Metal Industry Guidelines for Safe Work

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2 section 4 4lifting and moving 85 Moving and handling raw materials and products create hazards for everyone working in metal manufacturing. Numerous injuries occur every year as a result of improper handling methods, or unsafe use of lifting equipment. In addition, many people suffer discomfort, pain or injury caused by sudden, forceful or repeated movements. In this section you will find information about: lifting with cranes, overhead gantries and hoists rigging forklift safety manual handling and lifting discomfort, pain and injury. 4

3 section 4 lifting and moving 4.1 Lifting with cranes, overhead gantries and hoists Cranes, gantries and hoists are used to move heavy loads. They are important tools for metal manufacturing. To be safe, this machinery has to be operated carefully by trained operators. The safe operation of this machinery is covered by the Approved Code of Practice for Cranes issued by the Department of Labour. All operators must refer to this document for full details of safe operating procedures. hazards Any load that is suspended above ground level is a hazard. A load that is above people s heads, and is moving, presents even greater hazards. If the load falls or tips it could cause serious harm to personnel and equipment below it and around it. Loads can fall as a result of: incorrect attachment methods (rigging) faulty equipment such as strops, lifting eyes, crane wires, and hooks using equipment that is not rated for the weight of the load. 86

4 action points Crane operators Cranes must only be operated by people who are fully trained. Trainee operators need to be supervised at all times while they are being trained. Before the load is attached, run the crane to check its operation is smooth and the limit switches and stops are all working. Check the condition of sheaves, hooks and wires by checking for cracks and confirming that they move freely and that all safety mechanisms are in place. 4 Before starting Make sure you are comfortable with the weight of the load. If not, change the set-up until you are. Allow a good safety margin when deciding the method of rigging and the equipment to use. Work out the centre of gravity of the load (point where it will balance). In practice this may need a few adjustments after lifting the load slightly off the ground a few times. Think about how the load needs to be controlled. One or more Tag Lines may be required. Check for obstructions in the proposed path of the load. Put up barriers or post sentries to ensure people cannot walk under the load. Make sure all persons are clear and those involved in the lift are wearing safety helmets and safety shoes. 87

5 section 4 lifting and moving action points Lifting/Moving the load Keep your full attention on the job. Make sure the crane/hoist wire is directly above the load before lifting. Operate the crane slowly and carefully. Never leave a suspended load unattended. Make sure people don t walk under the load. Lift only as high as necessary to clear obstructions. On completion Land all loads under control. Once detached from the load raise the hook to a height of at least 3 metres from the floor. Apply brakes and switch off normal and emergency stops. 4.2 Rigging The most important job of any crane operation is the rigging of the load. Poor rigging may result in the dropping of the load and lead to serious injury or property damage. Rigging is the most timeconsuming part of any crane operation and it is important to take the time to do this job carefully and correctly. If in doubt about the security of your rigging, ask for help. Not doing so may result in catastrophic consequences. 88

6 action points Loads must be well secured. Slings must be adequate for the task. Visually check all equipment: Wire ropes and strops for kinks. Wire ropes and strops for broken strands (rule of thumb: two out of nine maximum are allowed to be broken). Nylon slings for bleed through (red ink mark on surface) and other wear that may impair its strength. Make sure you check that all safety catches/latches are in the correct position. Use pad pieces to protect slings and strops from being cut by sharp metal edges during the lift. Rigging should be checked by lifting the load a few inches off the ground to make sure that no swing develops and that the load is completely secure. 4 Centre of gravity The centre of gravity is the point where an object would balance. When an object is suspended, the centre of gravity should be directly below the centre of the hook or attachment point. Predicting the centre of gravity is no easy task. You may take several attempts to get it right. Adjust the slinging harness so the load hangs the way you want it to in the air. This must take into consideration the way you want to land it. 89

7 section 4 lifting and moving action points Weight versus angle When using slings, the angle at which they pull influences how much load goes on them. The greater the angle (from the vertical), the greater the effective mass becomes and the greater the strain on the strops. Work out the load on each strop before you select the strops for the lift. Make sure you select strops that are rated for the load that is actually imposed on them. A C kgs kgs kgs kgs kgs kgs kgs kgs B D kgs kgs kgs kgs Sling position The slings can be arranged in three general ways: Vertical. Basket. Choker. The type of sling selected and the way it is connected affects the capacity of the sling. Ratios are illustrated below: Vertical 3,600kg Basket 7,200kg (increase capacity) Choker 2,900kg (decreased capacity) 90

8 action points Sling selection There are four types of sling: Chain. Wire Rope. Mesh. Sling. There are charts available that give safe capacities for type and size of sling for each position and angle used. The PCA Crane Safety Manual includes these. Choose an appropriate type of sling for the object. Take into account its construction, material and shape. 4 Choose the appropriate size of sling for the type selected.! employer s responsibilities: Employers need to: make sure that any workers using cranes, gantries and hoists are fully trained and following the requirements of the Codes of Practice for cranes and rigging. 91

