Mechanical Handling

1. MECHANICAL HANDLING
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2. TYPES OF MECHANICAL MEANS
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CRANES POWERED INDUSTRIAL
TRUCKS
CONVEYERS

3. WHAT IS MECHANICAL
HANDLING
The act of loading, unloading and moving
goods with the use mechanical devices
within a factory or other work area.
Mechanical handling refers to the
handling of goods and other materials by
mechanical means.
There are different ways of handling
materials, these are generally classified
according to the type of equipment used.
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4. CLASSIFICATION OF
MECHANICAL EQUIPMENT
the International Materials Management
Society (IMMS) has classified mechanical
equipment as:
(2) Conveyors
(5) Railroad Cars
(1) Aircraft
(3) Motor Vehicles (4) Marine Carriers
(7) Containers & Supports
(6) Industrial Vehicles
(8) Cranes, Elevators, and Hoists
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5. BASIC SAFETY PRINCIPALS
Basic safety principles should be applied to all
mechanical equipment. These principles are:
 that the equipment should be of good
construction.
 Made from sound material of adequate
strength and be free from obvious faults.
 All should be tested and regularly examined
to ensure their integrity. They should always
be properly used. 5

6. CRANES
What are Cranes?
Cranes are lifting machines equipped with a
winder, wire ropes or chains and sheaves that
can be used both to lift and lower materials and
to move them horizontally.
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It uses one or more simple machines to create
mechanical advantage and thus move loads
beyond the normal capability of a human.

7. TYPES OF CRANES
 Sidelift
 Mobile Cranes
Truck mounted
 Aerial
 Rough Terrain
 All Terrain
 Crawler
 Railroad
 Floating
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 Fixed Cranes
 Stacker
 Gantry
 Self-erecting
 Hammerhead
 Level Luffing
 Deck
 Bulk Handling
 Loader
There are two (2) types of cranes

8.  The manufacturing industry for the
assembling of heavy equipment.
SOME BASIC USE OF CRANES
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They are commonly employed in:
 The transport industry for loading and
unloading freight;
 The construction industry for the
movement of materials; and

9. Is a modern form of balance crane. Fixed
to the ground (and sometimes attached to
the sides of structures as well) give the
best combination of height and lifting
capacity and are used in the construction
of tall buildings.
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TOWER CRANES (FIXED)

10. 10
LOADER CRANES (FIXED)
Is also called a knuckle-boom or an articulating
crane, it is a hydraulically powered articulated arm
fitted to a truck or trailer, and is used for loading
and unloading vehicle. The numerous jointed
sections can be folded into a small space when the
crane is not in use.

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These are often truck-mounted.
TELESCOPIC CRANES (FIXED)
These types of booms are often
used for short term construction
projects, rescue jobs, lifting boats in
and out of the water, etc.
Telescopic cranes have a boom that consists
of a number of tubes fitted one inside the
other.

12. OVERHEAD CRANE (FIXED)
Also known as a suspended crane, instead of
the whole crane moving, only the hoist/trolley
assembly moves in fixed beams, often mounted
along the side walls or on elevated columns in
the assembly area of factory. Some of these
cranes can lift very heavy loads
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13. TRUCK MOUNTED (MOBILE)
Truck provides the
mobility for this type
of crane.
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Generally, these cranes
are designed to travel on
streets and highways,
eliminating the need for
special equipment to
transport them to and
from jobsites.

14. This crane is mounted on an
undercarriage with a set of
tracks (also called crawlers)
that provide for the stability
and mobility of the crane.
The main advantage of a
crawler is that they can
CRAWLER CRANES (MOBILE)
This crane is stable on its tracks with no
outriggers. In addition, a crawler crane is
capable of traveling with a load. 14
move around on site and
then perform each lift with very little set-up.

15. ROUGH TERRAIN (MOBILE)
These are mounted on an undercarriage with
four rubber tires that is designed for pick-and-
carry operations and for off-road and "rough
terrain" applications.
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16. BEFORE CRANE CAN BE USED
Because of the variety of these lifting appliances
and the different control layout, standardization of
crane control is important.
Crane Layout
The controls should be within easy reach of the
operator to be accessed without effort and to avoid
operational errors.
Attention should be given to visibility, access,
seating and environmental.
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The load capacity limits should be stamped or
affixed to all rigging components.

17. Comfortable seats should be provided and
properly positioned to provide maximum view of all
lifting operations, while maintaining full view of the
controls.
BEFORE CRANE CAN BE USED
Crane Layout
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Training
To be an operator one must be over eighteen (18)
years.
Would be operators should complete a course in
crane and hoist safety and hazard control, which
should include hands-on training from a qualified
operator.

