2. Session 1: Material Handling; Material-Handling Equipment

3. Session One Objectives
Related Performance Tasks
Demonstrate safe manual lifting techniques.
Demonstrate how to tie two of the following common knots:
Square
Bowline
Half hitch
Clove hitch
When trainees have completed this session, they should be able to do the following:
Describe the basic concepts of material handling and common safety precautions.
Describe the basic concepts of material handling and manual lifting.
Identify common material-handling safety precautions.
Identify and describe how to tie knots commonly used in material handling.
Identify various types of material-handling equipment and describe how they are used.
Identify non-motorized material-handling equipment and describe how they are used.
Identify motorized material-handling equipment and describe how they are used.
Introduction to Material Handling

4. Kickoff Activity – What’s Changed
MATERIAL HANDLING –THEN AND NOW
What basic aspects of material handling have changed relatively little over time?
What aspects have changed a great deal?
Ask trainees to identify basic aspects of material handling that have changed relatively little over time as well as those that have changed a great deal. Record their answers on a whiteboard/chalkboard. Retain the list and refer back to it to check off items as they are covered during the classroom session.
Introduction to Material Handling

5. Section 1.1.0 – Material-Handling Basics
To prevent injuries when handling materials:
Pre-plan the task.
Wear appropriate PPE.
Follow proper lifting procedures.
Be aware of hazards posed by heights and suspended loads.
Identify the four basic aspects of material handling that will be covered in the following sections.
Introduction to Material Handling

6. Sections 1.1.1 and 1.1.2 BASIC GUIDELINES
Assess the situation before attempting a lift.
Wear the proper clothing.
Use the appropriate PPE.
Follow established policies.
Talk about why mentally planning a material-handling task is important. Review the steps for assessing the situation before attempting to lift any material.
Emphasize the importance of wearing the proper clothing and using the appropriate personal protective equipment (PPE) when handling any material. Review the safety guidelines for dressing properly to perform material-handling operations.
Introduction to Material Handling

7. GUIDELINES FOR LOWERING A LOAD
Section 1.1.3
GUIDELINES FOR LOWERING A LOAD
Size up the load first.
Lower the load in the same way it would be lifted.
Treat the area that the load is being lowered into as a fall zone.
Describe proper techniques for lifting and lowering loads. Describe when a worker should ask for assistance with lifting or lowering a load. Talk about how to handle long or cumbersome loads. Discuss dangers and precautions specifically associated with lowering overhead loads. Talk about ways to prevent back injuries when lifting and lowering materials.
Safe Lifting Technique
Introduction to Material Handling

8. Section 1.2.1 – Stacking and Storing Materials
A stack of masonry blocks is set back one-half block per layer above six feet (1.8 m).
Stack loose bricks no higher than seven feet (2.1 m). Above four feet (1.2 m), begin stacking two inches (5 cm) in from the edge, continuing in this manner for each additional foot of height up to seven feet (2.1 m).
Follow safety guidelines for stacking and storing items such as:
Cartons
Lumber
Pipes
Items that should be chocked
Items that should be tied down or banded
Bags
Bricks
Masonry blocks
Flammable materials
Talk about the benefits of storing and stacking materials correctly. Describe negative results that can occur when materials and equipment are not stored properly. Review the bulleted list of guidelines for stacking and storing materials.
Introduction to Material Handling

9. Section 1.2.2 – Working from Heights
Safety Guidelines
Use a safety harness with a fall-arrest lanyard at heights over 6 feet (2 m).
Use a rope to raise or lower tools and materials.
Tie off tools and materials to keep them secured in elevated work areas.
Follow precautions to use ladders safely.
Never stack or store materials on scaffolds or runways.
Describe safe practices for material handling when working from heights.
Introduction to Material Handling

