New England Roofing Industry PartnershipMaterials Handling, Rigging, & Cranes

Training ObjectivesAfter completing this unit, you will:

Know the basic OSHA requirements for the storage and disposal of materials.Know hazards in both mechanical and manual material handling.Understand hazards of rigging and crane operations and how to minimize them.Be aware of proper lifting techniques.

Materials Handling, Rigging & CranesSUBPARTS1 H,N,O

References29 CFR 1926.250; Subpart H, Materials Handling, Storage, Use, and Disposal

29CFR1926.500, Subpart N Cranes, Derricks, Hoists, Elevators, and Conveyors

29CFR1926.600, Subpart O Motor Vehicles, Mechanized Equipment, and Marine Operations

ANSI and ASME Standards Materials Handling, Rigging & CranesSUBPARTS2 H,N,O

Materials Handling DangersUnsafe storage and materials movement can lead to:

Back injuries (the number one cause of worker compensation claims).Struck-by or crushed by falling loads due to rigging failures.Electrocutions due to power line contact.Injury from falling materials.Injury from slipping, tripping and falling.Materials Handling, Rigging & CranesSUBPARTS3 H,N,O

Moving Materials by Hand: Back Facts8 out of 10 Americans will have a back injury during their life.Approximately 1 out of 3 injuries at work are back injuries.Personal pain and inconvenience can not be measured.Back injuries cost employers an estimated 10 billion dollars each year!Materials Handling, Rigging & CranesH, N, OSUBPARTS4

Preventing Back InjuriesYou can avoid back injuries by:Using mechanical aids.Using proper lifting techniques.Keeping in lifting shape.Working as a team when lifting.Knowing the truth about back belts.Materials Handling, Rigging & CranesH, N, OSUBPARTS5

Proper Lifting TechniqueBasic moves of a proper lift:Plan your lift.Use a wide-balanced stance.Get close to the load and keep it close to your body.Tighten your stomach muscles.Keep your back straight and use your legs.Turn with with your feet dont twist your back.Avoid lifting above shoulder height.Materials Handling, Rigging & CranesH, N, OSUBPARTS6

A Proper LiftMaterials Handling, Rigging & CranesH, N, OSUBPARTS7

Keeping in Lifting ShapeKeeping your stomach and back muscles strong can help prevent back injuries.Even if you dont work out in a gym, you can prevent back injuries.Strength and flexibility exercises should be done at least every other day. Materials Handling, Rigging & Cranes8SUBPART H,N,O

For Strength and FlexibilityMaterials Handling, Rigging & CranesH, N, OSUBPARTS9

Mechanical AidsUse hand trucks, dollies, carts, wheel barrows, and wagons whenever possible.Encourage management to include mechanical aids whenever possible.Materials Handling, Rigging & CranesSUBPARTS10 H,N,O

Mechanical AidsMaterials Handling, Rigging & CranesSUBPARTS11 H,N,O Slab carrying righere has eliminated bending over and has provided securenon-abrasive hand-holds.

Team LiftingUse team lifting for:Loads too heavy for one person.Loads too bulky for one person.Long loads such as pipes and rolls of material.Talk to your team-mate!Coordinate your lift!Materials Handling, Rigging & CranesH, N, OSUBPARTS12

What About Back Belts?The National Institute for Occupational Safety and Health (NIOSH) says:Back belts may not reduce stress on the back.May increase blood pressure and heart rate.May make you think you can lift heavier loads with a belt on and you could get hurt trying to.

If you want to wear a belt; dont wear it too tight and dont lift more than you usually would.Materials Handling, Rigging & CranesH, N, OSUBPARTS13

Material Storage Five basic rules for safe storage:

Keep total weight within the safe loading limits of the buildings floors.Keep passageways clear.

Control materials so they do not slide, fall, or collapse.

Provide cribbing for heavy loads on unstable surfaces.