9 section 4 lifting and moving Further information: more information: Safety Hints for Users of Lifting Gear available from Power Crane Association Crane Safety Manual available from Safe Operation of vehicle-mounted truck loader cranes, DOL Construction Bulletin available from Crane death sounds warning to all operators, DOL Construction Bulletin available from Cranes and overhead power lines, DOL Construction Bulletin available from the law: Legal requirements: Cranes - Approved Code of Practice for - Includes the Design, Manufacture, Supply, Safe Operation, Maintenance and Inspection of Cranes available from Rigging - Approved Code of Practice for Load Lifting available from 92

10 4.3 Forklift safety Although they are useful tools, forklifts can be one of the most hazardous pieces of equipment in the workplace. A medium size forklift weighs about the same as a small truck and can cause just as much damage and injury. hazards 4 Forklift operators are at the greatest risk from the forklift tipping or rolling over. This is the leading cause of operator deaths: Driving with unbalanced loads can tip the forklift. Lifting loads over the capacity of the machine can cause the forklift to tip. Driving with the forks raised (loaded or unloaded) will reduce the stability of the forklift. Exhaust fumes from petrol, diesel or LPG powered forklifts are dangerous when these machines are used in confined spaces or with poor ventilation. Many people have been injured or killed when they ve been struck by a forklift. This can occur when a person is in an area where they shouldn t be or the driver s vision is obscured. Abrupt actions will cause loads to shift and possibly fall. 93

11 section 4 lifting and moving action points Only trained operators with a current certificate are to operate forklifts and they must remember the following points. Make sure the work area is properly ventilated to remove any exhaust fumes. Make sure you are comfortable with the weight of the load. Work out the centre of gravity of the load. In practice this may need a few adjustments after lifting the load off the ground a few times. Don t stack loads on forks too high. Erect barriers or post sentries to make sure people do not walk into the working area of the forklift. Check for obstructions in the proposed path of the load. Make sure forks are centred and a sensible distance apart for the load. Load centrally on the forks. Don t lift extra long loads without control sentries on either side. Tilt forks and mast back to keep the load against the mast. Push loads back against the mast. Don t place loads on the front of the forks. 94

12 action points Take extreme care when tilting forward. Only tilt forward once the forks are above the target resting place for the load. 4 When moving past or into a blind spot use the forklift s horn to warn people. Don t ride on a forklift. If it is being used for access, use a certified personnel cage. 95

13 section 4 lifting and moving! employer s responsibilities: Employers need to: make sure that all workers using forklifts are fully trained and competent to operate them safely. Further information: more information: Fork-Lift Truck Operators - Safety Code No. 1 - Front Loading Forklift Trucks available from the law: Legal requirements: Forklifts - The Approved Code of Practice for Training Operators and Instructors of Powered Industrial Lift Trucks available from 96

14 4.4 Manual handling and lifting Manual handling and lifting of heavy objects is a daily event for people working in metal manufacturing. Special care needs to be taken to prevent injury from excessive lifting or repetitive movements. hazards 4 Carrying loads that are heavy (over 20kg) or sharp-edged increases the chance of being injured. Loads that are awkward to lift or move manually can lead to poor lifting positions and movements that can cause sprains and strains. Reaching very high or low or making twisting movements while moving a load are common causes of injury. Moving loads in slippery conditions or across uneven surfaces increases the chance of falling and injury. Lifting items of sizes, shapes or weights that you are not used to lifting can be dangerous. 97

15 section 4 lifting and moving action points Remove or reduce the need for manual handling by using lifting aids whenever possible. Before lifting Check the weight of the object. It may be written on the freight docket or on the package itself. If it is over 20kg (or estimated to be) work out if it can be moved by two people or if a lifting aid is needed. Check you have enough space and that the path you are about to take with the load is clear of obstruction or slippery substances. 98

16 action points If you can t hang on to the rail with one hand don t carry loads up or down steps. Use lifting equipment if there is any doubt about being able to carry the load safely. 4 During lifting Position your body as close as possible to the object you are lifting. Think about your feet. Are they in a position that will be steady once you have the weight? (Shoulder width apart with one slightly in front of the other is recommended.) Get a firm and comfortable grip on the object. If the object is low or on the ground squat down bending at the knees. Keep your back as vertical as possible. Use smooth movements. Commence lifting the object using your leg muscles, then straighten your knees. 99

17 section 4 lifting and moving action points Keep your body facing the object. If you have to turn, move your whole body around. Don t twist at the waist. Keep the object as close to your body as possible. Carry the object between your shoulders and waist. Don t stack too high (e.g. keep stacks below shoulder height if possible). 100

