belt forward.
 The powered pulley is called the drive pulley while the
unpowered pulley is called the idler.

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Types:
 There are two main industrial classes of belt conveyors;
1. General material handling such as those moving boxes
along inside a factory.
2. Bulk material handling such as grain, coal, ores,
etc. generally in outdoor locations.
 In addition there are a number of commercial applications
of belt conveyors such as those in grocery stores, airports
etc.
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Benefits
 Small or delicate part handling
 Accumulation
 Inclining and elevating with
high friction or cleated belts
 Clean room environments
 Small parts transfer
 Back lighted inspection Typical belt conveyor

 Quiet operation 24
Belt Construction
Conveyor belts generally are composed of three main components.
1. Carcass: The reinforcement usually found on the inside of a conveyor
belt is normally referred to as the “carcass.”
2. Skims: The rubber, PVC or urethane between plies is called a “skim.”
Skims are important contributors to internal belt adhesions, impact
resistance, and play a significant role in determining belt “load support”
and “troughability (Transverse flexibility).”
3. Covers: Covers are used in conveyor belt constructions in order to
protect the base conveyor belt carcass and, if possible, to extend its
service life. 25
Essential Properties of belt
 Flexibility
 Transverse rigidity
 Low mass per unit length
 High strength
 Simplicity and inexpensive
 Longer life
 Should not stretch under normal working stresses ,i.e., low
relative elongation.
 Wear resistant
 Fire resistant
26
Belt Design
The actual belt of a system is determined on what the conveyor is
going to be used for.
 Items to consider when choosing a belt.
 Size of items being moved
 Weight of items
 Shape of items
This will help decide what belt to use so coefficients of friction can
stay low so the motors wont be over worked.
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Design Procedure
 Size of material.
1. Maximum lump size (dimension) of material is considered.
2. Material and width of belt is considered depending on the
material.
 Selection of belt speed
Factors : lump size factor, abrasiveness factor, air borne factor.
 Safe angle of Inclination/Declination & angle of surcharge of
material.
 Type of supporting idlers and their spacing.
 Calculations of tensions in belt for various conditions.
28
 Selection of belt with breaking strength= (maximum operating
tension X minimum factor of safety).
 Drive power with transmission losses and sources of power.
 Determining various pulley sizes.
 Selection of proper bearings for duty conditions.
 Location of take up and take down tensions.
 Location of hold back/brake with braking force and torque.

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Care and Maintenance
Steps to ensure conveyors perform at peak capacity
1.Regular inspections
2.Close monitoring of motors and reducers
3.Keeping key parts in stock
4.Proper training of personnel
Increasing the service life of your conveyor system involves
 choosing the right conveyor type, the right system design
and paying attention to regular maintenance practices.
30
1. Plan Preventative Maintenance
 The best thing you can do to keep your equipment
running efficiently is to follow the manufacturer's
recommendations for scheduling preventative
maintenance.
 Inspecting all components.
 Replacing any that show wear .

31
 Upgrading components such as wires and cables to higher
quality replacements will extend the life of your equipment
and avoid costly breakdowns.
 It is to your benefit to keep a log for each piece of equipment
to be certain that preventative maintenance practices are
being followed.

32
2. Clean Conveyors Regularly
 One of the biggest contributors to conveyor break down
is not regularly cleaning the conveyor.
 Gunk builds up and causes issues with the conveyor
parts.
 Adhering to a regular cleaning schedule will increase the
longevity of conveyor belts and parts.
33
3. Check Pressure on Pneumatic Systems
 Frequent inspection of pneumatic system regulators and
making proper adjustments is important to the life of your
conveyor system.
 Excessive pressure is not only costly, but can damage the
conveyor components, leading to a break down.
 Follow the manufacturer's suggestion for proper pressure
guidelines.

34
4. Lubricate Bearings
 Proper lubrication of bearings will keep your conveyor running
smoothly.
 Over and under lubricating is not good for the bearing, and can
lead to a break down.
 Follow the manufacturer's recommended guidelines for proper
bearing lubrication.

