BLOCK 2

INTRODUCTION TO INDUSTRIAL SAFETY

ENGINEERING
 MIS – 021
Safety Philosophy and
Indira Gandhi
National Open University
Principles of Accident
School of Engineering & Technology
Prevention

Block

2
INTRODUCTION TO INDUSTRIAL SAFETY ENGINEERING

UNIT 5
Concept of Safety Engineering (Ergonomics, Process Safety) 121

UNIT 6
Storage of Material Handling of Hazardous Material 139

UNIT 7
House Keeping (5S Concepts) 170

UNIT 8
Safeguarding of Machinery 185
INTRODUCTION TO INDUSTRIAL SAFETY
ENGINEERING
Safety implies the protection of people from any form of physical injury.
Evolution of Safety occurred post World War IInd, following which rules
were made mandatory for firms. Any work fields, whether it may be a small-
scale industry, construction site or a department that employs huge
mechanical equipment and machineries can be considered as industrial areas
which should follow safe working practices. It is therefore necessary to
follow 5S system, frame firm policies, audit by trained personnel, safety
drills, training of workers along with other measures in the industries. This
Block consists of four units.
The unit 5 entitled ‘Concept of Safety Engineering (Ergonomics, Process
Safety) deals with the concept of Safety and health of a workman in the
workplace. Today safety concerns are widely regarded essential in industry
and governments make regulations to ensure compliance by the employers. It
discusses the safety directives and policies made at corporate levels by the
firms. Implementation of firm’s policies is guided, reported and audited by
trained personnel. Further the unit elaborates on the regular safety drills and
training of workmen, availability and upkeep of protection gears along with
written instructions that have become common safety management functions.
The unit 6 entitled ‘Storage and Material Handling of Hazardous Material’
deals with how material handling equipment allows for the safe and efficient
transportation, movement, storage and protection of people and products
during the manufacturing and distribution process which in turn helps to
increase productivity. It also elaborates the four types of material handling
equipment. The four main categories of material handling equipment include:
storage, engineered systems, industrial trucks and bulk material handling.
This unit also discusses the safety tips and precautions and principles of
safety that one must take into consideration while performing any heavy load
material handling.
The unit 7 entitled ‘House Keeping (5S Concept)’ mainly highlights the most
well known and most proven 5S system. This system has been around as a
formal system for decades and has been proven effective at improving
virtually every aspect of nearly any business across all industries. This unit
elaborates on 5S as five Japanese words, Seiri, Seiton, Seiso, Seiketsu, and
Shitsuke, which translate in English to Sort, Set in Order, Shine, Standardize,
and Sustain. Finally, the unit concludes with the details of 5S methodology so
that anyone who is looking for a way to cut waste, improve efficiency,
improve product quality.
The unit 8 entitled ‘Safeguarding of Machinery’ explains the 7 common
types of cranes are used in the industry, namely, mobile cranes, telescopic
crane, tower crane, truck mounted crane (also known as boom truck or picker
truck), rough terrain crane, loader crane (also known as a folding boom crane)
and overhead crane. Further usual hazards of working with cranes are
discussed. The unit explains the safety precautions during the crane
operations.
A life without adventure is likely to be unsatisfying, but a life in which adventure is allowed
to take what ever form it will, is likely to be short.
— Bertrand/ Russell

UNIT 5 CONCEPT OF SAFETY

ENGINEERING (ERGONOMICS,
PROCESS SAFETY)
Structure

5.1 Introduction
Objectives
5.2 Safety Engineering: Scope
5.3 Evaluation of Safety
5.3.1 Historical Background
5.3.2 Safety Concerns: New Areas
5.4 Safety Cell
5.5 Safety Functions
5.6 General Awareness of Ergonomics
5.7 Workplace Operations Requiring Safety
5.8 Safety Benefits
5.9 Safety in Design
5.9.1 Life Cycle Phases of Safe Design
5.9.2 Benefits of Safety in Design
5.9.3 Opportunity to Influence Safety Outcomes
5.10 Let Us Sum Up
5.11 Key Words
5.12 Answers to SAQs
5.13 References and Further Readings
5.1 INTRODUCTION
For Safety Engineering to succeed in any industry, a safety culture has to be
built first. Safety engineering concepts provide the structure for Safety and
Industrial design engineers to develop intrinsically safe equipment, systems,
processes and facilities. When employed early in a design process, safety
engineers provide insight into how people will interface with the equipment
and facilitate safe design accordingly. Implementation of safety aspects at
design stage will ensure not only safe design for people, but also, a safe
operational concept that will reduce equipment/plant downtime and minimize
the cause-effect of accidents. Engineered safety includes fail safe process
equipment, fault-tolerant equipment, fire safety features and enclosed
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Introduction to
Industrial Safety hazardous systems that prevent exposure to both workmen and the
Engineering environment.
Safety engineering is the engineering discipline which train students to build
and maintain engineered systems that operate free of risk or with minimum
risk to the people and environment. It is an integral part of industrial
engineering/systems engineering, and the subset, system safety engineering.
Rapid advances in technology have led to increased use of more and more
dangerous operations and use of hazardous materials in the industry today. It
becomes imperative on the part of engineers and managers to adopt systems /
processes and design / operate / maintain devices that will reduce / eliminate
the risks of injury to the physical body and long term health of the workmen.
Objectives
After studying of this unit, you should be able to:
 appreciate the importance of safety in industrial practices,
 describe workmen’s viewpoint towards safety and accidents,
 explain how safety is organized in large industries, and
 identify safety functions and processes in workplace operations and
industries.

5.2 SAFETY ENGINEERING : SCOPE

Indian industry is yet to fully come out of the age old habits of unsafe
working practices. The first and foremost job of the Safety Engineer would
be to build a Safety Consciousness/Safety Culture in the organization where
it is absent or to tone up the standards, where it already exists.
The approach has to be top-down and involvement of the highest level of
management is necessary for safety practices to succeed. Building a Safety
Cell with a dedicated team and allocation of funds is the responsibility of the
higher management. The management will have to spell out a safety policy,
generate consciousness towards safety and protection and generally oversee
that engineering functions help to build safety consciousness in workmen and
train them on various safety aspects. The cost effectiveness of all protective
methods and equipment will have to be kept in mind too.
The managerial and supervisory functions become very important in seeing
that the workmen follow the rules for safety, use personal protective devices
and that the protective equipment are available at proper places.
The engineers must design devices and processes that will reduce or
eliminate any risk during operation. Example: employing safety guards for
moving machinery parts, interlocking machine movements liable to cause
injury etc. Engineers should also try to avoid use of hazardous materials or
ensure safe handling of hazardous materials.
It is worthwhile to mention at this point that safety from accidents alone
should not be the target of Safety Engineering. Health of workmen is also
122
associated with safety. Inhaling welding fumes may not cause an accident but Concept of Safety
Engineering (Ergonomics,
can be very detrimental to health in long term. The situations in workplace do Process Safety)
not only cause physical injury or stress but also psychological stress. A
workman who is mentally stressed may forget to follow a safety precaution
and subject himself to accident. This understanding broadens the field of
Safety Engineering and requires help of specialists like safety engineers,
industrial hygienists, health physicists, occupational therapists and risk
managers.
SAQ 1
a) Why is Safety important in industry?
…………………………………………………………………………….
…………………………………………………………………………….
…………………………………………………………………………….
…………………………………………………………………………….
…………………………………………………………………………….
b) What is the first and foremost job of a Safety Engineer?
…………………………………………………………………………….
…………………………………………………………………………….
…………………………………………………………………………….
…………………………………………………………………………….
…………………………………………………………………………….

5.3 EVALUATION OF SAFETY

5.3.1 Historical Background
Large-scale industrial expansion started in the beginning of nineteenth
century but at that time little or no importance was attached to safety in the
industries. With expansion of industrial activities, the sizes of industries
multiplied and so did the number of workmen in individual industries. The
productivity of workmen increased tremendously with the aid of newer
machineries and product quality too was visibly controlled and improved.
However, all these developments did not bring about any concern to human
lives, safety and general well being of factory workmen. By the beginning of
twentieth century lack of safety concern and consciousness began to speak
upon the health of the industry. Adverse health effects began to run rampant
in workplaces. With the advent of newer and more complex technologies the
number of serious industrial accidents began to rise. It was then that a few
enlightened and progressive factory managers started feeling the necessity of
abating the causes of rising number of accidents, serious injuries to workmen
and poor health conditions in workplaces that were affecting productivity.
The early thrust started with taking care of cuts and bruises and broken bones
of factory workmen. The responsibility was largely entrusted upon personnel
managers, maintenance foremen or plant engineers. These people tried to
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Introduction to
Industrial Safety
evolve methods of safe working by providing guards on machines, shields on
Engineering implements or by making workmen use gloves and wear glasses during some
specific activities. Soon these persons were replaced by safety engineers or
supervisors and safety managers. Such need was felt greatly by two industry
giants, viz, steel industry and railroad establishment. Yet the personnel made
responsible to prevent accidents were not specifically trained for the job but
were chosen from available force based upon their wide experience in an
industry.
The situation continued until 1912 when in USA the Cooperative Safety
Congress was organized. The Electrical Engineers from steel industry took
lead in organizing this conference. The congress resulted in establishment of
National Safety Council (NSC) in USA. This body was given charter to take
responsibility to look after prevention of accidents and development of safety
programs. In post 1920 period several safety codes were formulated by
American Standards Association. The onset of second World War caused a
setback in safety movement both in Europe and America. This period was
marked by workmen’s demand for higher wages, their insistence on forming
unions to demand their rights. There was a perceptible change in government
attitude towards sacrificing safety considerations in favour of desire to win
the war. The industry managers too developed a false notion that safety was a
nonproductive activity. This set back was short lived and soon the attitudes of
governments and managements changed and they started paying more
attention to safety aspects of industrial workmen.

5.3.2 Safety Concerns : New Areas

The industries started including newer aspects in safety concerns. The noise,
dust, fumes, heat, mists and radiation etc. got included in the growing lists of
hazards in industry. This became necessary because the industrial activities
widened and scope of industrial activities expanded. This renewal of interest
was followed by governments paying more attention to safety programs and
large industries began to organize special trainings to their engineers.
These steps helped increase the number of suitably trained personnel in the
area of industrial safety. New disciplines were added to safety practices in
industry. These were industrial hygiene, health physics, ergonomics, design
engineering, illumination engineering, audiology and workmen’s
compensation claim administration. Each of these fields had twin targets of
safeguarding workmen’s health and life and improving productivity.
Tremendous amount of research work and enunciation of safety theories
propelled safety practices into academic body of knowledge and information.
In 1949 the Government of India passed the Factories Act (1948) which
provided the guiding principles of safety in Indian industries. The Act
through the years has undergone many amendments and is constantly updated
depending on the demands of the industry. A list of the guiding Standards is
provided for reference at the end of the unit (Section____) as Annexure-1 to
this unit.

