MATERIAL HANDLINGMATERIAL HANDLING

Safe Rigging PracticesSafe Rigging Practices

Know How to Do It Right!Know How to Do It Right!

Then Do It Right!Then Do It Right!

THE NEED FOR MATERIALS HANDLING

• Required to handle materials in office, home, site, etc.

• 25% of total accidents are due to materials handling

• Materials handling from Prehistoric times

PRE-HISTORIC TIME MATERIALS HANDLING

The gigantic pyramid at Giza near Cairo (Egypt) built about 2700 B.C. which is 764 ft square at the base and 480 ft. high. About 2(1/3) million stones from 2 to 30 tons in weight each were transported from the quarry to the Nile River at the flood season, ferried across the river on rafts, dragged from river to the site of the pyramid and piled up on each other to a height of a 40 storied building. It is believed that a ramp was built up on one side of the pyramid and the stones were dragged up the slope by slaves working in teams.

MATERIAL HANDLINGMATERIAL HANDLING

WE SHALL DISCUSS ABOUT

• Material Handling Problems.

• Ropes.

• Rigging and safe rigging practice.

•“D” Shakle.

•Case Study.

MATERIAL HANDLING MATERIAL HANDLING PROBLEMSPROBLEMS

LEAD TO INJURIES DURING THE COURSE OF MATERIALS HANDLING e.g.

• CUT INJURIES

• BRUISES

• SPRAIN & STRAIN

• CRUSH INJURIES

• FRACTURE

MATERIAL HANDLING MATERIAL HANDLING PROBLEMS….PROBLEMS….

THESE INJURIES ARE DUE TO • UNSAFE WORKING PRACTICES

• IMPROPER LIFTING

• CARRYING TOO HEAVY LOADS MANUALLY

• INCORRECT GRIPPING

• NOT USING PPE

• FAILING TO HAVE PROPER FOOT AND HAND CLEARANCES, ETC.

ROPES ROPES

ROPES….ROPES….

• FIBRE ROPES

• WIRE ROPES

COMMONLY USE OFCOMMONLY USE OF

FIBRE ROPES USAGEFIBRE ROPES USAGE

• For light loads

• For construction

• Painting Jobs

• Marine Works

• Coconut Coir Rope

• Cotton Rope

• Jute Rope

• Manila Rope

FIBRE ROPES TYPESFIBRE ROPES TYPES

FIBRE ROPESFIBRE ROPES10 USEFULL TIPS ON HANDLING CARE & USE OF FIBRE ROPE

1. It should be hung up in loose coils on large diameter wooden pegs.

2. It should be kept away from heat sources.

3. It should be kept away from acid fumes.

4. For opening a new coil of rope, the end of the rope should be at the bottom of the core or eye and the end should be pulled out through the core. If this is not followed kinks will be formed which will damage the rope.

5. When used as slings should not be passed over sharp edges. Proper padding should be used.

6. Strength of Fibre Ropes

1. At 60 ° -- 86 % of their strength when vertical

2. At 45 ° -- 71% of their strength when vertical

3. At 30 ° -- 50% of their strength when vertical

7. Rope should not be dragged on ground to avoid abrasive action.

8. Fibre rope should be inspected thoroughly before and after use.

10 USEFULL TIPS ….

9. When a rope is condemned, it should be destroyed at once to cut up into short hand lines so that it cannot again be used for hoisting.

10. If the rope is used for lifting loads with pulley blocks, it is advisable to reverse the ends periodically so that the rope is worn out more or less uniformly through-out.

10 USEFULL TIPS ….

WIRE ROPESWIRE ROPES

A Wire Rope is usually made up of a number of wires laid left or right handed into a strand and number of wires laid left or right handed into a strand and number of strands, usually 6 or 8, laid right or left handed round a hemp rope center to form the wire rope, or steel cable as it is generally called.

WIRE ROPESCONSTRUCTION OF WIRE ROPES

WIRE ROPESWIRE ROPES

There are 4 different ways of laying the wire rope.

1. Right-lay, regular-lay

2. Left-lay, regular-lay

3. Right-lay, lang-lay

4. Left-lay, lang-lay

WIRE ROPESWIRE ROPES

There are a different possible constructions of wire rope.

(Number of Strands) X (Number of Wires in a Strand)

Example:

6X7 6 Strands and 7 Wires in each strand

6X19 6 Strands and 19 Wires in each strand

6X37 6 Strands and 37 Wires in each strand

CONSTRUCTION OF WIRE ROPES:

WIRE ROPESWIRE ROPES

6X7 (Regular Lay) Guys, Suspension Ropes, etc.

6X19 (Regular lay with hemp core) Slings, elevators, etc.

6X19 (Regular lay with steel core) Blast furnace bell hoist

6X37 (Regular lay with hemp core) Overhead Cranes, Mill Hoist, etc.

6X37 (Regular lay with steel core) Hot Metal Cranes, Blast Furnace bell, etc.

COMMON USE OF VARIOUS CONSTRUCTION OF WIRE ROPES

•BROKEN WIRES

•WORN OUT WIRES

•REDUCTION IN ROPE DIA.

•ROPE STRETCH

•BIRD CAGE

•KINKS

•CORE PROTRUSION

WIRE ROPESINSPECTION OF WIRE ROPES

WIRE ROPES

BROKEN WIRES

•6 OR MORE BROKEN WIRES IN ONE LAY •3 OR MORE BROKEN WIRES IN ONE STRAND IN ONE LAY•MORE THAN 5% IN ANY LENGTH OF 10 DIAMETERS

WIRE ROPES

•1mm FOR ROPE DIA UPTO 19mm

•1.5mm FOR ROPE DIA UPTO 22-28mm

•2mm FOR ROPE DIA UPTO 32-38mm

REDUCTION IN ROPE DIA.

