Material Handling:

Cranes, Conveyors
and Lift Trucks

12.02.2009 N. Siva Shanmugam 1

Lecturer / MED
 Common Industrial Cranes
• Jib cranes
• Monorail cranes
• Bridge cranes

12.02.2009 N. Siva Shanmugam 2

Lecturer / MED
 Common Industrial Cranes
• Gantry cranes
• Semi-gantry cranes

12.02.2009 N. Siva Shanmugam 3

Lecturer / MED
 Common Industrial Cranes
• Tower and hammerhead cranes for yards
• Mobile cranes (maintenance)

12.02.2009 N. Siva Shanmugam 4

Lecturer / MED
 Components and Terms
• Hoist
• Rails
• Brakes
• Dynamic braking
• Trolley
• Rail stops and stop
plates
• Bridge rail sweeps
• Sheaves

12.02.2009 N. Siva Shanmugam 5

Lecturer / MED
 Components and Terms
• Reeving
• Ropes
• Pendant
• Upper limit switch
• Load block
• Safety latch
• Below-the-hook device

12.02.2009 N. Siva Shanmugam 6

Lecturer / MED
 Operator Qualifications
• Physical exam
• Training
• Skill testing
• Licensing???

12.02.2009 N. Siva Shanmugam 7

Lecturer / MED
 General Construction & Installation
• Rated load markings
– Hoist
– Rails (not part of crane)
– Crane
• Manufacturer’s identification
• Clearance
– Proximity to electrical conductors, gas lines, etc.
– Movement past mezzanines and platforms
• Service platforms
• Cabs
– Access
– Emergency egress
• Trolley stops and bumpers
• Bridge bumpers
12.02.2009
• Rail sweeps N. Siva Shanmugam 8
Lecturer / MED
 Construction and Installation
• Guarding for moving parts
– Power transmission apparatus guarding
– 200 lb. strength capacity (ANSI)
– Guarding for hoisting ropes at the block
• Brakes
– Hoist
• Holding brake
– 125% of rated load hoisting torque if non-mechanical control braking
used
– 100% of rated load hoisting torque if mechanical control braking used
• Control braking – control the load during lowering to a maximum
speed of 120% of rated lowering speed
– Trolley – stop within a distance equal to 10% of rated load speed
when traveling with rated load
– Bridge – same requirement as for trolley brakes
• Movement warning devices
12.02.2009 N. Siva Shanmugam 9
Lecturer / MED
 Inspections and Testing
• Depends on frequency of use and service classification:
normal, heavy and severe
• Initial
– All operational functions and code provisions
– Load test at 100% - 125% of rated capacity
• Beginning of shift or daily
• Monthly or frequent
• Annual or periodic – Full maintenance detailed
inspection
• Prior to special lifts
– Lifting personnel
– Planned engineered lifts up to 125% of rated cap.
• Inspections must be documented and retained
12.02.2009 N. Siva Shanmugam 10
Lecturer / MED
 Beginning of Shift / Daily Inspections
• Operating mechanisms for proper operation
• Upper limit switch testing
• Oil and other leaks
• Hooks and hook latches
• Hoist ropes and end connections
• Proper spooling of rope onto the drum and
sheave(s)
• Hoist brake if loads approach rated capacity
12.02.2009 N. Siva Shanmugam 11
Lecturer / MED
 Key Operating Rules
• Load ratings not exceeded
• Side loading and pulling
• Attaching a load securely
• Lifting personnel
• Carrying loads overhead
• Two wraps of rope remain on hoisting drum
• Operator must not leave the controls if a load is
suspended over an area accessible to people.
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Lecturer / MED
 Slings, grabs, hooks and other
below-the-hook devices
• Special training required
• Daily and periodic inspections
• Damage

12.02.2009 N. Siva Shanmugam 13

Lecturer / MED
 Common Issues and Concerns
• Evidence of side loading

• Damaged wire rope, chain, and below-the-hook devices

• Lifting without freeing the load, resulting in overloading

• Jib not swinging properly

• Monorail crane side loaded or used for pulling

• Improper upper limit switch adjustment

• Damaged or missing safety latch

• Inadequate care around dip tanks and chemicals

• Hook or load contact with electrical and other equipment

12.02.2009 N. Siva Shanmugam 14
Lecturer / MED
 Common Issues and Concerns
• Carrying loads over personnel or high value / sensitive equipment

• Improper maintenance and testing

• Bridges or trolleys dislodged from running rails

• Brake failures or excessive travel

• Excessive swinging of loads, resulting in contact with humans or

dropped loads

• Failure to place rail stops when performing maintenance on bridge

cranes

• Radio frequency interference

• Ergonomic issues for high use operators

12.02.2009 N. Siva Shanmugam 15

Lecturer / MED
12.02.2009 N. Siva Shanmugam 16
Lecturer / MED
 Conveyors

12.02.2009 N. Siva Shanmugam 17

Lecturer / MED
 Definition
• A horizontal, inclined, or vertical device for
moving or transporting bulk material,
packages, or objects in a path
predetermined by the design of the device,
and having points of loading and
discharge, fixed or selective.