124
It has now become possible for engineers and managers to specialize in Concept of Safety
Engineering (Ergonomics,
safety engineering and safety management through formal education. That a Process Safety)
chief executive of an industry needs to be equally conscious about safety and
quality is of crucial importance now. Safety, health and environmental
controls have become essential staff functions. In most industries today,
safety finds place as one of the important industrial activities along with
manufacturing, research, design and development, purchase, sales, service
and profits.
Along with the University curriculum you should also apprise yourself with
the existing Government regulations on safety.

5.4 SAFETY CELL

Every industry must have a Safety Cell with a Standard Operating Procedure
that clearly defines the objectives and functions of the Cell. It has been
experienced that safety policies often fail if safety functions are distributed or
made part of activities of several departments. Under the system of
distributed responsibilities, the safety functions have often been reported to
corporate managers through personnel and human resource department,
operational office or legal office. Such practices have mostly failed in
successful implementation of safety programs.
Safety policies can be properly implemented and safety practices succeed if
they are controlled by a single department with safety personnel interacting
with other activities functionally.
Structure of the Safety Cell in an organization will largely depend on the size
of its workforce and type of industry. Certain industries need to have
different Safety Cell structure with qualified experts at the right positions like
steel producing industry, light engineering industry and industries producing
or handling hazardous chemicals.

5.4.1 Safety Cell structure of a large industry

In a large industry, a top level corporate manager must supervise the Safety
Cell. Safety director or manager at industry level may report to the corporate
manager heading the Safety Cell. There may be several managers reporting to
safety director who would each be responsible for special safety functions
such as fire, environment, occupational health, claim for compensation etc.
These managers will necessarily interact with all other departments wherever
workmen are involved. A safety person should not be a specialist with
compartmentalized view but a broad-based expert with clear idea of
workmen’s safety and health being as the objective. Teamwork and
cooperation with others are other attributes required for being successful and
responsible safety personnel. Organizantionl chart for large, safety concious
industry has been shown in Figure5.1.

125
Introduction to
Industrial Safety
Engineering

Figure 5.1: Organizational Chart for Large, Safety Conscious Industry

Various levels of responsibility are identified and described below:
i) Level 1
This is the corporate level and there should be a company director who
will be engaged in formulating safety policies at this level. These
policies will be continuously monitored and upgraded as required. The
company director will have to see that safety audits are made regularly.
She must be readily available for advising and guiding the safety
personnel. The company director must appoint a general manager safety
at company level.
ii) Level 2
This is at company level and the general manager, safety directly reports
to the corporate director. He has to continuously monitor safety policies
of the company and bring about necessary improvement in the light of
directives issued from time to time by the higher management and
experiences gained from the field. She must also see that the directives
and policies are in accordance with governmental regulatory standards.
She should provide guidance and assistance for training of safety
personnel at various levels and must conduct seminars / workshops on
Introduction to Safety Engineering and arrange internal and external
industrial Safety audits. He must see that safety records are properly
maintained and data and information regarding safety status of the
company are available.
iii) Level 3
This level works at plant level and would directly report to general
manager safety. There must be four plant safety managers, one each for
fire safety, environmental control, occupational health and professional
service. Specific conditions and size of plant may dictate combining two
or three of these functions under a single plant level manager but in all
126
 cases the functions should remain separate and, identifiable. The main Concept of Safety
Engineering (Ergonomics,
responsibilities at this level include : (1) development of procedures for Process Safety)
implementing safety measures on equipment / processes and outlining
safe working practices for workmen in consultation with the shop floor
safety supervisors and taking into account their feedback on existing
systems. (2) Readiness and preparedness to deal with emergency
situations, (3) coordination and providing feedback to other managers in
the areas of design, manufacture, purchase, sale, research & development,
etc. to have a comprehensive safety policy in place. (4) A plant manager
will also have the full responsibility to investigate the injuries to a
workman on job site and report the matter to higher officials.
iv) Level 4
This level comprises representatives of safety departments working at
shop floor level or with workmen. They are the first line of defense
against any mishap in the workplace and need to be on a strict vigil all
the time. The personnel will actually
1. implementing the main responsibilities of such personnel include
safety procedures,
2. training workmen on procedures,
3. guiding them in adopting the procedure.
4. They also monitor and analyse how workmen follow safety
procedures and take preventive action where necessary.
5. They provide all support for maintenance of environment and its
preservation.
The Plant Safety manager has to put due importance to their
feedback and suggestions for continuous improvement on the safety
aspect.
6. Most importantly the personnel at level 4 will conduct safety drills at
regular intervals.

5.5 SAFETY FUNCTIONS

In the statement about safety cell various functions have been mentioned. The
same are explained in detail here:
 Industrial safety Compensation:
There are two kinds of compensation. One is against injury or long term
occupational health hazards covered by the Workmen's Compensation
Act, 1923 and other is against longer working hours covered by Sec. 59
of Factories Act, 1948.
 Property conservation:
Under this segment the role of the Safety Engineer is to ensure that apart
from ensuring safety of the workmen, property of the organization is also
safeguarded from all possible hazards, mainly fire.
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Introduction to
Industrial Safety
 Safety in material handling:
Engineering
The Indian Government has several IS specifications for guidance on
safe material handling procedures to be followed. Eg. IS 8324-1988
applies to Lifting chain & chain slings.
Employers, supervisors, owners and constructors, among others, are
required to know and comply with the regulations that apply to their
workplaces. For the specifics on the regulations that cover one’s
workplace, one will need to look up the applicable IS specification/s.
 Industrial hygiene:
Complying with occupational health and safety regulations is not just
about providing helmets and protective clothing. A work place could be
a source of risk through exposure to gases and radiation, as well as
hazards relating to temperature control, noise and micro pollutant
contamination. As a Safety Engineer to maintain the hygiene of your
workmen, mainly you will have to reduce or eliminate the ill effects of
acidic gases, Ammonia and sulphuric acid, asbestos and irrespirable dust,
heat stress, harmful organic gases and vapours, illumination problems
(light intensity) and noise pollution.
 Environmental control:
To exercise proper environmental control in a factory you will have to
monitor and take action on the following:
I. Air quality: This requires checking of parameters like VOC
(Volatile Organic Compounds), Benzene, NOx, H2S, SO2, SPM
(Suspended Particulate Matter) and RSPM (Respirable Suspended
Particulate Matter) and keeping within acceptable limits.
II. Stack Monitoring: This involves stack emission testing from Boiler,
DG set stack, Chimney, scrubber etc. for parameters like sulphur
dioxide (SO2), Total Productive Management (TPM), Dichloride
(Cl2) etc..
III. Noise level monitoring: This involves monitoring and impact
assessment of problem areas which may impact human health and
employing measures to contain them.
IV. Waste water management: This includes effluent treatment or
sewage treatment to bring it to acceptable levels before releasing to
outside drainage.
Another aspect is to take effective steps for conservation of water.
 Occupational health:
The major occupational diseases of concern in India are accidents,
silicosis, musculo-skeletal injuries, coal workers' pneumoconiosis,
chronic obstructive lung diseases, asbestosis, byssinosis, skin related
disorders, pesticide poisoning, noise induced hearing loss and workplace
128
 stress. As a Safety Engineer one has to ensure that the workmen do not Concept of Safety
Engineering (Ergonomics,
suffer from the above problems. Process Safety)

 Health and safety information system:

Maintaining proper records at all stages of the safety programme is of
utmost importance. Record of safety training and drills will allow you to
maintain repeatability and keep the programme alive in people’s mind.
Record of accidents, their analysis, record of hazardous waste disposal
and such other activities are declared mandatory by the Government.

SAQ 2
a) As a Safety Engineer in an industry what are the aspects you need to
look into?
b) Under what circumstances do Safety Policies of an organization fail?
c) Briefly describe the various levels of responsibility in the Safety Cell
of a large organization.
d) What are the different safety functions?
e) What type of occupational health hazards are usually found in Indian
industries?

5.6 GENERAL AWARENESS OF ERGONOMICS

Ergonomics, also called human factors is the application of psychological and
physiological principles of human body to engineering and designing of
products, processes and systems. It combines the knowledge of multiple
disciplines like psychology, physiology, sociology, engineering,
biomechanics, visual design, user interface design and others. Through these
disciplines, human behaviour in studied so that the findings are applied to the
primary objectives of reducing human error, increasing productively safety
and comfort and promoting interaction.
Using Ergonomics in workplace reduces costs, improves productivity and
quality, improves employee engagement and creates a better safety culture.
Simply put, ergonomics is an applied science of designing and arranging
things people use in order to increase efficient and safe interaction of people
with those things. For example, studying how office goers who sit in offices
get work related back injuries or those working for long hours on computers
weaken their eye sight.
The first international ergonomics standard developed (based on a German
DIN national standard) is ISO 6385, ‘Ergonomic principles in the design of
work systems which was published in 1981. It is the basic standard of the
ergonomics standards series and set the stage for the standards which
followed by defining the basic concepts and stating the general principles of
the ergonomic design of work systems, including tasks, tools, machinery,
workstations, work space, work environment and work organization.

129
Introduction to
Industrial Safety
This international standard is a guideline standard, and provided guidelines to
Engineering be followed. It does not, however, provide technical or physical
specifications which have to be met. These can be found in a different type of
standard called specification standards. For example, those on anthropometry
or thermal conditions.
Both types of standards fulfil different functions. While guideline standards
intend to show their users, “what to do and how to do it” and indicate those
principles that must or should be observed, for example, with respect to
mental workload; specification standards provide users with detailed
information about safety distances or measurement procedures for example,
that have to be met and where compliance with these prescriptions can be
tested by specified procedures.
This is not always possible with guideline standards, although despite their
relative lack of specificity, it can usually be demonstrated when and where
guidelines have been violated. A subset of specification standards are
“database” standards, which provide the user with relevant ergonomics data,
for example, body dimensions.
CEN (European) standards are classified as ‘A’, ‘B’ and ‘C’ type standards,
depending on their scope and field of application. ‘A’ type standards are
general, basic standards which apply to all kinds of applications, ‘B’ type
standards are specific for an area of application (which means that most of
the ergonomics standards within the CEN will be of this type), and ‘C’ type
standards are specific for a certain kind of machinery, for example, hand-held
drilling machines.
To reduce the chance of injury, work tasks should be designed to limit
exposure to ergonomic risk factors. Engineering controls are the most
desirable, where possible. Administrative or work practice controls may be
appropriate in some cases where engineering controls cannot be implemented
or when different procedures are needed after implementation of the new
engineering controls. Personal protection solutions have only limited
effectiveness when dealing with ergonomic hazards. For example if a
workman has to continuously bend or twist his body as a requirement to
execute the job, in the long run, he may damage his spine. PPE (Personal
Protective Equipment) would not be of much help in such cases. Your job as
a safety engineer would be to review the work process and equipment and
provide an ergonomic solution.

