Material Handling in the Roofing Industry

Material Handling in the Material Handling in the Roofing IndustryRoofing Industry

Manual Material Handling

Forklifts / Roof Buggies

Storage & Disposal

Crane & Rigging

Mechanical Hoist / Derrick

DANGERS OF MATERIAL DANGERS OF MATERIAL HANDLINGHANDLING

Unsafe storage and material Unsafe storage and material movement can lead to:movement can lead to:

Back injuries (the number Back injuries (the number one cause of worker one cause of worker compensation claims).compensation claims).

Struck-by or crushed by Struck-by or crushed by falling loads due to rigging falling loads due to rigging failures.failures.

Electrocutions due to power Electrocutions due to power line contact.line contact.

Injury from falling materials.Injury from falling materials. Injury from slipping, tripping Injury from slipping, tripping

and falling.and falling. Property DamageProperty Damage Equipment FailureEquipment Failure

Crane & Rigging SafetyCrane & Rigging Safety

What exactly does we need to What exactly does we need to know about crane safety?know about crane safety?

Those working with & around cranes Those working with & around cranes should be aware of;should be aware of; Common causes of crane incidentsCommon causes of crane incidents How to recognize improper crane setupsHow to recognize improper crane setups Electrical hazardsElectrical hazards Understanding of crane limitations due to Understanding of crane limitations due to

angle, wind, and weightangle, wind, and weight Hand signalsHand signals OSHA & Captive inspection requirementsOSHA & Captive inspection requirements

http://www.liveleak.com/view?i=3e8_1190600875

Common Causes of Crane Common Causes of Crane FatalitiesFatalities

Electrocution44%

RiggingFailure

15%Load Handling14%

Operator Error 7%

Overload 7%

Dismantling Boom 5%

Wire Rope Failure 3%

Miscellaneous 3%

Struck by Crane 3%

Common Causes of Crane Common Causes of Crane AccidentsAccidents

Support Failure31.5%

High Wind1.6%

Machinery &Structural Failure

11.2%

Failure to Use Outriggers

22.6%

Operator Error33.1%

55% of crane accidents are due to improper set up

(Support failure, failure to use outriggers)

Crane SetupCrane Setup

Outriggers in use and on stable ground

Outrigger pads in use when necessary

The crane shall be uniformly level within one percent of The crane shall be uniformly level within one percent of

level grade and located on firm footing. 1 Degree out of level grade and located on firm footing. 1 Degree out of

level can reduce rated capacities by as much as 30%!!level can reduce rated capacities by as much as 30%!!

Boom Length and

Lift Radius 1% 2% 3%

Chart Capacity Lost When Crane Out of Level

Short Boom, Minimum Radius.

Short Boom, Maximum Radius

Long Boom, Minimum Radius

Long Boom, Maximum Radius

10% 20% 30%

8% 15% 20%

30% 41% 50%

5% 10% 15%



(a)(9) Accessible areas within (a)(9) Accessible areas within the swing radius of the rear of the swing radius of the rear of the rotating superstructure of the rotating superstructure of the crane, either permanently the crane, either permanently or temporarily mounted, shall or temporarily mounted, shall be barricaded in such a be barricaded in such a manner as to prevent an manner as to prevent an employee from being struck employee from being struck or crushed by the crane.or crushed by the crane.

Crane SetupCrane Setup (a)(15) Except where electrical (a)(15) Except where electrical

distribution and transmission lines distribution and transmission lines have been deenergized and visibly have been deenergized and visibly grounded at point of work or where grounded at point of work or where insulating barriers, not a part of or an insulating barriers, not a part of or an attachment to the equipment or attachment to the equipment or machinery, have been erected to machinery, have been erected to prevent physical contact with the prevent physical contact with the lines, equipment or machines shall be lines, equipment or machines shall be operated proximate to power lines operated proximate to power lines only in accordance with the following:only in accordance with the following:

- For lines rated 50 kV. 10 feet;

- For lines rated over 50 kV., 10 feet plus .4 inches for each kV. over 50 kV.

A person shall be designated to observe

clearance!

Crane Limitations & Load ChartsCrane Limitations & Load Charts

Rated Load Charts must be in Rated Load Charts must be in the crane.the crane.