18. BEFORE CRANE CAN BE USED
Training
Operators are required to have an operator’s
license, which is renewable every three (3) years.
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JUST PRIOR TO CRANE USE
Particular attention should be paid to the
following areas, which should be set out on the
pre-work sheet:
Controls – clutches, breaks, electric, air-
hydraulic system, steering.
Outriggers – operation & leakage, pads and
locks.

19. Safety Devices – lower limit switch, upper limit
switch, trolley limit switches, boom angle
indicator, load weight indicator, anti-two-blocking
device and signal horn.
JUST PRIOR TO CRANE USE
Boom – jib stop and block, hook and safety
latches. Check to make sure protective devices
and panels are in place.
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Wire Rope – wire rope keepers condition and
lube, connection and clamps, kinking and crushing
wear, corrosion, bird-caging, broken wires and
reeving.
Operations Cab – glass & windscreen wiper, fire
extinguisher, load inspect chart and hand signal
chart.

20. BANKSMAN
Crane operators do not always have clear visibility
of the loading area, consequently a signaler or
banksman is most important and necessary.
a banksman is the skilled person who directs the
operations of a crane from the point near where
loads are attached and detached.
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DURING CRANE USE
A banksman may also be responsible for the
loading and unloading of lorries and directing the
movement of other plant.
Engine– idle and power checks.
General– lube, fuel, hydraulic oil, coolant and
others.

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DURING CRANE USE
There should also be inspections through out
during the use cranes, for the detection of
potential deficiencies of other hazards and in
particular, for the following of rules while
operating.

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SIGNALS
•MOVE SLOWLY: Use one
hand to give any motion
signal and place other hand
motionless in front of hand
engaging in motion signal.
•HOIST: With forearm
vertical, forefinger pointing
up, move hand in small
horizontal circles.
•STOP: Arm extended, palm
down, hold position rigidly.
•LOWER: With arm
extended downward,
forefinger pointing down,
move hand in small
horizontal circles.
•EMERGENCY STOP: Arm
extended, palm down, move
hand rapidly right and left. An
emergency stop signal must
be accepted from any person.
•BRIDGE TRAVEL: Arm
extended forward, hand
open and slightly raised,
make pushing motions in
direction of travel
•TROLLEY TRAVEL: Palm
up, fingers closed, thumb
pointing in direction of
motion, jerk hand
horizontally.

23. The operator should:
 Making sure the weight capacity of the
crane bridge in not exceeded.
 Avoid side pulls, which can destabilise the
crane.
DURING CRANE USE
 Respond to the signals only from the
signaler/banksman. However, obey stop
signals at all times, no matter who gives it.
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A banksman may also control the movements of
an excavator, by carefully monitoring the bucket
for any obstructions or underground services.

24. DURING CRANE USE
 Do not move loads over people, nether
should persons be allowed to work under
suspended load, unless loads are supported
by blocks, jacks or solid footing.
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 Do not engage in any practice that will divert
your attention while operating.
WHAT CAN GO WRONG
Overturning – caused by weak support, or
operating outside the machine’s capabilities or
by striking obstructions.

25. Overloading – exceeding operating capacity or
operating radii, or by failure of safety devices.
Collision – with other cranes, overhead cables
or structures.
WHAT CAN GO WRONG
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Failure of Support – placement over cellars
and drains, outriggers not extended, not made-
up on solid ground.
Operator errors – from impaired or restricted
visibility, poor eyesight, inadequate training.
Loss of Load – failure of the lifting tackle or
slinging procedure.

26. OTHER CRANE HAZARDS
 Electrical
 Travelling crane track hazards
 Crushing between moving parts and fixed
objects
 Fire
 Environmental conditions
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 Workers can be struck by falling load.
 Struck when erecting or dismantling a crane.
 Electrocution to operators can occur from
electrically driven cranes if not properly earthed
or grounded, or from horizontal wires overhead
while climbing ladder to enter crane.

27.  Accidents can occur if sub contractor
personnel do not adhere to safety standards.
OTHER CRANE HAZARDS
 Offensive and dangerous fumes, smoke,
vapours and toxic gases often rise to the
crane cabin and can be a health hazard.
struck by falling load.
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ELIMINATING THE HAZARD
Identification and Testing
Every crane should be tested, and a certificate
issued following each test.