Store materials away from traffic.Materials Handling, Rigging & CranesH,N, OSUBPARTS14

What Does OSHA Require?Basic requirements:

Dont put materials within 10 feet of roof edge.Dont store materials on scaffolds or runways.Keep materials at least 6 feet from floor openings and hoistways.Keep aisles clear.Keep work area free from tripping, fire, explosion, pest and vegetation hazards.Materials Handling, Rigging & CranesH,N,OSUBPARTS15

OSHA Also Requires Specific requirements:

Stack bagged materials by stepping back the layers and cross-keying the bags at least every 10 bags high.

Stack bricks no higher than 7 feet.

Taper masonry blocks back one-half block per tier for stacks above 6 feet.

Stack lumber on sills and on level solid ground - never exceed 16 feet high and always remove nails!Materials Handling, Rigging & CranesH,N,OSUBPARTS16

Setting Materials on the DeckWhat could happen to these stacked materials?Materials Handling, Rigging & CranesH,N,OSUBPARTS17

Disposal of Waste MaterialOSHA requirements:

Scrap lumber, waste and trash must be regularly removed from the work area.

Burning must meet local regulations.

Materials dropped more than 20 feet require a chute.

Solvent waste, oily rags, and flammables must be kept in fire resistant containers until removed.

If the waste is considered hazardous, your employer will have to follow federal, state, and local regulations.Materials Handling, Rigging & CranesH,N,OSUBPARTS18

Debris Chutes Objectives in using a chute: material control, dust control and protection of workers and bystanders note the differences here.Materials Handling, Rigging & CranesH ,N, OSUBPARTS19

Mechanical Materials HandlingDepending on the job, you might use or work around:BuggiesRoof HoistsConveyorsSkid-steers (Bobcats)Rough Terrain Forklifts (Lulls) CranesMaterials Handling, Rigging & CranesH, N, OSUBPARTS20

BuggiesWhat are the safety concerns while moving materials with these?Materials Handling, Rigging & CranesH, N, OSUBPARTS21

Mechanical Equipment on Flat RoofsWill the deck support the weight of the equipment?Has the equipment been inspected?Are all equipment guards in place?Is the operator trained?See Subpart C - .20(b)(4)Are all aware that the equipment is not to be operated outside warning lines due to the fall hazard? See Subpart M - Fall Protection -.502Closest approach is 6 feet parallel and 10 feet perpendicular to direction of travel.Materials Handling, Rigging & CranesH, N, OSUBPARTS22

Roof HoistsWhat are the manufacturersinstructions for set up & use?

What does OSHA say?Materials Handling, Rigging & CranesH, N, OSUBPARTS23

Roof Hoist Safety Concerns.552(a)(1) Compliance with manufacturers specifications and limitations..552(a)(2) Load capacity, hazard warnings and instructions must be posted..552(a)(3)(i-iv) Wire rope replacement criteria..552(a)(4) Hoist rope is to be installed in accordance with manufacturers instructions..501(b)(3) Fall Protection (Subpart M) in hoist area.Materials Handling, Rigging & CranesH, N, OSUBPARTS24

Is the Hoist Operator Protected?Materials Handling, Rigging & CranesH, N, OSUBPARTS25

Using Conveyors to Move MaterialsMaterials Handling, Rigging & CranesH, N, OSUBPARTS26

Safety Concerns In Conveyor UseSet up and used in accordance with the manufacturers instructions?

Guards in place on pinch points?

Power line clearances maintained?

Maintenance program in place?Materials Handling, Rigging & CranesH, N, O27SUBPART

Safety Concerns In Conveyor Use

No riders on conveyor!

.555(a) Means for stopping motor at operators station and start up warning.

.555(a)(5) Protection for workers below against falling objects.

.555(a)(7) Lockout/Tagout for maintenance.Materials Handling, Rigging & CranesH, N, O28SUBPART

Using Conveyors to Move MaterialsMaterials Handling, Rigging & CranesH, N, O29Power line clearance?

Back up alarm orsignal person?

Fall protection for roof workers?

SUBPART

Using Skid SteersIf on the roof will it take the load?