5.7 WORKPLACE OPERATIONS REQUIRING

SAFETY
The operations performed by workmen in their workplace are of different
nature, but they involve some machine, equipment and material. The safety
precautions are adopted for machines and operations performed on them.
Many operations require hazardous material or handling of materials in
hazardous state.
Here are some operations which are either machine or equipment or material
130 specific and need safety practices.
i) Electrical assembly and fabrication Concept of Safety
Engineering (Ergonomics,
ii) Electronic assembly and cleaning Process Safety)
iii) Use of electrical tools
iv) Use of chemical agents and chemical treatments
v) Use of biological materials and treatments
vi) Use of acidic and alkaline materials
vii) Toxic vapour applications
viii) Use and production of mists, dust
ix) Use of boiler and use of compressed air and gas
xi) Use of combustible and toxic gases and liquids
xii) Processing of radioactive sources and treatments
xiii) Painting and mixing of paints
xiv) Spraying of paints and liquid metals
xv) Welding gas and electric, brazing and soldering
xvi) Wood cutting and working
xvii) Sawing metal and wood
xviii) Sanding, sand blasting and shot peening
xix) Burning and furnace application
xx) Casting and foundry practice
xxi) Digging
xxii) Climbing
xxiii) Masonry work particularly at lofty heights
xxiv) Hoisting and lifting
xxv) Machining on lathes and mills
xxvi) Shearing
xxvii) Cutting
xxviii) Drilling
xxix) Jointing

5.8 SAFETY BENEFITS

An industry or a company that follows safety programs is benefitted in
several ways. The benefits are shared between employer and employees
directly and consumers are indirectly benefitted. A sound safety policy will
eliminate or reduce greatly the accidents where by the employer will save
cost of lost man-hours and machine down-time. The employer will also save
on paying compensation and replacement or repair of equipment. The
employees feeling safe to work will show better productivity. Also since a
sound safety policy will guarantee an adequate compensation, the employees
will work without apprehension and psychological pressure. The latter factor
often causes accidents.
The increased productivity and quality consciousness will produce goods
which will be to the liking of the customer.
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Introduction to
Industrial Safety 5.9 SAFETY IN DESIGN
Engineering

Amec Foster Wheeler was a British multinational consultancy which is now

owned by the Wood Group. It give a systematic approach to engineering
safety into the design. It is a five‐step approach to engineering design which
results in the ability to demonstrate that hazards to people, the environment,
assets, and reputation have been systematically and comprehensively
identified, and eliminated or controlled during the design phase of the
facility/system or equipment. These five steps are:
1) Defining safety goals: Goals are necessary to maintain focus in the safety
by design process. They should reflect regulatory requirements,
legislation of risk and sustainability strategies on safety and environment.
2) Understanding hazards: If hazards are not known they cannot be
controlled. Project specific health and safety hazards and environmental
impacts should be understood well in advance.
3) Implementing inherent safer design principles: Inherently safer design
can be achieved by adopting a strategy based on the following principles:
a) Eliminate: removal of dangerous material, processes and activities.
b) Minimise: using smaller quantities of hazardous substances and
minimizing the number of hazardous activities.
c) Substitute: Replacement of hazardous or expensive material or
activity with a lesser one.
d) Moderate: minimizing the potential impact of release of substances
or energy and the number of people exposed to it.
e) Simplify: eliminating complexity to minimise the possibility of
human error.
4) Managing residual risks and environmental impacts: If inherent control
cannot be fully achieved or is inadequate, residual risks and
environmental impacts will remain and need to be managed. This may
require additional engineered or procedural controls.
5) Consolidating and communicating: Once the safety by Design process
has been completed as required and the goals identified in the first step
have been met, the process may be closed. The findings are consolidated
and communicated to the external and internal stakeholders.
As a result of the safety by design process, the overall risks of operation of
the designed equipment / plant are minimized by eliminating hazards or
applying the right hazard controls to minimize the identified hazards. Further
more, the design elements to control or eliminate the hazards are identified
and designed early in the design process when the implementation cost is at a
minimum.

132
5.9.1 Life Cycle Phases of Safe Design Concept of Safety
Engineering (Ergonomics,
Process Safety)
The life cycle phase of safe design is shown in Figure5.2

Figure 5.2: Life Cycle Phases of Safe Design

5.9.2 Benefits of Safety

The benifits of life cycle phase in work place health and safety benefits and
its benefit on project is given below:

Life cycle Workplace Health and Project Benefits

Phase Safety (WHS) Benefits
Design • Risks Identified • Reduced re-design or
• Risks reduced/ retrofitting
controlled • Reduced life cycle OHS
costs
Construction • Communication of • Informed contractor
residual risks to reduces risk contingency
contractor • Decreased time and no
• Reduced likelihood of over-running cost
accidents
Operation • Occupant Health & • Reduced costs (absence &
Safety claims)
• Public Health & • Company image - Reduced
Safety civil claims
Maintenance • Safe access for • Informed contractor
& Repair maintenance and reduces risk contingency
repair strategies • Reduction in maintenance
• Reduced likelihood of costs
accident  Reduction in repair costs

Demolition/  Communication of  Informed contractor

Refurbishment residual risks to the reduces risk contingency
contractor  Decreased time and no
 Reduced likelihood of over-running cost
unplanned events

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Introduction to
Industrial Safety
5.9.3 Opportunity to Influence Safety Outcomes
Engineering
Various opportunity to Influence Safety Outcomes has been shown in Figure
5.3

Figure 5.3: Opportunity to Influence Safety Outcomes

SAQ 3
a) What are the benefits of using ergonomics in the industry?
b) Name five common operations in the factories which need safety
practices to be implemented.
c) What are the benefits of following safety practices?
d) What are the benefits of incorporating safety at the design stage of
an equipment / plant?

5.10 LET US SUM UP

Safety and health of a workman in the workplace is important for industrial
practices to benefit all. Today safety concerns are widely regarded essential
in industry and governments make regulations to see that employers
implement safety practices. However, this concern started to be felt first in
1912 in USA. Before it could mature, the onset of Second World War
diminished the importance of safety. The industrial nations of that time
sacrificed safety for victory in war. But soon the professionals were
convinced that safety could not be overlooked. It not only established itself as
an essential practice but also developed into an academic subject in its own
right requiring specialized knowledge and research. Thus, trained and
educated safety engineers become available.
Now the industries follow safety directives and policies made at corporate
levels. At company or factory level their implementation is guided, reported
and audited by trained personnel. Such policies also keep government
regulations in mind and their compliance is necessary. Regular safety drills
134 and training of workmen, availability and upkeep of protection gears along
with written instructions have become common safety management functions. Concept of Safety
Engineering (Ergonomics,
Each industry must identify its safety functions and operations that will Process Safety)
attract safety considerations. Sound safety policies keep all three of
employees, employers and customer satisfied.

5.11 KEYWORDS
Safety: Workmen are not hurt, injured physically or psychologically and
maintain good health.
Workplace:The place where industrial and construction works are carried
out.
Health: The state of well being of workmen so that capacity of working is
not adversely affected.
Safety manager and supervisor: The personnel who initiate and monitor the
safety policies of the organization are safety managers. The personnel who
supervise implementation of Engineering safety policies are supervisors
Industrial hygiene: The conditions leading to keeping of good health in the
industrial atmosphere, mainly related to cleanliness.
Health physics: The conditions related to physical facilities and conditions
that help workmen to maintain good health.
Safety functions: Establishing of policies and execution in respect of safety.
Safety Cell: The designated department or unit in an organisation
responsible for maintaining safety.
Safety Benefits: Advantages accrued from safety policies.
Operations: The physical actions for production, repair and services.

5.12 ANSWER TO SAQs

SAQ 1
a) Rapid advances in technology have led to increased use of more and
more dangerous operations and use of hazardous materials in the
industry today.
Safety in industry have become important so that risks of injury to
the physical body and long term health of the workmen, as also
machineries can be reduced or eliminated. This in turn helps to
boost employee morale, increase throughput and quality of product
that finally improves the organization’s bottom line.
b) The first and foremost job of the Safety Engineer would be to build a
Safety Consciousness / safety Culture in the organization where it is
absent or to tone up the standards, where it already has the roots.
The approach has to be top-down and involvement of the highest
level of management is necessary for Safety practices to succeed.
Building a Safety Cell with a dedicated team and allocation of funds
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Industrial Safety
is the responsibility of the Higher Management which will have to
Engineering be initiated by the Safety Engineer.
SAQ 2
a) A Safety Engineer should cover the aspects of industrial hygiene,
health physics, ergonomics, design engineering, illumination
engineering, audiology and workmen’s compensation claim
administration. Each of these fields had twin targets of safeguarding
workmen’s health and life and improving productivity.
b) It has been experienced that safety policies often fail if safety
functions are distributed or made part of activities of several
departments. Under the system of distributed responsibilities, the
safety functions have often been reported to corporate managers
through personnel and human resource department, operational office
or legal office. Such practices have mostly failed in successful
implementation of safety programs.
c) Various levels of responsibilities in the Safety Cell of a large
organization are briefly described below.
i) Level 1
This is a corporate level and there should be a company director who
will be engaged in formulating safety policies at corporate level.
These policies will be continuously monitored and upgraded as
required with the help of personnel at the lower levels.
ii) Level 2
This is at company level and the general manager will directly report
to the corporate director. He has to continuously monitor safety
policies of the company and bring about necessary improvement in
the light of directives issued from time to time by the higher
management and experiences gained from the plant level. He must
also see that the directives and policies are in accordance with
governmental regulatory standards.
iii) Level 3
This level works at plant level and would directly report to general
manager safety. There must be four plant safety managers as
identified by four plant safety functions, namely fire safety,
environmental control, occupational health and professional service.
iv) Level 4
This level comprises representatives of safety departments working
at shop floor level or with workmen. The personnel will actually
implement safety procedures, train workmen on procedures, guide
them to adoption of procedure. They will monitor and analyse on
how workmen are following safety procedures and take preventive
action where necessary.

136
 d) The different Safety functions are as listed below: Concept of Safety
Engineering (Ergonomics,
 Industrial safety Compensation Process Safety)
 Property conservation
 Safety in material handling
 Industrial hygiene
 Environmental control
 Occupational health.
 Health and safety information system.
e) The major occupational diseases/morbidity of concern in India are
accidents, silicosis, musculo-skeletal injuries, coal workers'
pneumoconiosis, chronic obstructive lung diseases, asbestosis,
byssinosis, skin related disorders, pesticide poisoning, noise induced
hearing loss and workplace stress.
SAQ 3
a) Using Ergonomics in a workplace reduces costs, improves
productivity and quality, improves employee engagement and creates a
better safety culture. It reduces the fatigue of workmen resulting their
better health and reduction in handling time increases productivity.
b) Some common operations in factories that require safety practices to
be implemented are,
 Use of electrical tools
 Use of chemical agents and chemical treatments
 Toxic vapour applications
 Casting and foundry practice
 Masonry work particularly at lofty heights
c) A sound safety policy will eliminate or reduce greatly the accidents
whereby the employer will save cost of lost man-hours and machine
down-time. The employer will also save on paying compensation and
replacement or repair of equipment. The employees feeling safe to
work will show better productivity. Also since a sound safety policy
will guarantee an adequate compensation, the employees will work
without apprehension and psychological pressure.
d) By incorporating safety at the design stage the overall risks of
operation of the designed equipment / plant are minimized by
eliminating hazards or applying the right hazards controls to minimize
the identified hazards. By eliminating the hazards in the design process,
the implementation cost is also minimum. Future machine down-time
compensation to employees can be avoided.