28. Identification and Testing
ELIMINATING THE HAZARD
Test should be by independent third parties to
ensure unbiased results.
The working load which must be clearly
marked, should never be exceeded, except
under test conditions.
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Maintenance
Inspection is divided into two general
classification based on the regularity of the
inspection:

29. Maintenance
ELIMINATING THE HAZARD
 Frequent – daily to monthly
 Periodic – annually or as recommended by
the manufacturer
Cranes should be inspected regularly, and any
faults be repaired immediately and records of
checks kept.
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Safety measures for eliminating or reducing
crane hazards includes:
1. Ensure the load indicators are in working
condition. This can be both visual and
audible.

30. ELIMINATING THE HAZARD
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2. During night work, working areas should
have adequate lighting.
3. Operator should not leave cranes or lifting
machinery with suspended load.
4. Operator should lower the bucket, the
grapple and the load to the ground and
engage the switch lock.
5. All newly installed, repaired, modified or
rebuilt cranes should be load tested.
6. Directional signs N-W-S-E should be
displayed on the bridge upper side and the
pendant.

31. ELIMINATING THE HAZARD
7. All cabs and remote controlled bridges should
have a motion alarm to signal bridge movement.
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8. There should be a main electrical disconnect
switch in a separate box labeled with lock-out
capacity.
9. There should also be proper earthing or
grounding for electrically driven cranes. Every
cranes should be fitted with a fire extinguisher.
10. Consideration should be given to climatic
conditions, differences in climate can create
different kinds of hazards, which need to be
addressed, such as, excessive heat or cold, ice,
and other extremes of environmental conditions.

32. ELIMINATING THE HAZARD
11. Do not use slings, eyebolts, shackles or hooks
that have been cut, welded or brazed.
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12. Passengers should not be carried without
authorization, and even then not on lifting tackle.
13. Do not let the load or bucket hit the boom, don’t
let the boom rest on or hit against a building or
any other object. Care should be taken when
working around or lifting in a hostile
environment.
14. Operators manuals should be maintained in a
central file for programme reference and easy
access. Operators should be required to
familiarise themselves with its contents.

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POWERED
INDUSTRIAL
TRUCKS

34.  Can be powered through electric or
combustion engines.
WHAT ARE POWERED INDUSTRIAL
TRUCKS?
 A mobile, power-propelled truck used to
carry, push, pull, lift, stack or tier materials.
 Commonly known as forklifts, pallet trucks,
rider trucks, fork-trucks, or lift-trucks.
 Excluded are vehicles used for earth moving
and over-the-road hauling.
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35. TYPES OF POWERED
INDUSTRIAL TRUCKS
There are many different types of powered
industrial trucks. Commonly used types include:
 Rider trucks
 forklift trucks
 Pallet trucks
 Straddle trucks
 High lift trucks
 Cantilever trucks
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 High lift platform trucks  low lift trucks
 Counterbalanced trucks
 High lift order picker trucks
 Counterbalanced front/side loader lift trucks.

36. TYPES OF POWERED
INDUSTRIAL TRUCKS
 reach rider trucks
 Motorised hand/rider trucks
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Each type of powered industrial truck has its
own unique characteristics and some inherent
hazards.

37. POWERED INDUSTRIAL TRUCKS
Trucks should be of good
construction, free from
defects and suitable for the
purpose for which they have
been designed. In terms of
capacity, size and type.
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The type of power supply to be used should be
checked, the nature of the work area may
require one type of power source instead of
another.

38. CLASS I -ELECTRIC MOTOR
RIDER TRUCKS
 Counterbalanced rider type, stand up
 Three wheel electric sit-down trucks.
 Counterbalance rider type cushion tires, sit-
down (high and low platform)
 Counterbalance rider,
pneumatic tire sit-down
(high and low platform)
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39. CLASS VIII ROUGH TERRAIN
POWERED INDUSTRIAL TRUCKS
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Trucks should only be operated
according to manufacturer’s instructions
Internal combustion engines will
not be acceptable, because of
toxic gases produced, especially
in poorly ventilated or confined
spaces.

40. FORKLIFT CAPACITY
 The model number of some forklifts may be
confused with its lifting capacity. Ensure you use
the load capacity data plate to accurately
determine the capacity. The weight, shape, size
and composition of a load affect the way it should
be lifted.
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 PCBUs and supervisors should be involved in
knowing how loads and the loading are controlled.
(Person conducting a business or undertaking)
 A forklift’s capacity (also known as the rated
capacity) is the maximum weight it can safely carry
at a specified load centre. Overloading can
damage the forklift and increase the risk of forklift
related injuries.