Refer to shipping ticket or other Refer to shipping ticket or other documentation for weightdocumentation for weight

Ensure load is within load chart Ensure load is within load chart rating for boom length and load rating for boom length and load radius of craneradius of crane

Crane is rated by the Crane is rated by the maximum weight it will lift maximum weight it will lift at a minimum radius and at a minimum radius and minimum boom length – the minimum boom length – the further from its centerpoint, further from its centerpoint, the less it will liftthe less it will lift

Crane Limitations & Load ChartsCrane Limitations & Load Charts- Operators must be aware of different load

charts, and reductions.

- Numerous reductions must be made for items including;- Hook block

- Headache ball

- Jib

- Rigging

- Etc.

- Load charts differ if;- hoisting over the front or side

- On rubber, half outrigger, full outrigger

Load Example – Load Example – 65 ton crane 65 ton crane

Will lift 130,000 pounds at 10 feet from the Will lift 130,000 pounds at 10 feet from the center pin of the cranecenter pin of the crane

Based on level surface, no wind, and Based on level surface, no wind, and outriggers fully extendedoutriggers fully extended

At 25 feet from the center pin with an 82 foot At 25 feet from the center pin with an 82 foot boom, the capacity is only 47,150 poundsboom, the capacity is only 47,150 pounds

At 80 feet from the center pin, the capacity is At 80 feet from the center pin, the capacity is only 8,560 poundsonly 8,560 pounds

ALL WEIGHTS ARE BEFORE REDUCTIONSALL WEIGHTS ARE BEFORE REDUCTIONS

Grove RT865 65 Ton Grove RT865 65 Ton CapacityCapacity

ON OUTRIGGERS FULLY EXTENDED —

OVER THE FRONT

BEFORE REDUCTIONS!

• An illustration of the signals must be posted at the job site.

• The operator should have one “signal man” and point of contact. The only signal anyone can give is emergency stop.

Hand SignalsHand Signals

OSHA & CAPTIVE INSPECTION OSHA & CAPTIVE INSPECTION REQUIREMENTSREQUIREMENTS

OSHA: OSHA: Competent person inspect all machinery Competent person inspect all machinery

prior to each use, and prior to each use, and during use, during use,

Any deficiencies shall be repaired, or defective parts Any deficiencies shall be repaired, or defective parts replaced, replaced, before continued use.before continued use.

HC&A strongly recommends that an inspection log HC&A strongly recommends that an inspection log be maintained in every cranebe maintained in every crane

Safety Representatives should also be aware of certain inspection points;

Outriggers, tires properly inflated, proximity to electrical lines, cable condition, leaky or worn hoses, correct spooling, other obvious

deficiencies


• Although many in the captive who own cranes have already implemented this item, the LCC felt it was critical to make it mandatory.

• 3RD Party inspections;

• Provide comfort to the company & operator in knowing the crane is in good repair.

• Enhances the operators knowledge of crane & components

• Meets credentials for GC’s and Owners who now mandate this documentation.

SSOP: ANNUAL 3RD PARTY CRANE INSPECTIONS

Current OSHA regulations do very little to address operator Current OSHA regulations do very little to address operator training. training.

OSHA’s new proposed regulations provide four options for OSHA’s new proposed regulations provide four options for operator certification;operator certification;

1. Certification through an ‘accredited’ third party agency1. Certification through an ‘accredited’ third party agency 2. Qualification through an audited employer testing program2. Qualification through an audited employer testing program 3. Qualification through the military3. Qualification through the military 4. Qualification by a state or local licensing authority4. Qualification by a state or local licensing authority

Crane SSOP’S: 1. Operators working in states that require licensing must be licensed. (MANDATORY)

2. Operators working in states that do not require licensing must receive a minimum of 8-Hours Mobile Crane Awareness Training every two years. (MANDATORY)

3. Operators should obtain Certified Crane Operator certificates from the NCCCO. This requires specific training and testing from authorized training agencies. (RECOMMENDED)


CERTIFIED CRANE OPERATOR CERTIFIED CRANE OPERATOR (CCO) TRAINING & TESTING(CCO) TRAINING & TESTING

UNITED CRANEX INC.UNITED CRANEX INC.