5.13 REFERENCES AND FURTHER READINGS

[01] ELECTRICAL SAFETY HAZARDS HANDBOOK:
https://www.lanl.gov/safety/electrical/docs/arc_flash_safety. pdf
[02] Occupational Safety and Health Simplified for the Industrial Workplace
Frank R. Spellman.
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Industrial Safety
[03] Safety and Environmental Management, Frank R. Spellman, 3, Publisher
Engineering Bernan Press, 2015, ISBN 159888770X, 9781598887709.
[04]
https://www.bristol.ac.uk/civilengineering/bridges/Pages/Engineering%20Saf
ety%20By%20David%20Blockley.pdf

138
UNIT 6 STORAGE OF MATERIAL
HANDLING OF HAZARDOUS
MATERIAL
Structure
6.1 Introduction
Objectives
6.2 General Hazardous
6.3 Safe Storing of Hazardous Materials
6.3.1 Fire and Explosion Risks
6.3.2 Emergency Action Plan
6.4 Material Handling
6.4.1 Material Handling Equipment
6.4.2 Bulk Handling Material Equipment
6.4.3 Engineered Systems
6.4.4 Industrial Trucks
6.4.5 Storage and Handling Equipment
6.4.6 Types of Storage and Handling Equipment
6.5 Manual and mechanical material handling
6.5.1 Precautions when Lifting and Carrying Long Objects as Team
6.5.2 Precautions when lifting and Moving Furniture as a Team.
6.5.3 The Legal Aspect
6.6 Electrical Handling
6.7 Principles of Material Handling
6.8 Safety in Material Handling
6.9 Let Us Sum Up
6.10 Key Words
6.11 Answers to SAQs
6.12 References and Further Readings

6.1 INTRODUCTION
We all know how important it is to take precautions when working with
hazardous materials. But we may not always recognize that it’s equally
important to maintain the same high level of safety when these materials are
in storage.
You will recall the Bhopal gas tragedy of 1984 when an estimated 15 to 20
thousand people died and about three to five lakh people were genetically
affected and the genetic mutations continued into their future generations as
well. It is to be noted that the plant was not in operation for quite a few
months and it was faulty storing of toxic material that caused this massive
tragedy. There have been similar incidents in history time and again which
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have proved to be eye openers on the importance of safely storing hazardous
Engineering materials.
Even when hazardous materials are out of sight and in containers, one should
be mindful of their storage.If they're stored properly, these substances
shouldn't cause problems. But unless we're all aware of what safe storage
means, and how to protect ourselves in a storage area, we run the risk of
accidents. And we can't afford to take that risk with hazardous materials. So
in this unit, we will discuss the basics of safe storage of hazardous materials
and the precautions we should follow when we're in those areas. We will also
discuss Emergency Action Plan if hazardous materials go out of containment.
We will also look more closely at some specific high-risk substances so that
you can better understand why we store these materials as we do.
The Occupational Safety and Health Administration has detailed rules for the
location and construction of rooms or buildings that contain these substances,
including explanations of what can't be stored with different types of
hazardous materials. As you realize that every aspect of storage room design
has a reason and purpose, you'll be better able to see to it that those storage
areas and the substances stored in them, are kept safe.
Objectives
After studying this unit you will be able to:
 describe the kinds of health hazards;
 appreciate the importance of safe storing of hazardous material;
 classify material handling equipment;
 explain manual and mechanical material handling; and
 describe electrical handling and electrical safety tips.

6.2 GENERAL HAZARDS

A hazard is broadly defined as an agent which has the potential to cause harm
to a vulnerable target. They may be natural or man made. As regards storage
of hazardous material, the substances we use and store can pose a number of
different hazards if they're not handled and used properly and safely.
Some of the hazards are physical hazards. These could include:
 Fire
 Explosion
 Sudden release of pressure (for instance, if a tank of compressed gas is
punctured)
 Reactivity (fire, explosion, or release of dangerous gases that can result
from contact between chemicals and certain other chemicals or air or
water)
There are also many potential health hazards that can result from over
exposure to hazardous substance(s) through a length of time. Working in a
rubber factory can be an example. Sometimes the hazard is minor, like a
headache or mild skin rash. But other health hazards are much more serious.
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 Storage of Material
For instance, skin burns from contact with corrosive chemicals. With some Handling of Hazardous
substances, too much exposure or prolonged exposure could cause organ Material
damage, allergic reactions, cancer or, in the worst cases, death.
Sometimes the risk isn't just to the individuals working with or near the
substance in question. A major spill of a chemical that is dangerous to health
can pose dangers to many people if it gets into the water supply. If there's a
fire or explosion that releases toxic gases, they could spread out to harm
people in the neighbourhood.
So there are a lot of potential risks including some very serious ones in any
hazardous material storage area. Fortunately, there are also excellent
safeguards against those risks becoming realities. Our storage areas are
designed for safety and maintained for safety. That's only good sense, and in
many instances, it's also the law.
Handling and storing materials involve diverse operations such as hoisting
tons of steel with a crane; driving a truck loaded with concrete blocks;
carrying bags or materials manually; and stacking palletized bricks or other
materials such as drums, barrels, kegs, and lumber.

The efficient handling and storing of materials are vital to industry. In

addition to raw materials, these operations provide a continuous flow of parts
and assemblies through the workplace and ensure that materials are available
when needed. Unfortunately, improper handling and storing of materials
often result in costly injuries.

SAQ 1
a) What are the general hazards in industries?
b) Describe some hazards in storing and handling of materials.

6.3 SAFE STORING OF HAZARDOUS

MATERIALS
The Directorate General of Factory Advice Service and Labour Institutes under the
Ministry of Labour, GOI, has drafted a National Occupational Safety and
Health (OSH) Profile that industries are required to follow. One has to ensure
that chemicals and dangerous substances are stored and handled to minimise
risks and limit people's exposure to them.
One needs to assess the risks of storing and handling dangerous substances.
This includes the possibility of environmental damage caused by leaks and
spills.
Precautions needed to control risks must be taken. This includes:
 storing chemicals or other hazardous substances according to the
manufacturer's instructions on the safety data sheet.
 keeping the minimum quantity of hazardous substances needed.
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Industrial Safety
 storing incompatible substances separately.
Engineering
 taking steps to prevent release or leakage of dangerous substances.
 keeping a spill kit near the storage areas, and ensuring that staff are
trained in what to do in the event of a spill
 cleaning up any leaks or spills that occur
 using the right precautions when handling substances - for example,
wearing protective clothing or ensuring adequate ventilation.
 ensuring employees who store and handle dangerous substances are
properly trained
 checking that containers used for short-term storage are properly labelled.

6.3.1 Fire and Explosion Risks

There are certain safety measures to be taken in case of fire and explosion
related risks. These are discussed below:
1. If you store chemicals or dangerous substances that could create a fire or
explosion, you must also comply with the applicable Industrial Safety (IS)
specification. For example, IS 3594-1991 for General Storage &
warehouses and IS 3034-1993 for Electrical Generating & distribution in
industrial buildings.
2. Ensure that flammable substances are correctly stored in suitable
containers and are not stored near to a source of ignition such as a heater.
3. Some of the best practices are to:
 Place stores of liquid above the ground level where they are unlikely
to be damaged, eg. away from traffic routes
 Avoid overfilling containers
 Supervise deliveries
 Maintain gauges, valves and pipework
 Monitor oil use - unexpectedly high use may indicate a leak
 Have procedures for dealing with emergency leakages
 Use a secondary containment system such as a drip tray or bund (a
storage area designed to prevent liquids escaping)

6.3.2 Emergency Action Plan

In spite of taking all precautions disasters do happen. You will need to have
an Emergency Action Plan in place for such eventualities. The guidelines of
framing such a Policy is given for your understanding but the actual Policy of
any organisation will depend and have to be framed based on the type of
industry you are working in, its layout, the kind of possible hazards and other
individual characteristics of the organisation.
An emergency action plan (EAP) has to be a written document. The purpose
142 of an EAP is to facilitate and organize employer and employee actions during
 Storage of Material
workplace emergencies. Well-developed emergency plans and proper Handling of Hazardous
employee training (such that employees understand their roles and Material
responsibilities within the plan) will result in fewer and less severe employee
injuries and less structural damage to the facility during emergencies. A
poorly prepared plan, is likely to lead to a disorganized evacuation or
emergency response, resulting in confusion, injury, and property damage.

6.3.2.1 Minimum Requirements

Putting together a comprehensive emergency action plan that deals with those
issues specific to your worksite is not difficult. It involves taking what was
learned from your workplace evaluation and describing how employees will
respond to different types of emergencies, taking into account your specific
worksite layout, structural features, and emergency systems.

6.3.2.2 Develop and Implement an EAP

Drafting an emergency action plan (EAP) is not enough to ensure the safety
of your employees. When an evacuation is necessary, you will need
responsible, trained individuals who can supervise and coordinate activities
to ensure a safe and successful evacuation. A disorganized evacuation can
result in confusion, injury, and property damage.

6.3.2.3 Fight or Flee

A fire is the most common type of emergency for which small businesses too
must plan. Evacuation plans that designate or require some or all of the
employees to fight fires with portable fire extinguishers, increase the level of
complexity of the plan and the level of training that must be provided to the
employees.

6.3.2.4 Shelter-in-Place
Chemical, biological, or radiological contaminants may be released into the
environment in such quantity and/or proximity to a place of business that it
may be safer to remain indoors than to evacuate employees.

6.3.2.5 Fire, Rescue, Medical Services

Although most of us quickly move away from the hazardous environments
created during emergency situations, a group of dedicated and well-trained
professional emergency responders and medical service personnel should be
tasked with containing and mitigating these incidents, rescuing individuals at-
risk, and providing medical assistance to the injured.

6.3.2.6 Reporting Emergencies

Employees must know how to report emergencies. In times of crisis, there are
various means of internal communication like intercom, or public address
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Introduction to
Industrial Safety
systems to notify other employees. It is important for employees to further
Engineering notify the authorities such as fire, medical, or rescue services, if your
company relies on this type of assistance during an emergency.

SAQ 2
a) What are the best practices of storing hazardous materials?
b) What is EAP?

6.4 MATERIAL HANDLING

Material handling is the movement, protection, storage and control of
materials and products throughout manufacturing, warehousing, distribution,
consumption and disposal. As a process, material handling incorporates a
wide range of manual, semi-automated and automated equipment and
systems that support logistics and make the supply chain work.