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 Take the time to familiarise yourself with each
new type of load before you start work.
FORKLIFT CAPACITY
 When a load is raised, the forklift is less stable;
stability is decreased further if the load is off-
centre.
 Tilting forwards or backwards with a raised load
will also affect stability.
 Driving with a raised load is dangerous. It makes
the forklift less stable and leads to tipping over,
particularly if the forklift is being driven at speed,
around a corner, or on an uneven surface

42. CARRYING THE LOAD
 Do not pick up a load if you do not know its
mass.
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 Know how to read load capacity data plates.
Load capacity data plates detail the load each
forklift can safely lift at different mast
orientations, or when fitted with an attachment
 Know the capacity of your forklift and do not
exceed it. Check the marked weight of an
object, or use a weight gauge or scale to weigh
loads.
 If the load is not placed safely and correctly,
reload it.

43.  Set the fork arms width to provide the greatest
support for the load, and position the load so it is
balanced evenly on the fork arms .
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CARRYING THE LOAD
 If the pallets are damaged, remove them. If the
load is particularly long or wide, see if you need
to take an alternative route.
 If the load comprises different lengths of
material, ensure the point of balance is in the
middle of the fork arms when the load is lifted.
 Take special care with irregular loads or loads
that may slide (such as steel on steel). Ensure
the fork arms and the loads are centred.

44.  When operating the forklift on an incline, the load
must be tilted back and raised only as far as
needed to clear the road surface. The load must be
facing up the incline.
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CARRYING THE LOAD
 Insert the fork arms fully beneath the load.
 Ensure each load is against the backrest carried,
lowered and set down according to the
manufacturer’s recommendations and your safe
work procedures.
 Check around the load before lifting to ensure it
does not affect anything or anyone around it.

45. Overturning -
WHAT CAN GO WRONG
 Turning on or crossing ramps etc.
 Maneuvering with elevated load.
 Driving at too high a speed.
 Sudden braking.
 Striking obstructions.
 Forward tilt with load elevated.
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Overloading – exceeding the maximum lifting
capacity of the truck.

46. Collision with –
WHAT CAN GO WRONG
structure Pipes Other vehicles
Stacks
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Floor Failure –
 Due to uneven floor.
 Unsound floor.
 Exceeding the load capacity for the floor.
Loss of Load – occurs if devices are not fitted
properly to stop the loads slipping from the fork.

47. Explosion and Fire – can arise from electrical
shorting, leaking fuel pipes, dust accumulation
(spontaneous combustion) and generated
hydrogen during the charging of battery, or if the
ignition is operated in a flammable atmosphere.
Passengers – must not be carried unless
seats or other facilities are provided for this
purpose.
WHAT CAN GO WRONG
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48. HAZARD ELIMINATION
Area of operation
 The floor should be of suitable construction
for use by the trucks.
 Capacity of floors above ground level should
always be checked before the use of trucks.
 Floor surface should be flat.
 Area must be unobstructed where trucks are
expected to move.
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 All gullies and opening should be kept
covered.

49. HAZARD ELIMINATION
 Blind corners should be removed from any
area where trucks are expected to
maneuver.
 Storage area and isle should be laid out to
facilitate truck use and stacking should also
be given consideration.
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 Passing places, especially pedestrian
walkways, should be properly and clearly
marked, particularly where space in
restricted places or gangways are provided.

50. HAZARD ELIMINATION
 All pedestrians should be excluded from
operating area where possible.
 Priorities should be given to trucks. Warning
sings will be required to indicate Priorities.
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 Adequate lighting is a priority for stacking
area.
 Loading bay should be
appropriately designed, providing
for stability, with chocks supplying
support for wheels.
 Ramps and slopes should not exceed 1:10 or
as otherwise stipulated by manufacturer.

51.  No repairs or battery changing should take
place in undesignated areas.
HAZARD ELIMINATION
 The are for repairs must be well ventilated
and properly lit, with no smoking or naked
lights permitted.
 Adequate lifting facilities should be provided
for battery work.
 Reversing lights and/or sound warnings
should be fitted, especially where
pedestrians share the floor space.
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TRAINING
 Training should be provided for all operators
in the safe operation of their equipment.

52. TRAINING
HAZARD ELIMINATION
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 Following operators’ training a certificate
must be issued.
Apart from formal (classroom sessions) training of
lecture, discussion, videotapes, other programmes
and written material used, training should consist
of practical (demonstrations performed by the
trainer and exercises performed by the trainee).
The training should include an evaluation of the
operator's performance in the workplace.

53. CONVEYORS
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54. HISTORY
Conveyor systems have been a mainstay of
material handling for over 100 years.
New configurations and sophistication of controls
have kept conveyor systems in the state-of-the-art
category with other automated material handling
systems.
Overhead trolleys and belt conveyors were
moving materials in manufacturing plants before
the forklift was even invented.
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The extensive range of applications for conveyers
allowed for their use in small "mom and pop" type
operations as well as in tier manufacturing and
distribution operations.