Location: Location: Lakewood, NJ Lakewood, NJ Length of Class:Length of Class: 3-4 Days3-4 Days Cost:Cost: $950.00 Per Person $950.00 Per Person

(includes (includes written exam)written exam)

Practical Exam: Practical Exam: $260.00 $260.00 Success Rate:Success Rate: Claim its at 80% Claim its at 80%

($165.00 ($165.00 for for retest)retest)

Class Size: Class Size: Minimum 14 ee’s, Minimum 14 ee’s, maximum 20 maximum 20

ee’see’sAgain, this certification is recommended only, though there is no better way to ensure your operators have sufficient training, and upcoming OSHA legislation

will likely make this mandatory for crane operators in the future.

Other Crane Safety IssuesOther Crane Safety Issues When loading a roof, have pallets or other heavy material When loading a roof, have pallets or other heavy material

set on beams to disperse weight. set on beams to disperse weight.

Be careful when stockpiling debris to be unloaded by Be careful when stockpiling debris to be unloaded by cranes, both for weight distribution and damages by wind-cranes, both for weight distribution and damages by wind-blown materials.blown materials.

The area below a swinging load must be kept clear of The area below a swinging load must be kept clear of employees and pedestrians. employees and pedestrians.

Hard hats are required of all involved in crane operations.Hard hats are required of all involved in crane operations.

Tag lines should be used for awkward shaped loads or in Tag lines should be used for awkward shaped loads or in windy situations.windy situations.

The Riggers ResponsibilitiesThe Riggers Responsibilities

Rigger

Crane Operator

The Users ResponsibilitiesThe Users Responsibilities

1. Utilize Appropriate Rigging Suitable For Overhead Lifting.

2. Utilize The Rigging Gear Within Industry Standards And The Manufacturers Recommendations.

3. Conduct Regular Inspection And Maintenance Of The Rigging Gear.

Three Types of SlingsThree Types of Slings

1.1. Chain SlingsChain Slings

2.2. Wire Rope SlingsWire Rope Slings

3.3. Synthetic Web SlingsSynthetic Web Slings

Frequency of Sling Frequency of Sling InspectionsInspections

1926.251 – Rigging equipment for material 1926.251 – Rigging equipment for material handling shall be inspected handling shall be inspected prior to use on prior to use on each shift and as necessary during its each shift and as necessary during its

use to ensure use to ensure that it is safethat it is safe. .

- Damaged or defective slings shall be - Damaged or defective slings shall be immediately removed from service.immediately removed from service.

DefinitionsDefinitions

Hitch “Basket”Hitch “Basket” - loading with the sling passed - loading with the sling passed under the load and both ends on the hook or a under the load and both ends on the hook or a single master link.single master link.


Hitch “Choker”Hitch “Choker” – loading with the sling passed through – loading with the sling passed through one eye and suspended by the other.one eye and suspended by the other.


Hitch “Vertical”Hitch “Vertical” – loading with the the load – loading with the the load suspended vertically on a single part or leg of the suspended vertically on a single part or leg of the sling.sling.

Wire Rope CapacitiesWire Rope Capacities

Sling CapacitiesSling CapacitiesWhichever sling is used, the rigger must understand the Whichever sling is used, the rigger must understand the

effects sling angles presenteffects sling angles present

SLING CAPACITY DECREASES, AS THE SLING ANGLE DECREASES

60

45

30

90 4

56030

Rated Lifting CapacitiesRated Lifting Capacities

• ALL SLINGS MUST HAVE THE RATED HOIST CAPACITIES LISTED AND LEGIBLE.

• Synthetic slings will have a sewn in label.

• Cable & chain rigging will have attached capacity tags.

Without legible hoisted capacities, the sling cannot

be used!

Wire Rope ConstructionWire Rope Construction

Wire Rope Sling Inspection ItemsWire Rope Sling Inspection Items

Three randomly distributed Three randomly distributed broken wires in one strand, in broken wires in one strand, in one rope lay.one rope lay.

Wear or scraping of 1/3 the Wear or scraping of 1/3 the original diameter of outside original diameter of outside individual wires.individual wires.

Kinking, crushing or any damage Kinking, crushing or any damage resulting in distortion of the wire resulting in distortion of the wire rope.rope.

End attachments that are End attachments that are cracked, worn or deformed.cracked, worn or deformed.

Corrosion of the rope or end Corrosion of the rope or end attachments.attachments.

Wire Rope Slings Remove From Service

If these happen, remove the wire rope sling from service

Crushing

KinkingBird Caging

Wire Rope DamageWire Rope Damage

A permanent kink in a wire rope sling causes loss of strength.