10. Section 1.3.0 – Knots Knots and Hitches
True knots must be unwoven to be unfastened.
Hitches can be undone by pulling in the reverse direction from that in which the knots are meant to hold.
Key knot-tying terms are: standing end, working end, standing part, and capsize.
Explain the difference between knots and hitches. Identify the four types of knots that will be covered in the sections that follow. Define the following knot tying terms: standing end, working end, standing part, and capsize. Point out the need to be aware of differences in knot-tying techniques.
Introduction to Material Handling

11. Section 1.3.1 – The Square Knot
THIS…
…not THIS!
Describe a square knot, applications for which it is suitable, and applications for which it is not suitable. Explain how to tie a square knot. Point out the dangers of mistakenly tying a granny knot instead of a square knot.
The granny knot is the result if the second half knot is tied in the wrong direction when tying a square knot.
It is a highly insecure knot!
Introduction to Material Handling

12. Section – The Bowline
Do not use this knot if the rope may have to be released while under load!
Describe a bowline, applications for which it is suitable, and applications for which it is not suitable. Explain how to tie a bowline.
Introduction to Material Handling

13. Section 1.3.3 – The Half Hitch
Do not use this knot alone for heavy loads or when safety is critical!
Describe a half hitch, applications for which it is suitable, and applications for which it is not suitable. Explain how to tie a half hitch.
Introduction to Material Handling

14. Section 1.3.4 – The Clove Hitch
Do not use this knot alone; use additional half hitches to make it more secure.
Describe a clove hitch, applications for which it is suitable, and applications for which it is not suitable. Explain how to tie a clove hitch using the threading the end technique, the stacked loops technique, and the two half hitches technique.
CLOVE HITCH—THREADING-THE END-TECHNIQUE
CLOVE HITCH—TWO HALF HITCHES TECHNIQUE
CLOVE HITCH—STACKED LOOPS TECHNIQUE
Introduction to Material Handling

15. Sections 2.1.1 to 2.1.4 – Carts and Dollies
Cylinder carts are designed for transporting compressed gas cylinders, which are explosion hazards. Use carts with a partition when transporting oxygen and any fuel gas cylinder together.
Dollies are excellent for drums kept upright, making them easy to move on a smooth floor. For transporting a cylinder longer distances, a drum cart is best.
Describe the basic features and uses of cylinder carts. Review the bulleted list of guidelines for transporting gas cylinders. Stress the dangers associated with a compressed gas cylinder that ruptures or cracks during transport. Describe the basic features and uses of drum dollies and drum carts. Review the bulleted list of guidelines for using a rotating drum cart.
Introduction to Material Handling

16. Sections 2.1.7 to 2.1.9 – Pipe Mules and Transports
PIPE TRANSPORT
Similar to pipe mule, but used for larger pieces of pipe
Has frame attached to two rubber wheels
Requires two people to operate it
PIPE MULES
Two-wheeled devices for transporting medium-length pipes, tubing, or scaffolding
Also called a tunnel buggy, V-cart, or grasshopper
Requires use of proper lifting techniques and a spotter for full lengths of pipe
Describe the basic features and uses of a pipe mule. Describe proper lifting techniques for loading and unloading a pipe mule. Describe the basic features and uses of a pipe transport. Emphasize the information listed in the warning about pinch points, overloading, and maintaining control when using a pipe transport.
Introduction to Material Handling

17. Section 2.2.0
Operators of equipment powered by gasoline or electric motors must…
be properly trained, certified, and authorized.
know the weight of the load.
never exceed the load-handling capacity of the equipment.
inspect the equipment before using it.
Describe motorized material handling equipment. Emphasize the training requirements for operators of motorized material handling equipment. Talk about how to avoid accidents when using motorized material handling equipment. Review guidelines for handling materials with a machine.
Introduction to Material Handling