6.4.1 Material Handling Equipment

The term ‘material handling equipment’ is a broad one. There are plenty of
situations where it’s critical to move large and often heavy materials in a
production environment. Any piece of equipment that helps with this process
is called material handling equipment. Plenty of items fall under this
definition, from tools and storage units to vehicles and major appliances.
Anything that deals with the transportation, storage and control at any stage
of the processing of materials can also be classified as material handling
equipment.
6.4.1.1 Categories of Material Handling Euipment
There are 4 main categories of material handling equipment:
 Bulk material handling
 Engineered systems
 Industrial trucks
 Storage and handling equipment

6.4.2 Bulk Handling Material Equipment

The term ‘bulk handling equipment’ refers to the storage, control and
transportation of materials in bulk and in loose form. There are plenty of
examples of this applicationlike large scale handling of food, beverages,
liquids, metal items (such as screws and nails) and minerals to name a few.
In general terms, such equipment is used to handle these items when they are
loose. One example is a conveyor belt that is used to move items from one
part of the production process to another. Drums and hoppers may be used as
well, to ‘funnel’ these loose items into a stage where they can be more easily
processed, or packaged.
Conveyor belts are used for horizontal transportation. For vertical
144 transportation, elevators are most commonly used.
Types of bulk handling material equipment Storage of Material
Handling of Hazardous
Material
There are different type of Bulk Handling equipment which are as follows:
 Bucket and Grain Elevators (Figure 6.1)

Figure 6.1: Bucket and Grain Elevators

 Conveyor Belts (Figure 6.2)

Figure 6.2: Conveyor Belts

 Hoppers and Silos (Figure 6.3)

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Introduction to
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Figure 6.3: Hoppers and Silos

 Reclaimers (Figure 6.4)

Figure 6.4: Reclaimers

 Stackers (Figure 6.5)

Figure 6.5: Stackers

6.4.3 Engineered Systems

146
 Storage of Material
An engineered system is one that is typically automated. Such systems are Handling of Hazardous
usually created from a variety of units. When combined, they work to enable Material
both storage and transportation.
An Automated Storage and Retrieval System (or AS/RS in short) is one
example of a system that is engineered. This is a large, automated device that
comes complete with racks, shelves and aisles. These storage solutions are
accessed by a ‘shuttle’ – a mechanized device.
This type of devices can be used by the system operator to manually select
the items as needed, or the entire system can be computerized and automated.
An AS/RS can be integrated with a production facility’s existing computer
network to keep a tab on stock control and other logistical systems. It can
also be integrated with other stages of the production process, so that as much
automation can be offered as possible.
6.4.3.1 Types of Engineered Systems
 Automated Guided Vehicles (Figure 6.6)

Figure 6.6: Automated Guided Vehicles (AGVs)

 Conveyor Systems (Figure 6.7)

Figure 6.7: Conveyor Systems

 Robotic Delivery System (Figure 6.8)

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Introduction to
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Figure 6.8: Robotic Delivery System

6.4.4 Industrial Trucks

Industrial trucks provide transportation and include different types of
equipment like small, hand-operated devices and large-scale motorized
vehicles. Some items can be driven, while others, such as pallet trucks,
simply add mobility to the materials being handled.
Industrial trucks have useful characteristics such as forks or a flat surface that
can be inserted under pallets or other types of storage platforms. Other trucks
need separate attachments to be used for lifting.
Trucks have the capability to lift and tilt via powered or manual means, and
can be ridden upon in a driver’s cab, or simply power-assisted when pushed.
Such tucks can also be steered by human intervention, or can be completely
automated, following a pre-defined track on the production floor, sunken or
raised tracks, or coloured strips that are laid out and sensed by optical sensors.
Such automated industrial trucks also have anti-collision technology that
senses when an employee or other obstacle is near.
Stacking trucks are used to stacks items, while a non-stacking truck is just
used for transportation, and not for product loading.
6.4.4.1 Types of Iindustrial Trucks:
Given below are the types of industrial trucks:
i) Automated guided vehicles (AGVs)
Automated guided vehicles has been shown in Figure 6.6.
ii) Hand, platform and pallet trucks
 Hand, platform (Figure 6.9)

148
 Storage of Material
Handling of Hazardous
Material

Figure 6.9: Hand, Platform

 Pallet jacks (Figure 6.10)

Figure 6.10:Hand Operated Pallet Jacks

 Order pickers (Figure 6.11)

Figure 6.11: Order Pickers

149
Introduction to  Side-loaders (Figure 6.12)
Industrial Safety
Engineering

Figure 6.12: Sid-loaders

 Walking stackers (Figure 6.13)

Figure 6.13: Walking Stackers

6.4.5 Storage and Handling Equipment

In the previous section, we learnt about engineered systems which are
automated storage and handling equipment. Equipment that is used for
storage usually consists of items that are not automated.
Storage equipment is equipment that is used to hold products and materials
when they are not being used, or when they are waiting to enter or leave the
production process. These periods could be long-term, or short-term in order
to allow a suitable build-up of stock or finished items.
Most items that can be described as storage and handling equipment are
refered to as pallets, racking or shelves. Materials are stored in a neat and
convenient manner to await transportation, or their entry into the production
process as necessary.
150
 Storage of Material
Having suitable storage equipment will add to any company’s production Handling of Hazardous
efficiency. The efficiency of any production system is maximized by the ease Material
at which each stage of the entire system operates. Any inefficient section
creates a bottleneck that will have an effect on all other sections of the system
further down the production line.
Space is also at a premium if you run a production environment. The better
utilized the available space is, the more the items that canbe stored. This
means the workflow can be in operation for much longer without worrying
about re-stocking. This helps to further increase efficiency.

6.4.6 Types of Storage and Handling Equipment

 Drive-through or drive-in racks (Figure 6.14)

Figure 6.14: Drive in Racks

 Pallet racks (Figure 6.15)

Figure 6.15: Pallet Racks

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Introduction to  Push-back Racks (Figure 6.16)
Industrial Safety
Engineering

Figure 6.16:Push Back Racks

 Shelving (Figure 6.17)

Figure 6.17: Shelving

 Sliding Racks (Figure 6.18)

Figure 6.18: Sliding Racks

152
 Storage of Material
Handling of Hazardous
 Stacking Frames (Figure 6.19) Material

Figure 6.19: Stacking Frames

SAQ 3
a) What are 4 main categories of material handling equipment?
b) Elaborate on ‘Engineered Material Handling Systems’.

6.5 MANUAL AND MECHANICAL MATERIAL

HANDLING
Manual material handling is the lifting, carrying or moving of materials,
articles or things by manual labour. Mechanical material handling is the
movement of materials, articles or things by such means as lift trucks,
conveyors, or cranes and hoists mostly through manual control.
One of the more frequent, higher risk outcomes of manual material handling
is musculo skeletal disorders (MSDs). MSDs are injuries or pain in the
human muscular and skeletal systems, including the joints, ligaments,
muscles, nerves, tendons and skeletal system that supports limbs, necks and
back. It is found that the most common MSD is caused due to obstructions on
floors interfering with safe movement of materials; unsafe material lifting,
carrying and moving; unsafe storage of material and lack of examination of
lifting devices.
MSDs have become an important workplace health and safety issue.
Commonly observed reasons for MSDs are:
 Improperly securing vehicles against accidental movement, tipping or
falling
 Unsafe loading and unloading procedures
 Not using wheel chocking
 Work surface hazards
 Pinch point hazards
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Material handling operations are carried out in most workplaces either with
Engineering the use of physical might only, or when heavier or awkward materials are to
be handled, by using either motorized or non-motorized lifting equipment.
Each handling task poses unique demands on the worker. However,
workplaces can help workers to perform these tasks safely and easily by
implementing and upholding proper policies and procedures.
Let us understand how purely manual handling of heavy loads can be
managed by the example of Team Lifting or Team Handling,.
"Team handling" occurs when more than one person are involved in lifting or
handling heavy loads. Here are a few steps that a team can take while
handling heavy loads:
 Use team lifting and carrying where other solutions are inappropriate.
 Remember that the combined strength of the team is less than the sum of
individual strength.
 Select team members of similar height and strength.
 Assign a leader to the team.
 Determine a set of commands to be used such as "lift", "walk", "stop",
 "down". Make sure that everyone knows what to do when they hear
the command.
 Follow the commands given by the team leader.
 Practice team lifting and carrying together before attempting the task.

6.5.1 Precautions When Lifting and Carrying Long Objects

as Team
Following are the pprecautions when lifting and ccarrying long oobjects as
team:
 Use a shoulder pad to reduce compression.
 Carry load on the same shoulder.
 Walk in step.
All above steps has been shown in Figure 6.20.

Figure 6.20: Lifting and Carrying Long Objects

6.5.2 Precautions When Lifting and Moving Furniture as a

Team
When lifting and moving furniture as a team, following precautions may be
adopted:

154  Use straps.

 Storage of Material
 Adjust the length of the straps according to your height. Handling of Hazardous
Material

Figure 6.21: Webbing to Secure Straps

 Use webbing (Figure 6.21) around straps to secure them from slipping
off.
 Obtain assistance while loading a heavy object on the truck.
 Use your body weight to tilt the object.
 Place the lip of the truck under the object (Figure 6.22).

Figure 6.22: Place the Lip of the Truck Under the Object

 Tip the truck back with assistance (Figure 6.23).

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Introduction to
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Engineering

Figure 6.23: Tip the Truck Back with Assistance

 Move off. The assisting person directs the movement (Figure 6.24).

Figure 6.24: Move off

6.5.3 The Legal Aspect

The Indian Government has several IS specifications for guidance on safe
material handling procedures to be followed. Eg.IS 8324-1988 applies to
Lifting chain & chain slings. Employers, supervisors, owners and
constructors, among others, have an obligation to know and comply with the
regulations that apply to their workplaces. For the specifics on the regulations
that cover your workplace, you will need to look up the applicable IS
specification/s.

SAQ 4
a) What is the major occupational health hazard on account of manual
material handling and what are its main causes?
b) Provide some guidelines on how heavy materials should be handled
when only manual labour is available.

156
6.6 ELECTRICAL HANDLING
 Storage of Material
Handling live electrical lines and equipment have been known to be one of Handling of Hazardous
the major causes of occupational hazard in the industry. The main causes and Material
their corrective actions of these hazards are listed below:
 Improper earthing of electrical circuitry, building or plant has been
observed to be a major cause of accidents and fire. Make sure all
electrical circuits are properly earthed following the guiding IS
specifications.
 Inspect portable cord-and-plug connected equipment, extension cords,
power bars, and electrical fittings for damage or wear before each use.
Repair or replace damaged equipment immediately.
 Always tape extension cords to walls or floors when necessary. Nails and
staples can damage extension cords causing fire and shock hazards.
 Use extension cords or equipment that is rated for the level of amperage
or wattage that you are using.
 Always use the correct size fuse. Replacing a fuse with one of a larger
size can cause excessive currents in the wiring in case of overload and
possibly start a fire.
 Be aware that unusually warm or hot outlets may be a sign that unsafe
wiring conditions exist. Unplug any cords or extension cords to these
outlets and do not use until a qualified electrician has checked the wiring.
 Always use ladders made with non-conductive side rails (e.g., fibreglass)
when working with or near electricity or power lines.
 Place halogen lights away from combustible materials such as cloths or
curtains. Halogen lamps can become very hot and may be a fire hazard.
 Risk of electric shock is greater in areas that are wet or damp. Install
Ground Fault Circuit Interrupters (GFCIs) as they will interrupt the
electrical circuit before a current sufficient to cause death or serious
injury.
 Use a portable in-line Ground Fault Circuit Interrupter (GFCI) if you are
not certain that the receptacle you are plugging your extension cord into
is GFCI protected.
 Make sure that exposed receptacle boxes are made of non-conductive
materials.
 Know where the panel and circuit breakers are located in case of an
emergency.
 Label all circuit breakers and fuse boxes clearly. Each switch should be
positively identified as to which outlet or appliance it is for.
 Do not use outlets or cords that have exposed wiring.
 Do not use portable cord-and-plug connected power tools with the
guards removed.
 Do not block access to panels and circuit breakers or fuse boxes.
 Do not touch a person or electrical apparatus in the event of an electrical
accident. Always disconnect the power source first.