REPLACE THE WIRE ROPE IF THE DIA REDUCES BY

ROPE STRETCH

150 mm PER 30m LENGTH OF SIX STRANDED ROPE

WIRE ROPESBIRD CAGES

L&T-HSEL&T-HSE

WIRE ROPESCORE PROTRUSION

INSPECTION PROCEDURE

Coding

Once in a month

Coloring

Announce

Record

‘U’ CLAMPS

DISTANCE BETWEEN THE ROPE CLIPS = 6 X Dia.

CLIPS AND SPACING FOR SAFE APPLICATION

Rope Diam. In.

Minimum No. Clips for Each Rope End

Spacing of Drop Forged Clips

in.

1/2 3 35/8 3 3.3/43/4 4 4.1/27/8 4 5.1/41 5 6

1.1/8 6 6.3/41.1/4 6 7.1/21.1/2 7 9

RIGGING

SLINGSTENSION ON SLINGS

T = W x L H x N

T = TENSION

W = WEIGHT OF THE LOAD

L = LENGTH OF SLING

N = NO. OF SLING LEGS

SLINGSTENSION ON SLINGS

If L is greater than S then sling angle is OK

SLINGS - HITCHESBASKET HITCH

SLINGS - HITCHESCHOKER HITCH

RIGGING PRECAUTIONS

Weight of ALL loads

Allowances for unknown factor

Capacity of equipment &

marked

RIGGING PRECAUTIONS

Rapid swinging increases the

stress

Avoid bending splice/ eye section

around the corners.

Avoid dragging of sling beneath

loads

Sharp Bends , Pinching &

crushing –avoid for slings –

provide packing- curve 7 lays

RIGGING PRECAUTIONS

Never wrap a wire rope

around a hook.

RIGGING PRECAUTIONS

Suspended loads –securely slung & properly

balanced

Tag Line

Safely landed & blocked

Lifting beams –SWL marked.

Hoist rope – don’t wrap it around the load.

Multiple part lines –don’t twistSlack rope condition –ensure it is seated properly on the drum

Stand clear of the load

LIFTING

SHACKLESINSPECTION OF D-SHACKLES

•SAFE WORKING LOAD MISSINGOR UNREADABLE

•IDENTIFICATION MISSING•OR UNREADABLE

•INCORRECT PIN

•DAMAGED THREAD ON PIN OR IN TAPPED EYE

•DISTORTED BODY

•WORN OUT BODY OR PIN

•NICKS, GOUGES, CRACKS,•CORROSION

DEFECTS:

L&T-HSEL&T-HSE

W s = 2.2W d Dmin emin

22 49 14 16 32 1 1.25 1.6

32 70 19 22 44 2 2.5 3.2

50 110 30 35 70 5 6.3 8

70 154 43 50 100 10 12.5 16

90 198 54 62 124 16 20 25

100 220 60 69 138 20 25 32

JAW INSIDE WIDTH

INSIDE LENGTH

BODY MATERIAL DIAMETER

PIN DIAMETER

EYE OUTSIDE

DIAMETER

SAFE WORKING LOAD TONNES

GRADE 30 GRADE 40 GRADE 63

Shackle

L&T-HSEL&T-HSE

L&T-HSEL&T-HSE

Observation Observation • Alignment of the boom top and the centre of the

load was not proper during lifting operation which

caused swinging of the load

• Before lifting of load the top of the boom and the centre of the load to be aligned properly to avoid swinging.

• Experienced Signal man should facilitate the same

RemedyRemedy

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L&T-HSEL&T-HSE

L&T-HSEL&T-HSE

Observation Observation • Defective storing. Plates were kept in vertically

inclined position by means of make shift arrangement

• Work method / Job Safety analysis not prepared

RemedyRemedy• Suitable stands to be used for keeping plates

vertically

• Work method statement / Job Safety analysis to be prepared and implemented

L&T-HSEL&T-HSE

L&T-HSEL&T-HSE

Observation Observation • Used worn threaded D-shackle• Checking of casing pipe and operation of the rig

were simultaneous• The rig is operated inside the excavation. No space

to run off• Routine checkup not made before starting fresh pile• Over confidence / carelessness of both rigger as well

as rig operator• Though the pin of D-shackle released from its

position is happened repeatedly none has given solution to avoid its recurrence

L&T-HSEL&T-HSE

• Routine visual check-up should be made before starting each pile by job engineer

• While checking welded joints of the casing pipe, the rig hammering should be paused

• Worn threaded D-shackle shall be discarded by means of lifting tools n tackles check, colour code etc.

• Frequent pep talk and toolbox meeting to be conducted

RemedyRemedy

L&T-HSEL&T-HSE

L&T-HSEL&T-HSE

• Use of improper sling

• Tag line / guiding ropes were not used for guiding the load from a safe distance, from crane

• The plate was tied with a single sling. In order to compensate the sling length, plate width and ground clearance the boom of Hydra was lifted to almost full, leading to just a gap of approx. 1 foot between the rear end of plate and front wheel of Hydra

• The victim was walking in front of crane holding the rear end in very close proximity to the wheel, at the left side of the road

ObservationObservation

• Proper sling to be used

• The use of guide ropes for controlling the load while travelling with crane; in order to keep workmen away from the crane range and load, should be ensured

• Worker should not be very close to the crane while walking along with the load

RemedyRemedy

L&T-HSEL&T-HSE