35
5. Avoid Misuse
 Most conveyors are designed for a specific product weight range.
 Placing heavier and larger objects on a conveyor designed for
lighter or small products will add stress to the system and wear
down the belt, motors, and reducers -and lead you straight to a
breakdown.
 Follow the manufacturer's weight and size limit guidelines for
your conveyor.
36
6. Stock Spare Parts
 No matter how much preventative maintenance you practice,
there is always the chance of an equipment breakdown.
 Stocking the recommended spare parts for your equipment will
decrease downtime and allow you to get the equipment up and
running again quickly.
 Items such as wires, cables, and shear pins should always be
stocked.
37
B. ELEVATORS
 An elevator is a type of vertical transport equipment.
 Elevators are generally powered by electric motors that either
drive traction cables or counterweight systems like a hoist, or
pump hydraulic fluid to raise a cylindrical piston like a jack.
 Because of wheelchair access laws, elevators are often a legal
requirement in new multistory buildings, especially where
wheelchair ramps would be impractical.

38
 A modern day lift consists of a cab mounted on a platform within
an enclosed space called a shaft or sometimes a “ hoistway “.
 Hydraulic lifts use the principles of hydraulics to pressurize an
above ground or in-ground piston to raise and lower the car.
 Roped hydraulics use a combination of both ropes and hydraulic
power to raise and lower cars.
 Hydraulic lifts are cheaper, but installing cylinders greater than a
certain length becomes impractical for very high lift hoistways.
 Hydraulic lifts are usually slower than traction lifts.
39
Types of hoist mechanisms
1.Traction elevators
 Geared traction machines are driven by AC or DC
electric motors.
 Geared machines use worm gears to control
mechanical movement of elevator cars by "rolling"
steel hoist ropes over a drive sheave which is
attached to a gearbox driven by a high speed
motor.

40
 These machines are generally the best option for basement or
overhead traction use for speeds up to 500 feet per minute (2.5
m/s).
 Gearless traction machines are low speed (low RPM), high
torque electric motors powered either by AC or DC.
 Gearless traction elevators can reach speeds of up to 2,000 feet per
minute (10 m/s), or even higher.

41
2.Hydraulic elevators
 Conventional hydraulic elevators: They use an underground
cylinder, are quite common for low level buildings with 2–5 floors
(sometimes but seldom up to 6–8 floors), and have speeds of up to 200
feet per minute (1.0 m/s).

 Holeless hydraulic elevators (pistons mounted inside the hoistway)

were developed in the 1970s, and use a pair of above ground cylinders,
which makes it practical for environmentally or cost sensitive buildings
with 2, 3, or 4 floors.
42
 Roped hydraulic elevators use both above ground cylinders and a
rope system, allowing the elevator to travel further than the piston
has to move.

 Traction-Hydraulic Elevators: The traction-hydraulic elevator has

overhead traction cables and counterweight, but is driven by
hydraulic power instead of an overhead traction motor.

43
3.Climbing elevators
 A climbing elevator is a self-ascending elevator with
its own propulsion.
 The propulsion can be done by an electric or a
combustion engine.
 An example would be the Moonlight towers in Austin,
Texas, where the elevator holds only one person and
equipment for maintenance.
44
Passenger Elevator Components
(Traction Elevator)
Main components inclue:
 car
 cables
 elevator machine
 controls
 counterweight
 hoistway
 rails
 penthouse
 pit
45
Standards
 The mechanical and electrical design of elevators is dictated according to
various standards (aka elevator codes), which may be international,
national, state, regional or city based.
 Some of the national elevator standards include:
 India- IS 14665 for Electric Traction Lifts (passengers and goods)
 Australia – AS1735
 Canada – CAN/CSA B44
 Europe – EN 81 series (EN 81-1, EN 81-2, EN 81-28, EN 81-70 etc.)
 USA – ASME A17

46
Passenger Elevator standards (US)
 In most US and Canadian jurisdictions, passenger elevators are
required to conform to the American Society of Mechanical
Engineers' (ASME) Standard A17.1, Safety Code for Elevators and
Escalators.
 Passenger elevators are tested using the ASME A17.2 Standard.
The frequency of these tests is mandated by the local jurisdiction,
which may be a town, city, state or provincial standard.
 In addition, passenger elevators may be required to conform to the
requirements of ASME A17.3 for existing elevators where
referenced by the local jurisdiction.

47
Recommendations

48
Construction
 Elevator Shaft
 Contain building components necessary for the operation of
elevator (vertical passage way).
 Its dimension depends upon elevator model, door design and
type of drive.
 They must have ventilation and smoke extracting openings.
 The cross section of these openings is generally 2.5% of the
shaft floor area, with minimum cross section stipulated as
0.1m.sq.