6.6.1 The characteristics and Hazards Associated with

Power Arcs and the Precautions that should be Taken
to Avoid Injury by an Arc Blast

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Electrical workers are frequently in close proximity to energized parts where
Engineering power arcs can occur. It is not necessary to touch an energized conductor to
receive an electrical shock. Anyone who has rubbed their feet across a
carpeted room and reached for a metal doorknob can attest to that. High
voltage may cause current flow through the air from one conductive surface
to another if the voltage is great enough and conditions are right. A lightning
strike, which might have an electrical potential of millions of volts, is an
electrical arc that could span miles. Similarly, in electrical work, when there
is a difference of potential between two points, an arc can occur under the
right set of conditions. Not only could an electrical arc jump from a
conductor to a person and give them a shock but arcing can result in serious
burns and explosive blasts.
Typically, arcing distances are rather small. Safe approach distances should
include a safety factor to the arcing distances in order to account for such
things as inadvertent movement and variable work conditions. Workers
should always be aware of the arcing hazard when handling tools and
equipment near energized electrical conductors. Personal Protective
Equipment (PPE) may be required in certain situations depending on the
amount of energy available at the source.
The power arc is a discharge of electricity through a combination of ionized
air and vaporized conductor material. The conductive material is vaporized
by temperatures in an arc which can be as high as 35,000 degrees Fahrenheit.
Burns associated with high energy arcs can be fatal even if the victim is
several feet from the arc, and severe burns at distances up to ten feet are
common. Clothing may also be ignited at distances of several feet. This may
also be fatal, because the clothing cannot be removed or extinguished quickly
enough to prevent serious burns over much of the body's skin. The following
Table1, gives several examples of the increased temperature of human skin
above normal when exposed to power arcs of varying lengths.
Table 6.1: Arc Temperature vs Distance

Arc Sphere Distance from Center

Diameter

In. Cm. 20” 24” 30” 36” 60” 120”

50.8 cm. 61 cm. 76.2 cm. 91.4 cm. 152 cm. 305 cm.

1 2.54 69 F 47 F 31 F 21 F 8F 2F

2 5.08 274F 191 F 122 F 85 F 30 F 8F

3 7.62 619 F 429 F 275 F 191 F 69 F 17 F

4 10.2 1100 F 764 F 489 F 339 F 122 F 31 F

6 15.2 2474 F 1718 F 1100 F 764 F 275 F 69 F

8 20.3 4398 F 3054 F 1955 F 1358 F 489 F 122 F

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 Storage of Material
10 25.4 6872 F 4772 F 3054 F 2121 F 764 F 191 F Handling of Hazardous
Material
12 30.5 9896 F 6872 F 4398 F 3054 F 1100 F 275 F

16 40.6 17593 F 12217 F 7819 F 5430 F 1954 F 489 F

6.6.2 Electrical Arc Blasts

In addition to an electrical shock and burns, another hazard to employees is
the blast effect that can result from arcing. If the current involved is great
enough, these arcs can cause injury and start fires. Extremely high-energy
arcs can damage equipment causing fragmented metal to fly in all directions.
Low-energy arcs can cause violent explosions or blasts in atmospheres
containing explosive gases, vapors or combustible dusts. The hot vaporized
metal from the arc blast will combine with oxygen and become an oxide of
the metal of the arc. These molten particles will stick to almost anything
actually melting into many surfaces. Clothing may ignite as a result of
contact with this molten material and a victim may receive serious burns.
Also, your body has an instinctive reaction when you are suddenly startled, to
breathe in heavy or gasp. Inhaling the hot vaporized particles will cause
serious damage to your respiratory system by burning the lungs, throat and
esophagus. There is no equipment available to completely protect electrical
workers from the effects of blast. However, safe practices, such as standing to
the hinged side of a cubicle door when operating a breaker and other
precautions listed below can be taken to minimize the effect of a blast. The
main protections against arc blasts are listed in Table 2.
Table 6.2: Protection against arc blasts
Electrical Hazards Awareness
Exoisure Limitation The amount of time you spend around high energy
equipment; don’t loiter.
Distance Always stay as far away as possible form high
energy equipment unless you have a need there.
Mass Try to keep some type of sturdy material between
you and a potential blast.
Protective Clothing Flash suits may offer some protection to minimize
burns resulting from blasts.

If an arcing fault occurs while a worker is in close proximity, the

survivability of the worker is mostly dependent upon system design aspects,
such as characteristics of the over-current protective device and precautions
the worker has taken prior to the event, such as wearing personal protective
equipment appropriate for the hazard. The effects of an arcing fault, as seen
in Figure 2 (below) can be devastating to a person. The intense thermal
energy released in a fraction of a second can cause severe burns. Molten
metal is blown out and can burn skin or ignite flammable clothing. One of the
major causes of serious burns and deaths to workers is ignition of flammable
clothing due to an arcing fault. The tremendous pressure blast from the

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vaporization of conducting materials and superheating of air can fracture ribs,
Engineering collapse lungs and knock workers off ladders or blow them across a room.

Figure 6.25: Electric Arc Model

6.6.3 Electrical Safety Tips

When working with any of the following, it is of utmost importance to
remember the Safety Tips which are also listed below:
 Power Tools
 Extension Cords
 Molded Case Circuit Breakers
 Downed Power Lines
 Ladders
Safety tips:
 Use the tool only for its designed purpose.
 Read the Owner’s Manual and follow manufacturer’s safety instructions.
 Remember electric-powered tools must have a three-wire plug with
ground or be double insulated.
 Use of electric-powered tools with a Ground Fault Circuit Interrupters
(GFCI) breakers will drastically reduce the possibility of electric shock
or electrocution.
 Don’t appropriate Personal Protective Equipment (PPE).
 If an extension cord is required, make sure it is for the correct wattage
and has the proper plugs. Verify condition of the cord and plugs and
check for rated use: indoor or outdoor.
 Ensure the power switch is “OFF” before plugging or unplugging tools.
 When working with the power line switched off, put a ‘DO NOT PUT
ON’ tag on the Main Switch to prevent others from inadvertently putting
it ON for their requirement.
 Never disconnect power by pulling on the cord – use the PLUG.
160  Never carry a tool by the cord.
 Storage of Material
 Unplug the cord before adjusting, changing/replacing parts/accessories. Handling of Hazardous
 Inspect tool before each use. Replace tool if parts are worn or damaged Material
as seen in figure 3. Remove from service and tag “Danger, Do Not
Operate.”
 When using a ladder preferably use one made of non-conductive material
or at least one with thick rubber pads at the resting points.
Hospital Emergency Rooms provide life-saving measures to tens of
thousands of individuals injured/maimed/impaired as a direct/indirect
result of the effects of electric current passing through their bodies
usually through a careless act. Over a thousand individuals are
electrocuted annually. Fires in the home and on-the-job are initiated as a
result of improper use and care of electrical equipment, extension cords,
and plugs. Causes for these events include inattention through repetition,
unexpected events and inexperience and overconfidence. We can
eliminate a large percentage of these injuries and death through the
application/use of safe tool/electrical practices. Contact with current
from machines, tools, appliances and light fixtures accounted for an
alarming number of electrocution deaths in construction. With the
myriad of extension cords and portable power tools used on a job site,
there is a real danger of shocks from damaged cords, lights and tools.
Dampness increases the risk.

Figure 6.26: Damaged Insulation and Plug

SAQ 5
a) What are some general safety tips for working with or near
electricity?
b) Describe the effects of a power arc blast and precautions needed
to avoid it.

6.7 PRINCIPLES OF MATERIAL HANDLING

Following are the principles of material handling:
1. Planning: All handling activities should be planned.
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2. Systems integration: As many handling activities should be integrated as
Engineering possible and the full scope of operations (receiving, storage, production,
inspection, packing, warehousing, supply and transportation) should be
well coordinated.
3. Space utilization: Make optimum use of cubic space.
4. Unit load principle: It implies athat materials should be handled in most
efficient, maximum size unit, mechanical means to reduce the number of
moves needed for a given amount of material..
5. Gravity: Utilize gravity to move a material wherever practicable.
6. Material flow: Plan an operation sequence and equipment arrangement to
optimize material flow.
7. Simplification: Reduce, combine or eliminate unnecessary movement
and/or equipment.
8. Safety: Provide for safe handling methods and equipment.
9. Mechanization: Use mechanical or automated material handling
equipment.
10. Standardization: Standardize method, types and size of material handling
equipment.
11. Flexibility: Use methods and equipment that can perform a variety of
tasks and applications.
12. Equipment selection: Consider all aspects of material, movement and
method to be utilized.
13. Dead weight principle: Reduce the ratio of dead weight and pay load in
mobile equipment.
14. Motion: Equipment designed to transport material should not lie idle.
15. Idle time principle: Reduce idle time/unproductive time of both MH
equipment and manpower.
16. Maintenance principle: Plan for preventive maintenance or scheduled
repair of all handling equipment.
17. Obsolescence principle: Replace obsolete handling methods/equipment
when more efficient method/equipment will improve operation.
18. Capacity principle: Use handling equipment to help achieve its full
capacity.
19. Control principle: Use material handling equipment to improve
production control, inventory control and other material handling.
20. Performance principle: Determine efficiency of handling performance in
terms of cost per unit handled which is the primary criterion of
performance.

6.8 SAFETY IN MATERIAL HANDLING

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The National Safety Council suggests employers relay the following Handling of Hazardous
information to employees to help reduce workplace incidents when handling Material
and moving materials:
 Avoid lifting materials from the floor while seated.
 Make use of available handling aids.
 Refrain from using sudden or jerky movements.
 Never lift a load over an obstacle.
 Perform lifts in areas with adequate footing, space and lighting.
 Modify objects and redesign jobs to make moving easier.
 Seek assistance from co-workers.
 Stay in good physical shape.
 Begin lifts close to the body.
 Use containers made of lighter materials.
 Reduce load sizes when possible.
 Do not twist or bend while lifting objects.
 Ensure that repetitive, heavy and bulky lifts are not performed.
 Keep lifts between shoulder and knuckle height.
 Use conveyors, slides or chutes to eliminate pushing or pulling.

SAQ 6
a) Write down any five important principles of material handling.
b) Name a few important safety aspects in material handling.