Discard the sling!

Remove From Service???

Synthetic SlingsSynthetic Slings

Remove from service if any Remove from service if any of these are present:of these are present: Acid or caustic burnsAcid or caustic burns Melting or charring of any Melting or charring of any

part part Snags, punctures, tears Snags, punctures, tears

or cutsor cuts Broken or worn stitchesBroken or worn stitches Distortion of fittingsDistortion of fittings STRETCHING!!STRETCHING!!

Synthetic Web Slings -Synthetic Web Slings -Remove from ServiceRemove from Service

Heat Damage

Red your dead…..isn’t always accurate.

OSHA will still issue citations if they believe a sling has been critically

damaged. A puncture, cut, or other types of damage which would require a sling to be removed from service,

may not expose the color wear indicators inside the strap.

Safe Usage PracticesSafe Usage Practices

Slings should be stored Slings should be stored off of the floor and hung off of the floor and hung on racks whenever on racks whenever possible in a clean, dry possible in a clean, dry environment.environment.

Never drag slings across the Never drag slings across the floor. floor.

► Hands and Fingers shall not Hands and Fingers shall not be placed between the sling be placed between the sling and the load while the sling and the load while the sling is being tightened around is being tightened around the load.the load.

Safe Usage PracticesSafe Usage Practices

TRAIN EMPLOYEES TO TRAIN EMPLOYEES TO “TEST LIFT” AND “TEST LIFT” AND STAND CLEAR OF STAND CLEAR OF LOAD DURING INITIAL LOAD DURING INITIAL LIFT.LIFT.

Cranes not directly over Cranes not directly over loads will cause the load loads will cause the load to swing upon hoisting, to swing upon hoisting, possibly striking those possibly striking those unsuspecting. STAND unsuspecting. STAND CLEAR!!CLEAR!!

Safe Usage Practices (Cont.)Safe Usage Practices (Cont.) Never shock load slings.Never shock load slings.

Keep loads balanced to Keep loads balanced to prevent overloading prevent overloading slings.slings.

Always lift loads Always lift loads straight up.straight up.

Never rest a load on a Never rest a load on a sling, or pinch a sling sling, or pinch a sling between the load and between the load and the floor.the floor.

A sling should not be A sling should not be pulled from under a pulled from under a load when the load is load when the load is resting on the sling.resting on the sling.

Make sure the hook is Make sure the hook is always over the center always over the center of gravity of the load of gravity of the load before lifting it.before lifting it.

Do not force or Do not force or hammer hooks or hammer hooks or chains into position.chains into position.

Sharp edges can slice a sling in two without warning as the load is

tensioned. Use softeners or padding on corners.

Rigging Protection FromRigging Protection FromCutting or SlippingCutting or Slipping

Roof HoistsRoof Hoists

What are the manufacturer’sinstructions for set up & use?

What does OSHA say?

.552(a)(1) Compliance with .552(a)(1) Compliance with manufacturer’s specifications and manufacturer’s specifications and limitations.limitations.

.552(a)(2) Load capacity, hazard .552(a)(2) Load capacity, hazard warnings and instructions must be warnings and instructions must be posted.posted.

.552(a)(3)(i-iv) Wire rope replacement .552(a)(3)(i-iv) Wire rope replacement criteria.criteria.

.552(a)(4) Hoist rope is to be installed .552(a)(4) Hoist rope is to be installed in accordance with manufacturer’s in accordance with manufacturer’s instructions.instructions.

.501(b)(3) Fall Protection (Subpart M) .501(b)(3) Fall Protection (Subpart M) in hoist area.in hoist area.

Roof HoistsRoof Hoists

Is the Hoist Operator Is the Hoist Operator Protected?Protected?

Common problems include;

Lack of fall protection, improperly sized or damaged rope, improper counterweights.

BuggiesBuggies

What are the safety concerns while moving materials with these?

BuggiesBuggies

• Guards must be in place

• Cannot be used outside of warning lines or in areas under the supervision of a safety monitor

• Speed control

• Use caution when refueling!

Basic requirements:Basic requirements:

Don’t put materials within 10 feet of roof edge.Don’t put materials within 10 feet of roof edge.

Don’t store materials on scaffolds or runways.Don’t store materials on scaffolds or runways.