49
 Shaft Pit: The bottom end of the shaft is called pit.
 The depth of the pit is measured from the top edge of the
finished floor at the lowest elevator stop to the top edge of the
finished floor of the pit floor.
 The minimum depth of pit is determined by:
 space required for construction

 over run and safety space stipulated by regulations

 The pit sits directly on the foundation.

 Shaft pits that are 1 to 2.5m deep must be equipped with a removable
access ladder.
 Pits with a depth greater than 2.5m must have a secure access door
to a building floor.
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 Shaft Head
 It is the upper section of the shaft, measured from the top edge of
the finished floor at the uppermost stop to the bottom edge of
the shaft ceiling.
 Shaft Access
 The size of the shaft access points is determined by the door
design, while their location is defined by shaft symmetry.
 Machine Room
 Depending upon the type of drive, machine room is located either
at the top above the shaft or at the bottom next to it.
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Elevator Car
 In addition to doors, the size of the elevator shaft is also largely
determined by dimensions of elevator car.

 All elevator cars must be well lit, with grid independent safety lights
which are battery operated.

 Passenger and freight elevator cars must be ventilated.

 Air intake and exhaust openings must be placed to ensure sufficient

diagonal and cross ventilation.

52
Design of Elevator Car
 An elevator is essentially a platform that is either pulled or pushed up
by a mechanical means.
 In the past, elevator drive mechanisms were powered by steam and
water hydraulic pistons or by hand.
 A modern day elevator consists of a cab (also called a "cage" or "car")
mounted on a platform within an enclosed space called a shaft or
sometimes a "hoistway".

53
 Hydraulic elevators use the principles of hydraulics (in the sense of
hydraulic power) to pressurize an above ground or in-ground piston
to raise and lower the car.
 Elevator doors protect riders from falling into the shaft.
 The most common configuration for elevator door is to have two
panels that meet in the middle, and slide open laterally.
 In a cascading telescopic configuration for elevator door (potentially
allowing wider entryways within limited space), the doors run on
independent tracks so that while open, they are tucked behind one
another, and while closed, they form cascading layers on one side.
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 Machine room-less (MRL) elevators are designed so that most of the
components fit within the shaft containing the elevator car; and a small
cabinet houses the elevator controller.
 The benefits of MRL are
-creates more usable space
-use less energy (70-80% less than hydraulic elevators)
-uses no oil
-can operate at faster speeds than hydraulics but not normal
traction units.

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For design of elevators factors to be considered are –
1. Population or no. of people who require lift service.
2. Handling capacity or maximum flow rate required by the people.
The handling capacity is calculated by the formula:
H = (300 x Q x 100)/T x P
Where, H = Handling capacity as the percentage of the peak population
handled during 5 min.
Q = Average number of passengers carried in a car
T = waiting interval, and P = Total population to be handled during peak
period.
3. Interval or quality of service required.

56
Characteristics controls designing elevator
 Speed of the Elevator.

 Dimensions of the car

 Loads

 Number of elevators.

 Location of entrances in the building.

 Location of the elevator area

57
Bucket Elevator
 Bucket elevators are the most common
location of primary explosions in the
grain industry but are not as
prevalent in other sectors.

 Combustible dust fire and explosion

hazards are not recognized in the
manufacturing sector.

58
Operation
START UP
 Check to insure elevator is free of foreign materials before
connecting power.
 Check to insure all guards, covers, safety devices and controls are in
place and operating correctly.
 Initial start up of elevator should commence with several short jogs
gradually lengthening in duration without material.
 Check take-up adjustment after 8 hours.
 Retighten all fasteners.
 Check and realign sprockets/pulleys as necessary.

59
 Gradually begin feeding material to the elevator.
 Increase feed rate slowly until reaching design capacity, empty
elevator.
 Ensure LOCK OUT/TAG OUT Facilities for ALL POWER.
 Check for loose fasteners.
 Check alignment of sprockets/pulleys.
 Elevator should be checked for loose fasteners and alignment at least
once a month.

60
Operation (Chain Type)
 When elevator is new it is common to have an occasional tight
chain joint. This will cause some vibration but will eventually
loosen.
 If plastic buckets are used in conjunction with metal breaker
buckets, it is normal to experience some pulsation.
 Characteristics of the material will affect the degree of pulsation.
 Pulsation is caused by the difference in bucket projection.
 Do not intermix old chain and new chain in parallel strands.
61
 Primary to satisfactory elevator operation is uniform material feed
rates—not surge loading and excessive boot flooding.
 When consulting the factory regarding a specific elevator, refer to
the purchase order number, year of manufacture if known, and
equipment number if appropriate.
 Regular inspection and maintenance will insure uninterrupted and
satisfactory elevator performance.