6.9 LET US SUM UP

In this unit, we learnt how material handling equipment allows for the safe
and efficient transportation, movement, storage and protection of people and
products during the manufacturing and distribution process which in turn
helps to increase productivity.
We also learnt about the four types of material handling equipment .The four
main categories of material handling equipment include: storage, engineered
systems, industrial trucks and bulk material handling. This unit also threw
light on safety tips and precautions and principles of safety that one must take
into consideration while performing any heavy load material handling.

6.10 KEY WORDS

Potential Health Hazards : that can result from over exposure to hazardous
substance(s) through a length of time
Hazards: A hazard is broadly defined as an agent which has the potential to
cause harm to a vulnerable target
Emergency Action Plan (EAP) : The purpose of an EAP is to facilitate and
organize employer and employee actions during workplace emergencies.

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Introduction to Material Handling: Material handling is the movement, protection, storage
Industrial Safety
Engineering and control of materials and products throughout manufacturing,
warehousing, distribution, consumption and siposal
Bulk handling equipment: Refers to the storage, control and transportation
of materials in bulk and in loose form
Enginered system: Automated and created from a variety of units to enbable
both storage and transportation
Automated Storage and Retrieval System (AS/RS): Large computerised
and automated device that comes complete with racks, shelves and aisles
Automated guided vehicles (AGV): Portable robot that follows along
marked long lines or wires ont he floor, or uses radio wves, vision cameras,
magnets, or lasers for navigation
Storage equipment: Equipment atha tis sued to hold products and materials
when whty are not being used, or when they are waiting to enter or leave the
production process
Team Lifting or Team Handling: When more than one person is involved
in lifting or handling heavy loads
Electrical handling: Handling live electrical lines and equipment
Ground Fault Circuit Interrrupters (GFCIs): Interrupt the electrical
circuit before a current sufficient to cause death or serious injury
Electrical Arc Blast: Electrical shock and burns, blast effect that can result
from arcing

6.11 ANSWER TO SAQs

SAQ 1
a) Some of the hazards in industries are physical in nature. These could
include:
 Fire
 Explosion
 Sudden release of pressure (for instance, if a tank of compressed gas
is punctured)
 Reactivity (fire, explosion, or release of dangerous gases that can
result from contact between chemicals and certain other chemicals
or air or water)
Other type of hazards may come from using or handling hazardous
chemicals like Sulphuric acid, for example. Sudden leakage of toxic
substances or overexposure to a hazardous substance through a
length of time can be other types of hazards.
b) Handling and storing materials involve diverse operations such as
hoisting tons of steel with a crane; driving a truck loaded with concrete
blocks; carrying bags or materials manually; and stacking palletized
bricks or other materials such as drums, barrels, kegs, and lumber. All
these activities are potential physical hazards.

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 Storage of Material
Handling and storing of hazardous chemicals or toxic substances can be Handling of Hazardous
a source of major disaster not only to the workmen of the factory Material
concerned but to the much bigger area adjacent to it. Bhopal Gas
Tragedy is an unfortunate example.
SAQ 2
a) While storing hazardous materials the best practices are:
 place stores of liquid above ground where they're unlikely to be
damaged, eg. away from traffic routes
 avoid overfilling containers
 supervise deliveries
 maintain gauges, valves and pipework
 monitor oil use - unexpectedly high use may indicate a leak
 have procedures for dealing with emergency leakages
 use a secondary containment system such as a drip tray or bund (a
storage area designed to prevent liquids escaping)
b) EAP stands for emergency action plan. It has to be a written document.
The purpose of an EAP is to facilitate and organize employer and
employee actions during workplace emergencies. Well-developed
emergency plans and proper employee training (such that employees
understand their roles and responsibilities within the plan) will result in
fewer and less severe employee injuries and less structural damage to the
facility during emergencies.
SAQ 3
a) There are 4 main categories of material handling equipment:
 Bulk material handling
 Engineered systems
 Industrial trucks
 Storage and handling equipment
b) An engineered material handling system is one that is typically
automated. Such systems are usually created by combining a variety of
units to enable both storage and transportation.
An Automated Storage and Retrieval System’ ( AS/RS ) is one example
of an engineered material handling system. An AS/RS can be integrated
with a production facility’s existing computer network to keep a tab on
stock control, plus other logistical systems.
Other examples of engineered systems are Automated guided vehicles
(AGVs), Conveyor systems, Robotic delivery systems etc.
SAQ 4
a) One of the more frequent, higher risk outcomes of manual material
handling is musculoskeletal disorders (MSDs). It is found that the most
common MSD were due to obstructions on floors interfering with safe

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movement of materials; unsafe material lifting, carrying and moving;
Engineering unsafe storage of material and lack of examination of lifting devices.
b) When heavy loads are required to be handled with purely manual labour,
one has to use Team Lifting or Team Handling.
Following are the basic criteria to be followed when using "Team Lifting
/ Handling".
 Use team lifting and carrying where other solutions are inappropriate.
 Remember that the combined strength of the team is less than the
sum of individual strength.
 Select team members of similar height and strength.
 Assign a leader to the team.
 Determine a set of commands to be used such as "lift", "walk",
"stop",
 "down". Make sure that everyone knows what to do when they hear
the command.
 Follow the commands given by the team leader.
 Practice team lifting and carrying together before attempting the task.
SAQ 5
a) Some general safety tips while working on live electrical lines are listed
below:
 Make sure all electrical circuits are properly earthed following the
guiding IS specifications.
 Repair or replace damaged or worn out portable cord-and-plug
connected equipment, extension cords, power bars, and electrical
fittings before each use.
 Always tape extension cords to walls or floors when necessary.
 Use extension cords or equipment that is rated for the level of
amperage or wattage that you are using.
 Always use the correct size fuse.
 Be aware that unusually warm or hot outlets may be a sign that
unsafe wiring conditions exists.
 Always use ladders made with non-conductive side rails (e.g.,
fibreglass) when working with or near electricity or power lines.
 Place halogen lights away from combustible materials such as cloths
or curtains.
 Risk of electric shock is greater in areas that are wet or damp. Install
Ground Fault Circuit Interrupters (GFCIs) as a safety measure.
 Make sure that exposed receptacle boxes are made of non-
conductive materials.
 Know where the panel and circuit breakers are located in case of an
emergency.
 Label all circuit breakers and fuse boxes clearly.
 Do not use outlets or cords that have exposed wiring.
 Do not use portable cord-and-plug connected power tools with the
guards removed.
 Do not block access to panels and circuit breakers or fuse boxes.
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 Storage of Material
 Do not touch a person or electrical apparatus in the event of an Handling of Hazardous
electrical accident. Always disconnect the power source first. Material

b) The effects of an arcing fault can be devastating to a person. The intense

thermal energy released in a fraction of a second can cause severe burns.
Molten metal blown out can burn the skin or ignite flammable clothing.
The tremendous pressure blast from the vaporization of conducting
materials and superheating of air can fracture ribs, collapse lungs and
knock workers off ladders or blow them across a room.
Following precautions can be taken to avoid arc blasts:
 Electrical systems should be worked on in a de-energized state.
Discuss with the site manager whether the required work could be
performed de-energized. This can often be accomplished through
pre-planning and scheduling.
 Isolate and lockout energy sources.
 Ensure that stored energy does not exist and apply appropriate
grounding if necessary.
 Use properly rated voltage testers to verify the absence of voltage at
each energy point. This should only be done by a qualified person.
 Plan and review the job carefully. Review all possible energy
sources and identify potential hazards and prevention methods
before starting the job.
 Wear appropriate personal protective equipment rated for the job,
including flame-resistant clothing. Never wear clothing made of
nylon, acetate, polyester, or rayon.
 Electrical apprentices and other electricians are the only people who
should assist an electrician in the field.
SAQ 6
a) Five important principles of material handling are listed below:
1. Planning principle: All handling activities should be planned.
2. Systems principle: Plan a system integrating as many handling
activities as possible and coordinating the full scope of operations
(receiving, storage, production, inspection, packing, warehousing,
supply and transportation).
3. Space utilization principle: Make optimum use of cubic space.
4. Gravity principle: Utilize gravity to move a material wherever
practicable.
5. Safety principle: Provide for safe handling methods and equipment.
b) Some of the important aspects of safety that should be followed during
material handling are listed below:
 Avoid lifting materials from the floor or while seated.
 Make use of available handling aids.
 Refrain from using sudden or jerky movements.
 Never lift a load over an obstacle.
 Perform lifts in areas with adequate footing, space and lighting.
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Industrial Safety
 Modify objects and redesign jobs to make moving easier.
Engineering  Seek assistance from co-workers.
 Stay in good physical shape.
 Begin lifts close to the body.
 Use containers made of lighter materials.
 Reduce load sizes when possible.
 Do not twist or bend while lifting objects.
 Ensure repetitive, heavy and bulky lifts are not performed.
 Keep lifts between shoulder and knuckle height.
 Use conveyors, slides or chutes to eliminate pushing or pulling.

6.12 REFERENCES AND FURTHER READINGS

[1] https://www.mtu.edu/ehs/documents/safety-manual/ch6.html
[2] Storage and Handling of Hazardous Materials, Createspace Independent
Pub (26 April 2013), ISBN-10: 1484816226.
[3] https://www.asecos.com/dokumente/M062_Code-of-Practice_Storage-of-
Hazardous-Substances.pdf

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UNIT 7 HOUSE KEEPING (5 S CONCEPTS)

Structure
7.1 Introduction
Objectives
7.2 5S: The Concept
7.3 Need for 5S
7.4 The Cycle
7.5 Implementation of 5S
7.5.1 Benefits of the Practice of 5S
7.5.2 Short - Seiri
7.5.3 Set in Order- Seiton
7.5.4 Shine-Seiso
7.5.5 Standardise-Seiketsu
7.5.6 Sustain-Shitsuke
7.6 Role of Management Implementing 5S
7.6.1 Additional Guidelies for Implementing of 5S
7.7 Let Us Sum Up
7.8 Key Words
7.9 Answers to SAQs
7.10 References and Further Readings

7.1 INTRODUCTION
Everyone appreciates a workplace that is free of clutter and facilitates
effective, efficient and safe work. Think of a Wall Mart store where you step
into and find all sorts of items neatly stacked and arranged in an organized
manner making it just as simple for a customer to pick and choose as it is for
the store account manager to bill the product. In contrast, think of traditional
grocer’s shop running in a 10 × 10 room which is more like a store house and
he alone knowns what item is kept where. Some of the items may be stored
well beyond the expiry date of unpackaged goods which may have been
attached by rodents or further still, wrong items may be stored together like
unpacked food grains with liquid phenyl or mothballs. So now you
understand the context of our discussion in this unit. Similar concept applies
to workplaces. The system of 5S focuses on putting everything where it
belongs and keeping the workplace clean, making it easier for people to do
their jobs without wasting time as or risking their safety in any manner.
Objectives
After the studying this unit, you will be able to:
 appreciate the need and importance of 5S system in workplaces.
 describe Value Stream Mapping (VSM).
 describe the meaning, methods and benefits of 5S. and
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Introduction to
Industrial Safety
 discuss the role of management in implementing 5S effectively.
Engineering
7.2 5S: THE CONCEPT
5S is amongst the first and fundamental steps implemented by an enterprise
towards the path of accomplishing Total Quality Management and continuous
improvement at the operation level. 5S is a process designed to organize the
workplace, keep it clean, maintain effective and standard conditions. It instils
the discipline required to enable everyone to achieve and maintain a world-
class working environment.
Over time, the 5S methodology led to many benefits that included, reduced
costs, higher quality, increased productivity, greater employee satisfaction
and safer work environment. And most importantly, it introduces standard
operational practices to ensure efficient, repeatable and safe ways of working.
The use of this tool was started in the 1920s by Henry Ford in the United
States as the CANDO program: Cleaning up, Arranging, Neatness, Discipline
and Ongoing improvement. The technique was popularized as ‘Japanese 5S’
in 1980 by Hiroyuki Hirano.
Many enterprises have practiced the 5S and derived significant benefits from
it. This technique has been widely practiced in Japan. Most Japanese 5S
practitioners consider 5S useful not just for improving their physical
environment, but also for improving their thinking processes. In Japan it is
also called ‘workplace management’.