55. HISTORY
Conveyors are very cost effective and the ease of
expandability and reconfiguration makes it ideal
for growing operations. A little imagination and a
small investment can do wonders for reducing
manual material handling through the use of
conveyor systems.
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CONVEYORS
The most common type of conveyors are:
 Belt conveyors
 Rollers conveyors

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Others include - Gravity Skate Wheel
CONVEYORS
Screw conveyors
receiving and assembly areas, Skate wheel
conveyors reduce manual material handling of
lightweight items over short distances.
Gravity skate wheel conveyor can
also come in roller type and is used
for conveying lightweight cartons,
trays, or totes. Used extensively in shipping and

57. Application for gravity roller
conveyor is similar to that of
gravity skate wheel, it is more
effective where heavier items
are being handled.
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GRAVITY ROLLER CONVEYOR
AUTOMATED BELT CONVEYOR
The automated belt conveyer has
similar applications to gravity roller
and skate wheel.
Single units can be incorporated into
gravity conveyor systems of a simple
semi-automated system.

58. This is an automated version of gravity roller
conveyor. Automated roller conveyors are used
extensively in large conveyor systems. A version of
automated roller conveyor is called Zero-Pressure
Accumulating Conveyor, the pressure is especially
useful in avoiding build-up which normally occurs
when product accumulates at a stationary operation.
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AUTOMATED ROLLER CONVEYOR

59. FLEXIBLE CONVEYOR
Flexible conveyor is usually
anchored at one end to fixed gravity
or automated conveyor, allowing
the other end to be expanded and
flexed into trailers at loading and
unloading bays. Used extensively in
shipping/receiving operations for
package handling.
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60. UNIT LOAD CONVEYOR
Unit Load Conveyor is a
heavy duty version of
roller conveyor used for
handling pallet loads or
larger totes or trays.
Unit load conveyer can be gravity flow or
automated and may be installed elevated or
recessed into the floor.
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61. SORTATION SYSTEMS
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Sortation systems are large, elaborate
conveyor systems. These are most frequently
used in high volume case quantity and piece
quantity picking, shipping, and parcel
processing operations.

62. WHAT COULD GO WRONG
Trapping – limbs can be drawn into in running
nips.
Contact – with moving parts such as drive
elements, screw conveyors.
Entanglement – rollers and/or drive mechanism
can draw in limbs/jewelry/clothing
Striking – materials falling from heights,
incorrectly handled. 62

63. HAZARD ELIMINATION
Belt Conveyors require:
 Guards or Enclosures at the drum, this
being one of the major hazard area.
 Guards or Enclosures are also needed
between the belt and drum, this area creates
a trapping point. It is needed wherever nip
occur as the belt changes direction or at the
guide plates or feed points.
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 Throughout the length of some conveyors
guards are also needed. Trip wires to cut off
supply can also be a safety feature.

64. HAZARD ELIMINATION
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 Safe access at the most appropriate intervals
should be provided especially over long
conveyor runs.
Roller Conveyors:
 Guards at the power drives are required where
rollers are either power driven or free-running.
 Guards may also be required in areas where in-
running nips are created.
Screw Conveyors:
 At all time guards are needed to prevent access
 Repairs and maintenance must only be effected
when drive is locked off.

65. 1. What checks should be made before a crane is used in
the workplace.
2. Classify Mechanical hazards in terms of motion.
3. For each classification of mechanical hazard, give the
different types of hazards created.
4. Outline the rules to be followed when a forklift is to be left
unattended.
5. Outline the health and safety consideration when a fork-
lift truck is to be used to unload palletized goods from a
vehicle packed in a factory cark park.
6. Identify four mechanical hazards presented by pedestal
drills and in each case, outline how injury may occur. 65
QUESTIONS

66. 7. (a) State five points which are considered important
in the safe use of mobile cranes
(b) What types of injury can result from incorrect
methods of handling heavy and awkward loads?
8. A decorator use a large portable electrical steamer
for wallpaper stripping:
(a) Identify four (4) hazards associated with the use
of a steamer
(b) outline the checks that should be made to ensure
electrical safety when using the steamer
9. (a) What can go wrong using a Forklift
(b) Causes of Crane Failures 66

67. 10. What do you look for when checking wire rope
safety?
11. What are two main safety devices required for use
with cranes?
12. Identify four (4) hazards when cutting grass on
roadside verges with a rider-operated motor-mower
and outline the precautions to be taken against
each.
13. List eight (8) rules to follow when a fork-lift truck is
left unattended in a workplace.
14. List three (3) types of crane used for lifting
operations.
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68. THE END
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