62
Operation (Belt Type)
 If plastic buckets are used in conjunction with metal breaker
buckets, it is normal to experience some pulsation.
 Characteristics of the material will affect the degree of pulsation.
Pulsation is caused by the difference in bucket projection.
 Primary to satisfactory elevator operation is uniform material feed
rates—not surge loading and excessive boot flooding.

63
 Regular inspection and maintenance will insure uninterrupted
and satisfactory elevator performance.
 When consulting the factory regarding a specific elevator, refer to
the purchase order number, year of manufacture if known, and
equipment number if appropriate.

64
Maintenance
 Periodic inspections must be performed to determine the wear rate
of all chains, buckets, belts and bearings.
 During these inspections the alignment of sprockets, pulleys and all
drive components shall be checked.
 Retightening of fasteners and checks to insure guards, covers,
gratings, controls, and safety devices are in place, secure, and operating
correctly.
 Keep a good supply of spare parts.

65
Maintenance Checklist:
 Buckets:
 Check buckets periodically for bucket damage and loose
bolts.
 All damaged buckets should be replaced or properly repaired.

 Discharge Bibb:
 Check adjustable discharge bibb for wear after a month of
operation and replace discharge bibb if worn.
 Inspect discharge bibb on a regular basis.
66
 Sprockets, Traction Wheels
 Check sprockets and traction wheels for excessive, uneven,
or unusual wear.
 Replace sprockets or traction wheels if worn.
 On segmental sprockets, check and re-torque bolts on
the replacement segments on both the head and boot
shafts.

67
 Chain, Belt
 Check the take-up for bucket clearance in the bottom of the boot
housing.
 Inspect chain/belt regularly.
 Consult manufacturer for wear guidelines

 Practice good housekeeping and use proper LOTO procedures.

 Keep the areas around loading, discharge, drive and control points,
clean and free from obstructions to maintain a safe environment for
all personnel.
68
THANKS

69
INTRODUCTION
 The hoisting is the lifting of the material against gravity
and maybe done with a wide range of equipment from the
small hand operated simple screw or hydraulic-jack to
modern high powered cranes and elevators.

3
Equipment:
 Pulley and sheave block
 Chain hoists
 Winches
 Mobile cranes
 Tower cranes
 Whirler cranes
 Derrick cranes
 Gantry cranes
 Fork Lift
4
Pulley and sheave block
http://www.finerfender.com/

 A pulley is a wheel on an axle or shaft that is designed to support

movement and change of direction of a cable or belt along its
circumference.
 Pulleys are used in a variety of ways to lift loads, apply forces, and to
transmit power.
 In nautical contexts, the assembly of wheel, axle, and supporting
shell is referred to as a "block.“
 A pulley may also be called a sheave or drum and may have a groove
between two flanges around its circumference.
5
 The drive element of a pulley system can be a rope, cable, belt,
or chain that runs over the pulley inside the groove.
 The pulley and sheave blocks suitable for lifting rough surface
and heavy loads.
 For these purposes the chains and wire ropes are used as drive
element.
 The alloy chains are best suited for hoisting operation.
 The weakest component of this system is the load hook.
 The hook fails by straightening.
 Once the hook gets elongated or straightened, it should be
replaced.
6
 https://www.lift-it.com/

Chain hoists
 The chain hoists are the popular mechanism for lifting loads
upto 100 tones.
 The system consists of two sets of chains, namely the hand
and load chain.
 The hand chains are particularly useful for the isolated
location, where an electric motor or other types of
mechanical equipment are not available.
 The pull applied through the hand chain is transmitted to
the load chain with a multiplication factor of over 20.

7
 The load to be lifted is held by a load hook while another hook
(called support hook) at the top, support the mechanism.
 The two hooks however, should not be interchange as the
support hook is made much stronger than the load hook.
Chain Hoists - How it works?
https://youtu.be/3j55IAg3GgE