Is the operator qualified?

.20(b)(4) Again! Training is available from some manufacturers.Skid Steers are powerful, work in close quarters with people and are very quick, with large areas where the operator cannot see (the no-zone).

Is the work area adequately barricaded?Materials Handling, Rigging & CranesH, N, OSUBPARTS30

Skid Steer LoaderWhat do weneed to know about this operator?Materials Handling, Rigging & CranesH, N, OSUBPARTS31

Eye level 5 ft - 5 in above ground level6 111 76 3Operator sight distancesfrom eye level to groundVehicle:S-44 Bobcat3 14 1011 521 8The NO-ZONEMaterials Handling, Rigging & CranesH, N, O32SUBPARTS

Using Forklifts to Move MaterialsWhat do we need to know?Is the operator trained?See .602(d)Has the machine been inspected and properly maintained?

Is the backup alarm audible?

Are ground personnel protected?

Is the balanced load within capacity?

Are workers on roof protected from falls?Materials Handling, Rigging & CranesH, N, OSUBPARTS33

Getting Materials to the RoofHow can we protect against falls in these situations?Materials Handling, Rigging & CranesH, N, OSUBPARTS34

Using Forklifts What precautions need to be taken around the machines operating area?Materials Handling, Rigging & CranesH, N, OSUBPARTS35

Eye level 7 ft - 3 in aboveground level39 021 2Operator sight distancesfrom eye level to groundVehicle: R-14793 High Reach Fork Lift10 97 93 085 014 1018 2The NO-ZoneN, OTS Materials Handling, Rigging & Cranes

SUBPARTSH, N, O36

Platforms on ForkliftsIf you work off of some attachment it must:

(1) Be secured to forks. (2) Have a guardrail. (3) Have a Personal Fall Arrest System tie-off. (4) Used only while the operator is in the seat.

Materials Handling, Rigging & CranesH, N, OSUBPARTS37

Rigging and Crane SafetyRigging is the lines or cables used to lift and move materials by hoisting with a crane.A rigger is a skilled mechanic who prepares heavy equipment or loads of material for movement.Materials Handling, Rigging & CranesH, N, OSUBPARTS38

Examples of RiggingMaterials Handling, Rigging & CranesH, N, OSUBPARTS39

The Hazards of RiggingPossible contact with power lines.Rigging failures due to overloaded, improper, or defective rigging.Out of control loads.Being struck by the cranes swing radius.Materials Handling, Rigging & CranesH, N, OSUBPARTS40

Can Anyone Rig or Lift Loads?Rigging must be done under the supervision of a Competent Person.The crane operator must be highly qualified and certified.Improper rigging or unqualified operators can be deadly!Materials Handling, Rigging & CranesH, N, OSUBPARTS41

The Riggers DutiesThe rigger selects the rigging.The rigger sets-up the rigging.The rigger directs the lift.Materials Handling, Rigging & CranesH, N, OSUBPARTS42

OSHA Rigging RequirementsAll slings and hardware must be manufactured to meet demanding specifications which include safety factors.

All web or alloy chain slings must be clearly stamped, marked, or labeled, for capacity.

OSHA prohibits job made: slings, hooks, links, and fasteners formed from bolts.

Before each use all components must be inspected by a Competent Person.Materials Handling, Rigging & CranesH, N, OSUBPARTS43

Safe Working Load (SWL)The maximum load allowed on rigging is the Safe Working Load (SWL).

The sling may actually be able to hold 5 times the SWL.

A safety factor is the ratio of the ultimate strength to the SWL.