12.02.2009 N. Siva Shanmugam 18

Lecturer / MED
 Types of Conveyors
• Belt
• Slat
• Apron
• Chain (e.g., monorail)
• Screw (aka. auger)
• Bucket
• Pneumatic (banks,
powders)

12.02.2009 N. Siva Shanmugam 19

Lecturer / MED
 Types of Conveyors
• Aerial
• Portable
• Gravity (e.g., roller, wheel or ball)
• Live roll (powered rollers)
• Flight
• Vibratory
• Vertical

12.02.2009 N. Siva Shanmugam 20

Lecturer / MED
 Distribution Conveyor Systems
• Merge step
• Induction
• Sortation
• Takeaway
• Discharge

12.02.2009 N. Siva Shanmugam 21

Lecturer / MED
 Common Conveyor Injury Types
• Caught in or by:
– Rotating drive shafts
– In-running nip points
– Power transmission apparatus
– Chain
– Belt seams / splices / lacing
– Hangers
• Struck by:
– Moving product being conveyed or carriers
– Falling parts or material
• Caught between:
– Accumulating parts
– Moving parts and structures or equipment

12.02.2009 N. Siva Shanmugam 22

Lecturer / MED
 Common Problems / Issues
• Upset conditions and jam ups
– Stored energy in jammed product
– Awkward postures accompanied by forceful, fast exertions
– Loss of situational awareness for body parts
– Slips and falls
• Falls
– Walking or stepping on rollers or moving belts
– Clearing jambs from overhead conveyors
– Working at elevation to adjust sortation and other components
– Maintenance
• Fires
– Static electricity build-up (belt and pneumatic)
– Overheated bearings
12.02.2009 N. Siva Shanmugam 23
Lecturer / MED
 Maintenance Activities with
Elevated Injury Risk
• Tracking belts
• Aligning guides, rollers, etc.
• Electrical debugging
• Interfacing with other processing equipment
• Working with gloves or loose clothing
• Poor visibility
• Falls from elevation when working on overhead conveyors
• Confined spaces when servicing pit conveyors
• Muscle strains when maintaining drives (awkward postures and high
force demands)
• Sortation device maintenance and adjustment
12.02.2009 N. Siva Shanmugam 24
Lecturer / MED
 Other Common Safety Issues
• Damage from forklifts
• Emergency stop provisions
• Sortation and discharge devices
– Pinch points
– Falling product
• Ergonomics
– Manual product induction and discharge
• Height
• Frequency
• Postures
– Force demands when clearing jams and dislodging material
– Maintenance activities

12.02.2009 N. Siva Shanmugam 25

Lecturer / MED
 Powered Industrial Trucks
(Forklifts)

12.02.2009 N. Siva Shanmugam 26

Lecturer / MED
 Lift Truck Fatalities
• Forklifts account for about 100 fatalities and 90,000+ injuries per year
• Causes of forklift accidents (Reports from OSHA database of accidents, 1984 –
1991)
– Operator inattention – 59
– Overturn – 53
– Unstable load – 45
– Operator struck by load – 37
– Elevated employees – 26
– No training – 19
– Overload, improper use – 15
– Accident during maintenance – 14
– Improper equipment – 10
– Obstructed view – 10
– Falling from platform or curb – 9
– Carrying excess passenger – 8
– Other employee struck by load – 8
– Falling from trailer – 6
– Vehicle left in gear – 6
– Speeding – 5
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Lecturer / MED
12.02.2009 N. Siva Shanmugam 28
Lecturer / MED
 Additional Accident Types
• Foot run over by wheel
• Struck by objects dislodged or being pushed
• Contact with electrical equipment
• Chemical spills and splashes from materials being
transported
• Fires and explosions
• Muscle strains from handling fuel tanks
• Contact with propane and other fuels
• Battery explosions and accidents
• Falls from order pickers
• Collisions with other vehicles and stationary objects
12.02.2009 N. Siva Shanmugam 29
Lecturer / MED
 More Injury Causes
• Musculoskeletal disorders
– Degenerative disc disease
– Neck and back
– Posture
– Vibration
– Impacts
– Shoulder and arm strains