Rigging & Slinging - Regulation and its Safety:

https://youtu.be/nLBr6nrxx5k

8
Winches
 A winch is a mechanism in the shape of a cylinder or drum, over
which rope or chain is wound.
 A winch is a mechanical device that is used to pull in (wind up) or let
out (wind out) or otherwise adjust the tension of a rope or wire rope
(also called "cable" or "wire cable").
 In its simplest form, it consists of a spool (or drum) attached to a
hand crank.
 If a winch is used only for raising and lowering, it is sometimes
referred to as hoist.
 The winches are of two types :-
 (1) hand winches (2) power winches
9
Hand Winch Motor/Power Winch

https://www.amazon.ca/
https://www.indiamart.com/

10
Mobile Cranes
 Mobile Cranes are used in big construction projects for lifting
heavy loads.
 It is used for loading and unloading for material in coal
mines. Loading and unloading of ships.
 To take the load from ground level and place it into the
trucks.
 The boom of a crane is the long, telescopic, or fixed, arm that
is used to move objects.
 Lattice construction includes fabricated construction of steel
angles or tubing.
11
https://en.wikipedia.org/

12
Types
 Lattice boom crane uses a long extension that moves up and down
but does not slide in and out like a hydraulic boom.
 There are three types of lattice boom cranes.
 The crawler crane has the advantage of moving with loads for a
short distance with maximum capacity is 1.6 T.
 The outrigger crane consists of the pedestal crane and the truck
crane.

13
Crawler Crane
Truck Crane Pedestal crane

https://www.indiamart.com/ https://www.weihuagrp.com/

https://www.terex.com/
14
Crawler Cranes- Applications

Source: Internet 15
Lifting Principles in Mobile cranes
 Center of Gravity
 Leverage
 Stability
 Structural Integrity

16
Operational requirements –Mobile crane
 Personnel training and competency
 Risk assessment and management
 Pre-job planning and inspection
 Correct crane and equipment for application
 Onsite arrival and review
 Onsite planning
 Correct setup of crane
 Outrigger operation & packing
 Trial operation
 Safe continual operation
 Safe completion of operation

17
Tower Cranes
 These are the crane of swing job type and are mounted on high
steel towers.
 The height of tower maybe 25 to 30 m and these cranes are found
to be suitable in the construction of tall buildings in congested
areas.
 The ground area required for such cranes is very small.
 Self-erecting cranes sit inside of buildings where they lift
themselves up using jacks, floor by floor, rising with the building.
 Eventually, the mast is raised to give the crane its height, followed
by the attached slewing unit (gear and motor) at the top so the
unit can rotate.
18
Source: https://www.thestructuralworld.com/ Source: Internet
19
Derrick cranes
 Derrick Crane is a combination of the Derrick and the Crane,
capable for hoisting and swinging the load horizontally.
 A derrick is a lifting device composed at minimum of one guyed
mast, as in a gin pole, which may be articulated over a load by
adjusting its guys.
 Most derricks have at least two components, either a guyed mast
or self-supporting tower and a boom hinged at its base to provide
articulation, as in a stiff leg derrick.

20
Hence derrick cranes are of two types:
(1) Guy derrick
(2) Stiff leg derrick
 The guy derrick consists of a vertical mast.
 This mast is supported by the number of guys and can revolve
through 360‫ﹾ‬ .
 While revolving, the radius of revolution should be such that the
revolving structure is not obstructed by the guy wires.
 The power is supplied by a diesel engine or by an electric motor.
 This derrick can be constructed upto 200 tonnes capacity .

21
Guy Derrick crane Stiff Leg Derrick crane

https://www.pinterest.com/ http://www.girdersandgears.com/ 22
 In stiff leg type derricks, the guy wires are replaced by trussed
structure.
 This type of derricks are suitable for loads from 10 to 50 tonnes.
 The most basic type of derrick is controlled by three or four lines
connected to the top of the mast, which allow it both to move
laterally and cant up and down.
 To lift a load, a separate line runs up and over the mast with a hook
on its free end, as with a crane.
 Forms of derricks are commonly found aboard ships and at docking
facilities. Some large derricks are mounted on dedicated vessels,
and known as floating derricks and sheer legs.
23
 http://www.soilmovingequipment.com/

Whirler cranes
 This crane is a combination of stationary and mobile unit.
 This combines the advantages of log boom of derrick crane and
mobility of the mobile crane.
 The rotating structure has an outer framework.
 The boom is attached to the front end of this framework.
 The counter weight is provided at the rear end.
 On the diagonally opposite corners of the base, two separate
motors are provided, which give movement to the central shaft.

24
Gantry cranes
 The Gantry cranes or overhead cranes are the indispensable
machines in factories and workshops.
 In large workshops, there are separate machines for fabrications
or repairs of the machine parts.
 The machine or the components, which are to be repaired, can be
transferred to the place of fabrication or assembly with the
help of Gantry cranes.