Keep materials at least 6 feet from floor Keep materials at least 6 feet from floor openings and hoistways.openings and hoistways.

Keep aisles clear.Keep aisles clear.

Keep work area free from tripping, fire, Keep work area free from tripping, fire, explosion, pest and vegetation hazards.explosion, pest and vegetation hazards.

Disposal of Waste MaterialsDisposal of Waste Materials

Disposal of Waste MaterialsDisposal of Waste Materials Use an enclosed Use an enclosed

chute when you drop chute when you drop material more than material more than 20 feet outside of a 20 feet outside of a building,building, or a crane, or a crane, forklift or other forklift or other controlled liftcontrolled lift

If you drop debris If you drop debris through holes in the through holes in the floor without chutes, floor without chutes, enclose the drop area enclose the drop area with barricadeswith barricades

Disposal of Waste MaterialsDisposal of Waste Materials

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

Manual Material HandlingManual Material Handling

Seek help:Seek help: When a load is too bulky to When a load is too bulky to

properly grasp or lift properly grasp or lift When you can’t see around When you can’t see around

or over the loador over the load When you can’t safely handle When you can’t safely handle

the loadthe load

Safe LiftingSafe Lifting

Break load into partsBreak load into parts Get help with heavy or bulky Get help with heavy or bulky

itemsitems Lift with legs, keep back Lift with legs, keep back

straight, do not twiststraight, do not twist Use handling aids - such as Use handling aids - such as

steps, trestles, shoulder pads, steps, trestles, shoulder pads, handles, and wheelshandles, and wheels

Avoid lifting above shoulder Avoid lifting above shoulder levellevel

Common Causes of Back InjuriesCommon Causes of Back Injuries

Lifting too much weight. Especially Lifting too much weight. Especially repetitivelyrepetitively Twisting at the waist while holding Twisting at the waist while holding a heavy load a heavy load Reaching and lifting overhead, or Reaching and lifting overhead, or away from the bodyaway from the body Lifting and carrying objects that have Lifting and carrying objects that have awkward shapesawkward shapes Working in awkward, uncomfortable Working in awkward, uncomfortable

positionspositions Sitting or standing too long in one positionSitting or standing too long in one position Slip / Trip / FallSlip / Trip / Fall

Personal Protective EquipmentPersonal Protective Equipment

For loads with sharp or For loads with sharp or rough edges, wear gloves rough edges, wear gloves or other hand and forearm or other hand and forearm protection protection

When loads are heavy or When loads are heavy or bulky, wear steel-toed bulky, wear steel-toed safety shoes to prevent safety shoes to prevent foot injuries if the load is foot injuries if the load is droppeddropped

PROPER LIFTING TECHNIQUESPROPER LIFTING TECHNIQUES

Use proper lift procedures . . . follow these Use proper lift procedures . . . follow these steps when lifting . .steps when lifting . .

1. Know where you are going. Is the path clear? 1. Know where you are going. Is the path clear?

2. Size up the load. (Is it too heavy? Do I need gloves?)2. Size up the load. (Is it too heavy? Do I need gloves?)

3. Take a balanced stance, 3. Take a balanced stance,

feet shoulder-widthfeet shoulder-width

apart.apart.

4. Squat down to lift, get4. Squat down to lift, get

as close as you can.as close as you can.


5. Get a secure grip, 5. Get a secure grip,

hug the load.hug the load.

6. Lift gradually using6. Lift gradually using

your legs, keep loadyour legs, keep load

close to you, keep backclose to you, keep back

and neck straight.and neck straight.


7. Once standing, change7. Once standing, change

directions by pointingdirections by pointing

your feet and turn youryour feet and turn your

whole body. Avoidwhole body. Avoid

twisting at your waist.twisting at your waist.

8. To put load down, use8. To put load down, use

these guidelines in these guidelines in

reversereverse..

Take care of your back…Take care of your back…

And it will take care of youAnd it will take care of you Exercise dailyExercise daily Avoid Heavy LiftingAvoid Heavy Lifting Get Help with heavy or bulky objectsGet Help with heavy or bulky objects If you must bend over, do it properlyIf you must bend over, do it properly Avoid twisting at the waist when Avoid twisting at the waist when

carrying objectscarrying objects Always watch where you’re goingAlways watch where you’re going

Questions?Questions?

Material Handling in the Roofing Industry

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