18. Sections 2.2.1 and 2.2.2 CONCRETE MULE
A wheeled device for concrete pours in locations where concrete delivery truck or pump cannot reach
Designed to carry materials such as concrete, sand, or gravel (concrete-related material)
Requires pre-use inspection
POWERED WHEELBARROW
Powered by an electric or gas motor
Requires pre-use inspection
Has specific guidelines for safe operation
Describe the basic features and uses of a powered wheelbarrow. Talk about how to inspect a powered wheelbarrow before using it. Review the bulleted list of safety guidelines for using a powered wheelbarrow. Describe the basic features and uses of a concrete mule. Talk about how to inspect a concrete mule before using it. Describe safety precautions to follow when refueling, discharging concrete mix from, and operating a concrete mule.
Introduction to Material Handling

19. Sections 2.2.4 and 2.2.5 – Forklifts
ROUGH-TERRAIN FORKLIFT
A forklift designed for use on rough surfaces and terrain
Has same safety guidelines that apply to industrial forklifts
Telehandler models have an articulated arm or boom
INDUSTRIAL FORKLIFT
A vehicle with a power-operated pronged platform for lifting, lowering, and transporting large or heavy loads
Used in smooth terrain areas
Requires daily pre-use inspection
Describe the basic features and uses of an industrial forklift. Review the bulleted list of safety guidelines to follow when working in the vicinity of a forklift. Talk about traffic safety rules and general safety precautions that forklift operators must follow. Review the bulleted list of items that should be inspected each day before using a forklift. Describe good driving practices and pedestrian safety concerns for forklift operators. Explain why modifications should not be made to forklifts without obtaining consent from the manufacturer or a mechanical engineer. Describe the basic features and uses of a rough terrain forklift. Explain why tipovers are common accidents for rough terrain forklifts. Review the bulleted list of safety guidelines for preventing tipovers.
Introduction to Material Handling

20. Section – Hand Signals
Explain why hand signals are used to communicate with the operators of motorized material-handling equipment. Emphasize that there is no globally accepted standard for hand signals. Review the meanings of the common hand signals depicted in the figure that is provided. Talk about how to make sure that you are using the correct hand signals and communicating effectively with the equipment operator.
Introduction to Material Handling

21. Wrap Up
What would be the most appropriate device or practice to use for the following material-handling situation?
A worker must deliver concrete mix to a pour in a location that cannot be reached by a concrete delivery truck or pump. The discharge location is near an open pit.
Use a concrete mule to transport the material. Use a tire stop board or chocks to keep the mule from rolling forward into the pit while the concrete mix is being discharged from the mule.
A worker needs to alert a forklift operator that the load is too far forward on the forks.
Use the appropriate hand signal to tell the forklift operator to tilt the mast backward.
A worker needs to move a sealed oil drum from the warehouse to the shop.
Use a drum cart to transport the oil drum.
A worker must stack 50 bags of material onto a pallet in a storage area at a work site.
Stack the bags by stepping back the layers and cross-keying the bags at least every 10 bags high.
A worker on the ground at a job site needs to tie a knot to secure a bucket of tools to a rope so the tools can be hauled up to co-workers who are on an elevated platform.
Use a bowline to secure the rope to the bucket.
Ask trainees to identify the approach that would be best for each of five material-handling scenarios. Discuss the correct answer for each scenario as it is presented. Allow for discussion of additional correct answers that trainees may provide beyond those identified on the slide.
Introduction to Material Handling

22. LABORATORY AND PERFORMANCE TASKS; MODULE REVIEW AND TESTING
Next Session…
LABORATORY AND PERFORMANCE TASKS; MODULE REVIEW AND TESTING
Review the complete module; complete the Module Review and Trade Terms Quiz
Assign a review of the complete module to prepare for the upcoming laboratory session and module exam. It is further suggested that trainees be assigned the Module Review and Trade Terms Quiz as homework. Inform trainees that the next session will begin with a laboratory devoted to safe manual lifting techniques and tying common knots. The laboratory work will be followed by the written exam.
Introduction to Material Handling