25
Components – Bridge crane

https://www.munckcranes.com/

26
Components – Jib crane

http://acecrane.blogspot.com/

https://www.brighthubengineering.com/
27
Applications of Hoisting Equipment
Hoisting equipment assists in the lifting and positioning of large, heavy
loads in a variety of industries, including:
 Automotive
 Chemicals
 Commercial printing
 Manufacturing
 Newspaper
 Paper
 Steel
 Warehousing and distribution
28
Areas of Usage:
Hoisting equipment is used in a variety of areas to support processing
and handling throughout a facility:
 Assembly: Moving products through production processes.
 Positioning: Securing a component for additional work.
 Transportation: Loading finished products onto open trailers or
railcars.
 Staging: Holding work-in-process for additional production
processes.
 Storage: Transporting heavy items to and from storage areas.
 Warehousing: Moving large, heavy products to and from docks.
29
Benefits:
 Customizable: Hoisting equipment can be customized with below
the hook attachments, end effectors or specialized tooling to handle a
diverse variety of products and loads.
 Ergonomics: By doing the heavy lifting, hoisting equipment takes
the strain off operators, reducing fatigue and lowering the risk of
injury.
 Flexible: Hoisting equipment can be easily re-fitted for longer lifting
capability.
 Indoor/outdoor use: Hoisting equipment can be used with
equipment both inside a facility and outside, on the dock or in the
yard.
30
 Lower maintenance costs: Incorporating the latest
technologies and offered in a variety of usage and capacity
ratings, hoisting equipment requires less maintenance
compared to other lifting devices.
 Portable: Hoisting equipment can be easily transported from
job to job or site to site.
 Positioning: Highly automated systems maneuver with the
precision of one thousandth of the rated speed to an exact
location.

31
 Reduction in product damage: By allowing for smooth, direct-
path lifting over obstacles—with soft start features, multiple
speed options and a variety of end effectors to interface with and
secure the load—products are handled gently to minimize
damage.
 Safety: Because they operate overhead and work in a specific
area, hoisting equipment is less likely than forklift traffic to
maneuver a load into personnel, walls, machinery or other
obstacles.

32
THANKS

33
Safety Guidelines for Crane operation
 Level the crane and ensure support surface is firm and able to
support the load.
 Contact power line owners and determine precautions. Know the
location and voltage of overhead power lines.
 Know the basic crane capacities, limitations, and job site restrictions,
such as the location of power lines, unstable soil, or high winds.
 Make other personnel aware of hoisting activities.
 Barricade areas within swing radius.
 Ensure proper maintenance and inspections.
 Determine safe areas to store materials and place machinery.
3
Hazards in crane operation
Improper load rating Working too close to power
Excessive speeds lines
No hand signals Improper exhaust system
Inadequate inspection and Shattered windows
maintenance
No steps/guardrails walkways
Unguarded parts
No boom angle indicator
Unguarded swing radius
Not using outriggers

4
Competent Person
 The competent person must
inspect all machinery and
equipment prior to each use, and
during use, to make sure it is in
safe operating condition. Damaged Track

 If it needs fixing, take it out of

service and don’t use it until it is
fixed. Source: Internet

5
Load Capacity - Speed – Warnings
 Make sure the crane operator has
checked -
 Rated Load Capacities
 Operating Speeds
 Special Hazard
 Warning or Instruction

Source: Internet

6
Know the Weight of the Load
 Refer documentation for tranfering load.
 Ensure lift calculations are correct.
 Ensure load is within load chart rating for boom length and load
radius of crane.
 Crane is rated by the maximum weight it will lift at a minimum
radius and minimum boom length – the further from its center
point, the less it will lift.

7
OVERTURNING ACCIDENTS
 Basically, overloading is responsible for a relatively small portion of mobile
craneaccident simply because a very small portion of lifted loads are at or
near rated loads.
 In concept, load and load-moment indicators are ideal means to assure
cranes will not be overloaded.
 Some reasons that load or load-moment indicators are not reliable:
(1) the device has been turned off or is down due to malfunction,
(2) the device is out of calibration, or
(3) operating conditions (wind or operating speeds or out of level) are so far
from ideal that the published rating can lead to failure.
 The mounting of a device is itself no assurance operations will be safe.
 Just like oil pressure or temperature gauges, those devices are not safety
devices; they are indicators that advise a knowledgeable
 operator of load parameters as an aid in making operating judgments.
8
Load Limiting Factors
Not level
Wind
Side loads
On its wheels
Lifting over the side
Use of extensions, jibs and other attachments
Limits of wire rope, slings and lifting devices

9
Load Example:
 Will lift 60,000 pounds at 10 feet from the center pin of the crane.
 Based on level surface, no wind, and outriggers fully extended.
 At 25 feet from the center pin with an 80 foot boom, the capacity is
only 14,950 pounds.
 At 74 feet from the center pin, the capacity is only 4,800 pounds.