If a rigger exceeds the SWL, then they lose some of the safety factor.Materials Handling, Rigging & CranesH, N, OSUBPARTS44

Knowing Safe Working LoadsMaterials Handling, Rigging & CranesH, N, OSUBPARTS45

Sling AngleThe safest sling angles are greater than 450 from the horizontal.Materials Handling, Rigging & CranesH, N, OSUBPARTS46

Rigging the LoadBalanced load; sling angle >600Sling angles

Working Safely Around RiggingGeneral safety practices:Keep at least ten feet away from power lines up to 50 kV.Increase power line clearance distance by .4 per kV >50kVNever hoist loads over workers.Never stand too close or under a load.Never ride a load.Materials Handling, Rigging & CranesH, N, OSUBPARTS48

Working Safely Around Rigging2General safety practices:Use tag lines to control loads while lifting.Test lift the rigging.Use proper equipment, make sure it is marked, not home-made, and in good shape.Materials Handling, Rigging & CranesH, N, OSUBPARTS49

Crane Hand SignalsOnly a qualified rigger will give hand signals.Materials Handling, Rigging & CranesH, N, OSUBPARTS50

Basic Crane SafetyDo we have the right crane for the job?Is the operator qualified on that crane?Has the crane been inspected?Is the crane set up on solid ground?Full outriggers with cribbing?Level, with tires off the ground?Are power line clearances known?Do we know the weight of the load?Is everyone aware that a lift is being made?Materials Handling, Rigging & CranesH, N, OSUBPARTS51

Basic Crane Safety2Is the load properly rigged for a stable, vertical lift?Is there a high wind condition?Is the swing radius barricaded?Can a tagline be properly used?Can the crane make the lift and set the load without interference?Materials Handling, Rigging & Cranes H, N, OSUBPARTS52

Truck-Mounted Cranes/Boom TrucksMaterials Handling, Rigging & CranesH, N, OSUBPARTS53

Case Study: What went wrong?Two employees were moving structural steel building beams to a storage area. After setting the fourth beam on the crib, the signal man signaled the crane operator to pull the sling from around a cribbed structural beam which was set on its flange side. The second employee then attempted to remove the shackle from the beam when the swaged fitting of the sling apparently caught and caused the steel beam to roll off the cribbing, crushing the second employee.

Materials Handling, Rigging & CranesH, N, OSUBPARTS54

Materials Handling(1926.250 - 252)Common OSHA Citations:

.251(a)(1) Rigging equipment inspection and removal from service.

.251(e)(8) Synthetic Web Slings removal from service.

.252(a) Exterior drop chutes

.251(a)(4) Rigging capacity not marked not proof- tested.

How can the hazards addressed by these Standards best be corrected, controlled, or eliminated?

SUBPARTSH, N,OMaterials Handling, Rigging & Cranes55

Review QuestionsTrue or False?

Back injuries are the number one cause of worker compensation claims.Using proper lifting techniques, staying in shape, using mechanical aids, and team lifting are the best ways to avoid back injuries.Using a back belt almost always prevents a back injury.Anyone can hook-up a sling and be a rigger.Materials Handling, Rigging & Cranes H, N, OSUBPARTS56

Review QuestionsTrue or False?

Job-made slings, hooks, links, and fasteners formed from bolts are allowed if a Competent Person says so.Proper knots are permitted in web-slings.Slings should be inspected before each use and pulled from service if found defective. The safest sling angles are less than 45 degrees from the horizontal. Materials Handling, Rigging & Cranes H, N, OSUBPARTS57

Review QuestionsTrue or False?

Cranes and rigging must stay at least 10 feet from power lines. Materials can be stored within 10 feet of the roofs edge. Materials dropped more than 20 feet require a chute. Materials must be kept at least 2 feet from floor openings and hoistways.

Materials Handling, Rigging & Cranes H, N, OSUBPARTS58

Trainer's Notes:

Duration: One and One-Half Hours

Training Aids: 1. Back Belt.2. Box for lifting demonstration.3. Various new and proper slings.4. Various damaged rigging equipment.5. Operators manuals for various mechanical equipment.6. Crane or other equipment models.7. Video options: Crane Safety for Site Supervisors [Natl Audio Visual]

Trainer's Notes:

This Training module is designed to help you recognize and control some of the more common hazards associated with materials handling when doing construction work.