• Broken fingers/hands from use of spinners

• Striking overhead objects and structures with loads or
the mast while traveling
12.02.2009 N. Siva Shanmugam 30
Lecturer / MED
 Safety Features
• Seatbelts
• Wrap-around seats
• Overhead guards
• Backup alarm lights
• Headlights
• Fail-safe brakes
• Air suspension seats
• Mirrors
• Horns
• Design for use in hazardous
environments
• Chemical shielding
• Weather enclosures
• Anti-tip system (Toyota)
• Fuel tank tip down rack (Toyota)
• Speed governors
12.02.2009 N. Siva Shanmugam 31
Lecturer / MED
 Safe Operating Practices
• Forks fully lowered when traveling
• No sharp turns with a raised load
• Drive in reverse down ramps, and forward going up
when feasible. Tilt the mast back.
• Low speed turns when loaded
• Turn vehicle off when pedestrians approach
• Inspect the vehicle each shift
• Drive backward when carrying loads that obstruct vision
• No riders
12.02.2009 N. Siva Shanmugam 32
Lecturer / MED
 Inspection and Maintenance
• Daily and periodic inspection
• Retain documentation
• Daily checks
– Battery
– Brakes
– Lights
– Horn
– Steering
– Tires
– Hydraulic hoses
– Housekeeping
– Seat belt
– Seat
– Controls
– Fuel andN.oil
Siva Shanmugam
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Lecturer / MED
 OSHA Training Requirements
• Truck topics
– Operating instructions, warnings and precautions for a specific truck type
– Differences between the truck and a auto’s operation
– Truck controls and instrumentation
– Engine or motor operation
– Steering and maneuvering
– Visibility due to loads
– Fork and attachment adaptations, operation, and use limitations
– Vehicle stability and capacity
– Vehicle inspection and maintenance that the operator will be required to perform
– Refueling and/or charging and recharging of batteries
– Operating limitations
– Operating instructions, warnings, or precautions in the manual for the specific
truck operated
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Lecturer / MED
 OSHA Training Requirements
• Workplace topics
– Surface conditions where the truck will be operated
– Composition of loads carried and load stability
– Load manipulation, stacking and unstacking
– Pedestrian traffic in areas where the truck will be operated
– Narrow aisles and other restricted places where the truck will be
operated
– Hazardous locations where the truck will be operated
– Ramps and other sloped surfaces that could affect the vehicle’s
stability
– Closed environments and other areas where insufficient ventilation
or poor vehicle maintenance could cause a buildup of CO or diesel
exhaust
– Other unique or potentially hazardous environmental conditions that
could affect safe operation
12.02.2009 N. Siva Shanmugam 35
Lecturer / MED
 Automatic Guided Vehicles (AGVs)
• Guided by rail, embedded wire, embedded RF markers,
or other means

• Equipped with presence sensing capabilities, as well as

perimeter touch panels or bumper and E-stops

• Generally operate at much slower speeds than forklifts

12.02.2009 N. Siva Shanmugam 36

Lecturer / MED
 AGV Safety Concerns
• Collisions with forklifts and other vehicles
• Program or guidance system faults (normally
programmed to fail safe in the event of a
receiver failure or control fault)
• Spilled loads
• Failure to program out pinch points with
conveyors and building structures
• Riding of vehicles by employees
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Lecturer / MED
 Walking & Working Surfaces

12.02.2009 N. Siva Shanmugam 38

Lecturer / MED
 Slips, Trips and Falls cause
• The majority of general industry
accidents

• 15% of all accidental deaths

• More fatalities than all other causes

except motor vehicles

12.02.2009 source: OSHA Office of Training & Education

N. Siva Shanmugam 39
Lecturer / MED
General Requirements Housekeeping
• All places of employment, passageways,
storerooms and service rooms shall be kept
clean and orderly and in a sanitary condition
• The floor of every workroom shall be maintained
in a clean and, so far as possible, a dry
condition….
• …every floor, working place and passageway
shall be kept free from protruding nails,
splinters, holes, or loose boards.
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Lecturer / MED
 Aisles & Passageways
• Keep clear and in good repair with no
obstruction across or in aisles that could create
a hazard
• Permanent aisles and passageways shall be
appropriately marked
• Aisles shall be sufficiently wide when
mechanical material handling equipment is used

12.02.2009 N. Siva Shanmugam 41

Lecturer / MED
Covers and Guardrails
Provide covers and/or guardrails to protect
personnel from the hazards of open pits,
tanks, vats, ditches and the like.