10
 Improper Load
Improper loads or speeds can result in the tipping of the crane.
• This crane overturned while performing
loading operations on a pier.
• The crane was attempting to remove a metal
container from a barge when it tipped and
slid into the water.
• The wind caused the load to swing violently
causing the load to go outside the swing
radius, at that point the load dropped into
Source: Internet
the water and took the crane with it.
11
Power Lines
Stay clear from power lines at least 10 feet
• Electrical distribution and transmission lines
have been de-energized.
• Visibly grounded at point of work or where
insulating barriers, not a part of or an
attachment to the equipment or machinery.
• It prevents physical contact with the lines,
equipment.
• Machines shall be operated proximate to
Source: Internet

power lines only in accordance with

guidelines.

12
Guidelines:
 (i) For lines rated 50 kV. or below, minimum clearance between the lines and
any part of the crane or load shall be 10 feet;
 (ii) For lines rated over 50 kV., minimum clearance between the lines and any
part of the crane or load shall be 10 feet plus 0.4 inch for each 1 kV. over 50 kV.,
or twice the length of the line insulator, but never less than 10 feet;
 (iii) In transit with no load and boom lowered, the equipment clearance shall be
a minimum of 4 feet for voltages less than 50 kV., and 10 feet for voltages over 50
kV., up to and including 345 kV., and 16 feet for voltages up to and including 750
kV.
 (iv) A person shall be designated to observe clearance of the equipment and
give timely warning for all operations where it is difficult for the operator to
maintain the desired clearance by visual means.
13
 Source: Internet

Hand Signals

Source: Internet 14
Guard Moving Parts

Belts, gears, shafts, pulleys,

sprockets, spindles, drums, fly
wheels, chains, or other
reciprocating, rotating, or other
moving parts or equipment shall
be guarded if such parts are
exposed to contact by employees,
or otherwise create a hazard.

Source: Internet

15
Swing Radius
• Stay out of the swing radius of the crane .
• Make sure there are barrier guards showing swing radius

Source: Internet
16
Operator Visibility
All windows in cabs shall be of safety glass, or equivalent, that
introduces no visible distortion that will interfere with the safe
operation of the machine.

Source: Internet 17
Ladders
(i)Where necessary for rigging or service
requirements, a ladder, or steps, shall be
provided to give access to a cab roof.
(ii) Guardrails, handholds, and steps shall be
provided on cranes for easy access to the
car and cab.
(iii) Platforms and walkways shall have anti-
skid surfaces.
Source: Internet

18
Guardrails

• Guardrails, handholds, and

steps shall be provided on
cranes for easy access to the car
and cab, conforming
• Platforms and walkways shall
have anti-skid surfaces.

Source: Internet

19
Suspended Loads
• Keep the load as close as
possible to the ground
when picking and
carrying a load.
• All employees shall be
kept away of loads about
to be lifted and of
suspended loads.

Source: Internet

20
Boom Angle Indicator
• Cranes and derricks with
variable angle booms shall be
equipped with a boom angle
indicator, readily visible to the
operator.
• The boom angle indicator is an
accessory device that measures
the angle of the boom base
Source: Internet
section centerline to horizontal.

21
Supporting Surface
• The crane shall be uniformly level within
one percent of level grade and located on
firm footing.
• Cranes equipped with outriggers shall
have them all fully deployed following
manufacturer's specifications, insofar as
applicable, when hoisting employees.
• Be mindful of asphalt which easily
Source: Internet
becomes a shifting, soft surface under a
concentrated load.
22
Sheaves • Sheave grooves shall be smooth and free from surface
defects which could cause rope damage.
• The cross sectional radius at the bottom of the
groove should be such as to form a close fitting
saddle for the size rope used.
• Flange corners should be rounded and the rims
should run true about the axis of the rotation.
• The sheaves in the lower loads block shall be
equipped with close-fitting guards.
• All sheave bearings shall be provided with means for
lubrication.
• Boom hoisting sheave shall have pitch diameters of
not less than 15 times the nominal diameter of the
rope used.
23
 Annual Inspections
Inspection of the hoisting
machinery must be made by
a competent person
The employer must
maintain a record of these
inspections
Crane wasn’t inspected
and tipped over
Source: Internet