If you spot problems on your site, or unsure of what to do, notify your supervisor. Awareness of basic aspects of material movement is critical, whether its equipment inspection or operation, rigging a load, or lifting something by hand.Trainer's Notes:

The law requires your employer to be in compliance in addition to exercising due diligence and recognize good practice.

ANSI American national Standards InstituteASME American Society of Mechanical Engineers

Trainer's Notes:

Review the dangers.

Emphasize the fact that materials handling occurs from the beginning of the job to the end and whether mechanical or manual, holds a potential for many injuries.

Trainer's Notes:

Review the facts with the participants.

Ask for a show of hands concerning back problems.

Trainer's Notes:

Review the components with the participants.

Trainer's Notes:

Review the components with the participants.

Trainer's Notes:

Review the steps a second time while you demonstrate with the box.

Stress the importance of using the leg muscles, keeping the back straight, and keeping the load close to the body.

Trainer's Notes:

Review the components with the participants.

Stress how much of a difference strong stomach muscles can make when trying to prevent back injuries.

Trainer's Notes:

Review the exercises with the participants.

1. Knee to Chest Raise: Hold ten seconds repeat ten times.2.Wall Slide: Slide to a sitting position, hold for 3 minutes.3. Press-up: Hold for ten seconds, repeat ten times.4. Round and Arch: round your back up and touch your chin to your knees.5. Lower back Stretch: Hold for ten seconds.6. Back Stretch: Press your lower back to the floor.

Trainer's Notes:

Ask the participants to name some of the more common mechanical aids they see around the work site.

Trainer's Notes:

Ask the participants to name some of the more common mechanical aids they see around the work site.

Trainer's Notes:

Ask them for examples of the type of materials they might team lift.

Trainer's Notes:

Review the NIOSH findings concerning back belts.

Ask the participants if any of them have ever worn a back belt.

Trainer's Notes:

Ask the participants which one of the five they think causes the most problems on their work site.

Trainer's Notes:

Ask the participants for stories concerning materials blowing or falling off of roof edges.

Trainer's Notes:

Review the specific requirements.

Ask the participants if they can think of any others.

Trainers Notes:

Use this or similar photographs to emphasize the importance of minimizing both fall hazards and falling material hazards in these situations.

Note also that the flat roof situation does not change the rule. Putting material outside the warning line may seem better as it is out of the way, it is not allowed and would be a citation.Trainer's Notes:

Getting rid of the trash is always a problem and housekeeping directly or indirectly is said to contribute to one-third of injuries.Trainers Notes:Trainers Notes:

Get a discussion going about all the different kinds of equipment that can get involved on a large roof job.Trainers Notes:

Trainers Notes:

Discuss use and movement of equipment on roofs beginning with the assessment of load-bearing capacity. Include inspection/maintenance/operation in accordance with the manufacturer (IAW) AND COMMON SENSE.Make sure all understand 6 ft/10 ft. rule about approach to the edge. Use OSHA interpretation for reference.Trainers Notes:

Use an actual manufacturers manual and go over set up procedure and safety precautions along with (again) COMMON SENSE

It is important to mention the counter weights required on these hoists must be as proscribed by the manufacturer and NOT construction, roofing materials.Trainers Notes:Trainers Notes:

This should be obvious, but maybe it isnt to the audience at hand. Discussion as necessary, especially if the reaction indicates that being tied off while operating the hoist is a hassle and/or gets in the way. Trainers Notes:Trainers Notes:Trainers Notes:Trainers Notes:Trainers Notes:

Ask who has operated skid steers. Are they aware of the no-zone? Has anyone ever attempted to climb out of the machine with bucket raised?Skid steers are (for now) exempt from back up alarm requirement unless original equipment as manufactured (OEM) or, if you install one, it must be working.Local regulations may require license, eg. Massachusetts does require one.Trainers Notes:Trainers Notes:

Explain the No-Zone Concept as the area around machinery where the operator cant see a pedestrian on the ground. Anyone in the shadowed area cant be seen.Trainers Notes:

Massachusetts requires a participants C Hydraulics License.