Floor Loading Protection

Load rating limits must be marked
on plates & posted.
Do not exceed the load rating
limits.
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Lecturer / MED
 Guarding Floor & Wall
Openings and Holes
• Standard railing = top rail, mid rail, & posts;
vertical height of 42 inches from floor,
platform, runway, or ramp. Midrail 21 inches

• Standard toeboard = 4 inches high with not

more than 1/4 inch clearance above floor

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Lecturer / MED
 Standard railings
Shall be provided on
all exposed sides
of a stairway
opening, except at
stairway entrance

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Lecturer / MED
 • Floor openings or holes may be covered rather
than guarded with rails (cover of standard strength
and construction)

• When the floor opening cover is removed, a

temporary guardrail shall be in place or an
attendant shall be stationed at the opening to warn
personnel

• While floor hole cover is not in place, the floor hole

shall be constantly attended or protected by a
standard removable railing

12.02.2009 N. Siva Shanmugam 45

Lecturer / MED
 Open-Sided
Floors/Platforms/Runways
• Every open-sided floor or platform 4 feet above
adjacent floor or ground level shall be guarded
by a standard railing on all open sides except an
entrance

• Provide a toeboard whenever persons can pass,

when there is moving machinery, or when there
is equipment with which falling materials could
create a hazard

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Lecturer / MED
 Open-Sided
Floors/Platforms/Runways
• Regardless of height, open-sided floors,
walkways, platforms, or runways above or
adjacent to dangerous equipment, pickling or
galvanizing tanks, degreasing units, and similar
hazards shall be guarded with a standard railing
and toeboard

12.02.2009 N. Siva Shanmugam 47

Lecturer / MED
 Stairway railings &
guards
Every flight of stairs
with 4 or more risers
must have standard
stair railings or handrails

12.02.2009 N. Siva Shanmugam 48

Lecturer / MED
 Fixed Industrial Stairs
• Required where operations necessitate regular
travel between levels
• Minimum width 22 inches
• Treads must be slip resistant with uniform rise
height and tread width
• Must be able to carry 5 times the expected load,
minimum 1000 lbs.
• Minimum clearance to overhead obstruction = 7 ft.
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Lecturer / MED
 Portable Ladders
• Maximum length for a portable stepladder = 20 ft.
• Maximum length for a single ladder = 30 ft.
• Maximum length for an extension ladder = 60 ft.

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Lecturer / MED
 • Ladders used to access
a roof shall extend at
least 3 ft. above the
point of support

• Use at angle where

the horizontal distance
from the top support to
the foot of the ladder is
¼ the working length
of the ladder

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Lecturer / MED
 Proper Use of Ladders
• Inspect ladders regularly for defects and
remove defective ladders from service

• Never use metal ladders around electrical

equipment

• The worker must always face the ladder when

climbing up or down

• Ladders must never be used in the horizontal

position as work platforms
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Lecturer / MED
 Fixed Ladders
• Permanently attached
to structures, buildings
or equipment
• Maximum unbroken
length of 20 to 30 ft. -
require cages or
safety devices
• Cage must extend to 7
– 8 ft. above base
12.02.2009 N. Siva Shanmugam 53
Lecturer / MED
 What are scaffolds?
• Elevated, temporary work platforms

• Types

– Supported scaffolds--one or more platforms supported by

rigid, load- bearing members, such as poles, legs, frames,
outriggers, etc.

– Suspended scaffolds--one or more platforms suspended by

ropes or other non-rigid, overhead support.

– Other scaffolds--principally manlifts, personnel hoists, etc

12.02.2009 N. Siva Shanmugam 54

Lecturer / MED
 Common Scaffold Hazards
• Falls from elevation, due to lack of fall
protection;

• Collapse of the scaffold, caused by instability or

overloading;

• Being struck by falling tools, work materials, or

debris; and

• Electrocution, principally due to proximity of the

scaffold to overhead power lines.
12.02.2009 N. Siva Shanmugam 55
Lecturer / MED
 Scaffolding
General Requirements
• Must be capable of supporting 4 times the maximum
intended load

• Do not alter or move while in use

• Protect workers on scaffolds from overhead hazards

• Higher than 10 ft. require guardrails, midrails, and

toeboard (wire mesh)

• Must be equipped with access ladder or equivalent

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Lecturer / MED
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Lecturer / MED