24
 Damaged wire rope

Crushed Rope

Broken Strands

Source: Internet Source: Internet

Damaged wire rope must be taken out of service

25
Worn Part

Source: Internet
26
 Tire Inspections

Conduct regular
inspections
of tires for excessive
wear or damage

Source: Internet

27
Training
 Operators:
 must qualify on specific crane type
 Must include on-the-job training
 Supervisor / competent person

28
FORKLIFT Safety

29
 Forklift Basics Mast

Overhead
Guard Lift
Cylinder

Lift
Control

Lift
Seat Chains
Belt

Tilt
Control Backrest

Carriage

Forks

Source: Internet
30
Determine a Load’s
Center of Gravity
 Center of gravity is
the balance point
 Load center is the point
where the heaviest part of
the load is located
 Pick up load on the side
closest to its center of
gravity

31
 Stability Triangle
Vehicle Center of Gravity
(unloaded)
Stability Triangle

Center of Gravity of Vehicle

and Maximum Load
(Theoretical)
Source: Internet

32
What Can Cause a Tipover ?

 Center of gravity
side to side

 Center of gravity forward

 Center of gravity backward

33
Operating Hazards— Pedestrians
Accidents involving pedestrians may
be caused by:
 Obstructed view
 Turning
 Speeding
 Pedestrian unaware forklift is
present
 Carrying passengers and horseplay

34
Operating Hazards—
Environmental Conditions
 Combustible fuel-operated
forklift in poorly ventilated area
 Traveling on ramps
 Crossing railroad tracks
 Slippery floors
 Operating on dirt
or gravel
 Poor lighting

35
Operating Hazards-
Load Carrying
 Working around loading
docks
 Loads that block the
forward vision
 Stacking and unstacking
on racks

36
While in the Operator Seat
 Make nonmoving checks—
gauges, lights, horn, backup
alarm, warning light, tilt-and-lift
mechanism, and parking brake
 Make moving checks—seat
belt, running
brakes, and steering
 Look for oil or water
leaks on the floor

37
Operating a Forklift
 Authorized operators only
 Quickly report accidents
 Always wear seat belts
 No person under the forks
 Operate controls only from
driver’s seat
 Never block exits or emergency
equipment

38
Tipover Safety Procedure
 Always wear your
seat belt
 Hold onto the
steering wheel
 Brace your feet
 Lean away from
the fall

39
Loading and Unloading
 Never overload forklift
 Check load weight
 Locate load’s
center of gravity
 Inspect the load
 Restack or secure unstable
loads
 Be sure forks are
under load
 Tow from rear
towing pin

40
 Traveling
 Avoid loose objects
 Look in the direction of
or holes
travel
 Never carry passengers
 Keep body inside cage
 Pedestrians have
 Keep forks low when the right-of-way
traveling  Keep a safe distance from the edge
 Sound the horn of ramps or docks
 Never eat or drink
 Don’t speed
 No horseplay
 Check clearance

41
Ramps and Railroads
 No turns on a ramp
 Load facing upgrade
 Go slow
 Cross railroad tracks
diagonally
 Never park within
8 feet of the center
of railroad tracks

42
 Docks Parking
 Inspect the dock plate  Don’t block exits
 Check the trailer floor condition or aisles
 Make sure trailer wheels are  Lower the forks
chocked  Set gear to
 Ensure that the nose of the neutral
trailer is supported  Set the parking
brake
 Turn off the key

43
Propane Refueling Battery Charging
 Fill in well-ventilated area
 Highly flammable gas-do not
smoke
 Report leaks immediately
 Distinct odor
 Hissing sound
 Frost on fittings
 Use gloves and safety glasses
 Charge batteries only in
protected areas with ventilation
 Inspect battery
connectors for damage
 No smoking
 Immediately clean up electrolyte
spills
 Wear PPE
44
General Guidelines for Forklift
 Facility hazards include pedestrians, environmental conditions, and
loading/unloading
 Position loads close to the vertical backrest
 Always conduct and document a preoperational inspection
 Follow the safe operating rules of the road
 Always refuel/recharge in ventilated areas and wear proper PPE

45
THANKS

46