18 ! employer s responsibilities: Employers need to: make sure all manual handling risks are identified and assessed provide lifting equipment and mechanical aids wherever practical encourage workers to report signs of discomfort or pain early. Assign them to lighter work or seek medical assistance as required investigate all incidents of discomfort, pain or injury to identify improvements that need to be made. 4 Further information: more information: Manual Handling in the Manufacturing Industry available from Code of Practice for Manual Handling available from Preventing and Managing Discomfort, Pain and Injury available from Online assistance to prevent and manage pain at work available from Develop Smart Tips for your workplace available from 101

19 section 4 lifting and moving 4.5 Discomfort, pain and injury Discomfort is the body telling you to change something before you cause injury or damage to yourself. There can be a number of factors that contribute to discomfort, pain and injury and they include: 1 Individual factors Fitness, health 2 Psychosocial factors Work and non-work things that may worry or stress people e.g. relationships, job satisfaction, financial worries 3 Work organisation Breaks, shifts, delegation, staffing levels 4 Workplace layout/ Poor body positions, reaching/ Awkward posture stretching positions 5 Load/Forceful movements Manual lifting, with no mechanical or other assistance 6 Task invariability Repetition, sustained position 7 Environmental issues Heat, cold, noise, vibration 102

20 Any one factor may or may not cause discomfort, pain or injury by itself. However, when a number of risk factors are present the combination can result in discomfort, pain and eventually injury. It is important to look for all the factors that contribute to your pain. 4 If you are working on a task that requires you to put your body in a difficult position, regular rest breaks and giving the body a good stretch may be effective in preventing injury. If you have to complete repetitive tasks, be aware of the risk of RSI or OOS. Keeping all the identified risk factors in mind when we plan and supervise work is part of keeping our workplace safe. For example, you might switch tasks with your workmates or move on to another activity to give yourself a break from the repetitive action. Early reporting You should report discomfort or pain to management, supervisors or health and safety reps at an early stage. Workers with pain or discomfort should not need to rush immediately to their GP although this must always remain an option. Early reporting can lead to the quick identification of problems with tasks, plant, equipment, work organisation, workstations and tools. Once recognised, the problem can be modified or corrected. Early reporting and action for pain and discomfort assists workplaces to prevent and manage discomfort, pain and injury. 103

21 section 4 lifting and moving Return to work Returning to work after an injury is an essential part of rehabilitation. Injuries, whether incurred at work or not, are likely to impact on the business. Having a worker off for an extended period will have wide-ranging effects, from productivity and financial costs to staff morale and employment relationships. By helping injured workers to return to work it is possible to assist with their successful recovery and limit the impact on the business. case study Neil, a 60-year-old engineer, has complained of severe lower back pain that is restricting his ability to work comfortably. When looking at the contributory factors it becomes clear that a combination of factors is at work. Neil has become increasingly unfit over the past few years (too busy to exercise) and gained considerable weight (too busy to shop or cook good meals), both of which make him feel bad about himself. Neil smokes over a packet of cigarettes a day and when questioned is very stressed and unhappy at work. His wife is suffering a long-term illness and he is very worried about her. He feels that because of his age and experience he is always being assigned the hard jobs, usually on his own (due to downsizing ). The latest task Neil has been given has him bending down using a grinder below knee height for long periods of time. Because of the space required, the job has been set up outdoors, exposing Neil to the elements and some unseasonably cold and wet weather. He has had to work a lot of overtime recently because they have a lot of work on and the customers have been promised quick delivery. To help Neil we must address all of the contributory factors rather than just the easy or obvious ones. From the case study you may start looking at the following (and from investigating these, other contributory factors may become apparent): 104

22 Contributory factor Neil s issues Possible solution Individual factors Unfit; weight; smoking. Support Neil to improve wellness. Psychosocial factors Worried about his wife; Talk to Neil about home unhappy about fitness/ and work demands and weight; feels hard done how he can be supported. by because he gets the hard jobs. Refer Neil to an Employee Assistance Programme. Work organisation Working long hours; Review staffing working without assistance. requirements; renegotiate delivery dates. Workplace layout/awkward Using grinder below knee Raise work height to posture level. improve working position. Loads/Forceful movements Lifting and moving heavy Provide lifting aids to items by himself. remove the need for manual lifting. Task invariability Lack of variety in job Provide more varied tasks (boredom?). (e.g. by job rotation). Environmental issues Working in cold and rain Move work inside or outdoors. provide shelter from the weather. 4! employer s responsibilities: Employers need to: plan work so that repetitive tasks are reduced and workers can use comfortable postures wherever possible encourage workers to report signs of discomfort or pain early investigate all incidents of discomfort, pain or injury to identify improvements that need to be made. 105

23 section 4 lifting and moving Further information: more information: Preventing and Managing Discomfort, Pain and Injury available from Code of Practice for Manual Handling available from Online assistance to prevent and manage pain at work refer to the CD enclosed with these Guidelines or to Develop Smart Tips for your workplace available from 106