OSHA requires certification that the operator has been trained on the machine he is operating. This requirement is found in 29CFR1910.178 (General Industry) and is referred to in 29CFR1926.602(d).

Trainers Notes:

Stress that getting the material off the lift, regardless of what kind, can be a fall hazard situation.Trainers Notes:

Emphasize the importance of protecting ground personnel, building occupants, and the visiting public while replacing a roof.Trainers Notes:

Same as for the Skid Steer slide each machine is different, but the operators blind spots are significant.Trainers Notes:

If the manufacturer says the machine is NOT to be used to lift personnel, then it is a violation to do so, regardless of the nature of the platform, and OSHA will cite.

Whatever platform is used , it must be approved by a qualified person for use on that machine.

Trainer's Notes:

Trainer's Notes:

Ask the participants what is the most common type of rigging equipment is used at their work site.

Ask them if they have ever seen home-made rigging.

Having actual used rigging here works better than pictures

Trainer's Notes:

Review the slide with participants.

Ask them if they can think of any other hazards.

Trainer's Notes:

Ask them for the definition of a Competent Person.

Review the definition with the participants.

Ask them why rigging must be supervised by a competent person.Trainer's Notes:

Review the riggers duties with the participants.

Trainer's Notes:

Ask them why OSHA will not allow job-made slings and other components.

Explain that the competent person must identify slings for a written inspection record and get rid of defective slings right away.

Trainer's Notes:

Explain that the rigger can never exceed the SWL of a given sling.

Explain that safety factors are applied in any situation where you want a margin of safety.

Trainer's Notes:

Explain that OSHA provides tables for riggers showing rated capacities for all rigging equipment. Have participants look up chart in standards. Explain that Mechanical Spliced (MS) slings have a higher rating than Hand Tucked Spliced (HT) slings.

On chart: HT = Hand- tucked Splice, MS = Mechanical Splice

The capacities shown must never be exceeded.

Most tables give the safety factor assigned to the specific type of sling.

Have the participants find these tables in the OSHA Standards.Trainer's Notes:

Explain that sling angles are crucial in determining safe working loads.

Explain that they should rarely see sling angles less than 45 degrees.

Remind them that the steeper the angle, the less stress is placed on the rigging.

Trainers Notes:

Present the question to your audience: What is wrong here?Trainer's Notes:

Review the safety practices with the participants.

Ask the participants of they can think of any other basic safety guidelines.

Emphasize the importance of never working under a suspended load, not even for a few seconds!

Trainer's Notes:

Review the guidelines with the participants.

Ask the participants of they can think of any other basic safety guidelines.

Emphasize the importance of never working under a suspended load, not even for a few seconds!

Trainers Notes:

The ANSI Hand Signal Chart should be posted near the crane lift area.Trainers Notes:

Even though most roofers would not be involved in crane setup or operation they still should be aware of the basic principles.

Note that power line contact continues to be the number one cause of crane-related fatalities.Trainers Notes:

Ask the participants Where is the best place to stand during a crane lift? Best answer: Stand behind the load, closer to the crane and to the side. That way, a swing or sudden load radius change would not result in swinging the load into the person or crush them between the load and the building, between the load and other material or between the load and the crane.Trainers Notes:Trainer's Notes:

Read the following fire related case study to the participants.

Ask what kind of hazard caused the fatality.

Ask them to name things that should have been done to prevent the fatality.

Make a list of the identified precautions.Trainer's Notes:

Review the Top Four Serious Citations

Ask the participants how each of the four hazards could be abated.

Trainers Notes:

Answers:1. TRUE2. TRUE3. FALSE back belts may cause moe harm than good.4.FALSE rigging must be done under supervision of Competent person by a trained rigger.

Trainers Notes:

Answers:5. FALSE prohibited by OSHA.6. FALSE7. TRUE8. FALSE safest sling angles are greater than 45 degrees from sling angle.

Trainers Notes:

Answers:9. TRUE10. FALSE11. TRUE12. FALSE 6 feet