7.3 NEED FOR 5S

5S is needed if the workplace is messy and unorganized. It is also be needed
if employees spend extra time in searching for tools, papers, information, etc.
Basically to implement 5S you will have to find out the following eight
wasteful items/procedures and eliminate them.
 Over production – Producing more than required or producing faster
than the downstream processes can lead to over production. One should
according to need.
 Excessive Inventory – This can be a direct result of over production or it
could be due to poor purchasing practices. Over purchasing supplies
because we got a great deal sometimes is no deal at all. Excessive or
unneeded inventory can propagate other forms of waste.
 Inappropriate or Non Value Added Processing – Waste is incurred
through use of the wrong tool, performing needless operations or not
using the most efficient processes or tools for the job. The right process
and the correct tools can reduce waste in your process.
 Waiting – Time and resources are wasted when waiting for parts,
supplies or information. One should try to ensure a steady supply of the
required material in order to avoid wastage.
 Transportation – Excessive travel or movement of materials is waste.
170 Proper planning and process layout can help reduce or eliminate excess
 transportation. The use of value stream mapping can help the team House Keeping (5S
Concepts)
visualize exactly how much of the material is travelling. (Let us briefly
understand what Value Stream Mapping (VSM) means. Also known as
‘material and information flow mapping,’ it is a lean management
method/tool that helps in visualizing the steps needed from product
creation to devlivering to the customer. VSM helps in better
understanding of one’s organization and analysis thereby bringing about
improvement in processes of an organistion.)
 Unnecessary Motion – Any movement or motion performed by the
operator that does not add value is waste. During the 5S exercise one
needs to examine the motions required to perform the task. One has to
organize the workstation so that all tools and supplies are easily located
and are within easy reach. In some cases, re-sequencing certain process
steps can reduce excessive and redundant movement or motion by the
operator. Safety must be the first consideration by reducing or
eliminating the waste of excess motion one is also creating a more
ergonomic workstation. Always consider safety first. Economics is the
process of designing or arranging workplaces, products and systems so
that they fit the people who use them. This branch of science studies
about human abilities and limitations and then apply this learning to
improve people’s interaction with products, systems and environments.
 Defects – This form of waste is one of the worst of all. Producing non-
conforming parts or assemblies increases scrap, reduces process
efficiency, wastes machine-time, process or assembly time and causes
non-value added tool wear. Defects can also create additional waste in
the form of wait time when the downstream operations run out of usable
parts.
 Untapped Employee Creativity (potential) – Many companies are now
realizing that their best asset is their employees. Companies must create
an atmosphere where exchange of ideas is encouraged. Some of the most
successful organizations have created a culture where employee’s ideas
are really heard and evaluated. When their good ideas are implemented,
the employee is recognized and rewarded. One never knows where the
next great idea is going to come from.

SAQ 1
a) Name the 8 forms of waste usually found in industries.
b) Describe the concept of 5S.
c) What is the need of 5S in Industry?

7.4 THE CYCLE

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5S is the acronym for five Japanese words: Seiri, Seiton, Seiso, Seiketsu and
Engineering Shitsuke and they represent the five steps for a systematic technique for good
housekeeping. The 5S cycle is represented in Figure. 7.1.

Figure 7.1: 5 S Cycle

The five steps and their corresponding actions are as indicated in the table 7.1
and Figure 7.2 shows the Five Steps of Japanese 5 S.
Table 7.1: The five steps of Japanese 5 S
Step Corresponding action
Seiri (Sort) Distinguish between necessary and unnecessary items.
Remove the latter.
Seiton (Set in order) Enforce the dictum ‘a place for everything and
everything in its place’.
Seiso (Shine) Clean up the workplace and look for ways to keep it
clean.
Seiketsu (Standardize) Maintain and monitor adherence to the first three Ss.
Standardise the way of maintaining cleanliness.
Shitsuke (Sustain) Stay committed to practicing the 5S daily make it a
way of life.

Figure 7.2: The Five Steps of Japanese 5 S

7.5 IMPLEMENTATION OF 5 S
172
7.5.1 Benefits of the Practice of 5 S House Keeping (5S
Concepts)
The general concept of the 5S is that they are intended to eliminate waste
(Osada, 1993). Working in disorder (Figure 7.3) is neither productive, nor
safe. 5S is a simple and practical method to instil a quality culture at the
workplace. It is relatively easy to undertake and requires minimal additional
resources. The first and small investment made in time and effort pays off in
a much bigger manner when the results are realized and maintained.
Among the main benefits of implementing 5S are:
 the workplace becomes cleaner, safer, well-organized and more pleasant
 floor space utilization is improved
 workflow becomes smoother and more systematic and non-value-added
activities are reduced;
 time for searching tools, materials and document is minimized;
 machine breakdowns are reduced since clean and well-maintained
equipment breaks down less frequently and it also becomes easier to
diagnose and repair before breakdowns occur, therefore extending
equipment life;
 errors are minimized leading to making defect-free products;
 consumables and material wastage are minimized;
 the morale and satisfaction of employees improves; and
 the productivity of the organization improves together with the quality of
products and services.

Figure 7.3: Disorder is neither Productive nor Safe

Each step of the 5S is further explained below

7.5.2 SORT – SEIRI

The emphasis of Seiri (Figure 7.4) is on being able to spot the unwanted and
unnecessary items/equipment/processes in a workplace before they become
problematic.

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Engineering

Figure 7.4: Sort – Seiri

Meaning Methods Benefits

This means  First decide what is necessary and  Your useful

distinguishing or what is unnecessary. To find out floor is saved.
sorting out unnecessary items you should not  Your
between ‘wanted’ only check the floor but also searching
and ‘unwanted shelves, lockers, storehouse, time for
items’ at place of stairs, roofs, notice boards, etc. tools ,material
work and The best people to provide s and papers
removal of information on unnecessary items is reduced.
unwanted items. are the people working in that  You have
area. better flow of
 Put a red tag on unnecessary work. Your
items and keep them in a separate inventory cost
area. is reduced.
 Discard or throw those items
which have not been used in the
past one year.
 Things used once in 6 to 12
months may be stored at a
distance from the workstation.
 Things used more than once a
month should be available at a
central point in the workplace.
 Things used
hourly/everyday/once a week
should be near the work station or
may be worn by or kept in the
pocket of your workman there.

7.5.3 Set in Order – Seiton

Seiton in essence can be defined as neatness, having things in the right places
or set up so that they are readily available for use, eliminating the need to
search. Once everything has a right place so that it’s functionally placed for
quality and safety, it can then be deemed that the workplace is neat (Osada,
174
1993). While Seiri helps you to decide what items are needed, Seiton helps House Keeping (5S
Concepts)
you to decide the way things are to be placed.

Meaning Methods Benefits

 Arranging  If necessary, reassign spaces,  You take

items in such a racks, cabinets, etc. things out and
manner that  Decide the right places for keep things
they are easy to everything. back easily.
use.  Put all materials and  You make
 Labelling them equipment at a place allocated lesser
so that they are to them with proper label or mistakes.
easy to find and signalization. Use alerts or  You reduce
put back. This indications for out-of-stock searching
means a place situations. time.
for everything  Use floor paint marking to  Your work
(necessary) and define working area, path, environment
everything in its entrance/exit, safety becomes safe.
place. No more equipment, cart/ trolley
homeless items. locations, etc.
 Use standard colour coding
for pipelines for steam, water,
gas, drainage, etc.
 Use display cautions,
messages and instructions,
written clearly at proper
places and at a proper height.

7.5.4 Shine – SEISO

Seiso places emphasis on cleaning so that things are clean; in other words,
carrying out cleaning as a form of inspection i.e. getting rid of waste, and
foreign matter. It is important to note that depending on the circumstance,
with higher quality, higher precision and finer processing technologies, even
the minute details may have the greatest ramifications, hence it is important
to carry out cleaning as a form of inspection.

Meaning Methods Benefits

 This means  Divide the total area in  Your

removing dirt, zones and allocate workplace
strain, filth, soot responsibility for becomes free
and dust from the cleaning of each zone. of dirt and
work area.  Decide on cleaning stains which
 This includes points, order of is the starting
cleaning and care cleaning, type of point for
for equipment and cleaning, cleaning aid quality.
facilities and required, etc.  Your
inspecting them for  Display cleaning equipment
abnormalities. schedule. life span will
 In a way it also  During cleaning look be prolonged,
includes primary for defective conditions and 175
Introduction to maintenance of (loose bolts, vibrations, breakdowns
Industrial Safety
Engineering equipment. excessive sound, high will be less.
Note: Cleaning is not temperature, fallen  Creates a
polishing to make the tools, etc.) and solve pleasant work
piece of equipment the problem. environment.
more beautiful, its more  Allocate space for  Prevents
about the condition and storage of cleaning aids accidents.
fitness for use. and consumables for
cleaning.

7.5.5 Standardize – SEIKETSU

This aspect of the 5S focuses on standardization, making the first three S’s,
Seiri, Seiton, and Seiso a constant routine. The emphasis here is on visual
management, an important aspect to attain and maintain standardized
conditions to ensure the individuals always act quickly.

Meaning Methods Benefits

This calls for  Document procedures Your activities

systematizing the above and guidelines for will be
3S practices. This sorting, set in order and simplified.
means ensuring that shine.
whatever cleanliness  Make a checklist for
and orderliness is each section and train You will have
achieved should be your people in using consistency in
maintained. them. the work
 Carry out periodic practices.
This requires that you
should develop a work evaluation by using the
structure that will above check list.
support the new  Use visual management You will avoid
practices and turn them to act quickly, for mistakes.
into habits. The example putting/using:
purpose of − Open and shut directional
standardization is to labels on switches, etc. With better
make sure that visual
− Temperature and safety transparency
everyone in the labels
company follows the management of
same procedure, the − Zone labels on work and
same names of items, measuring metres efficiency will
the same size of (normal zone, danger improve.
signalization/floor zone, etc.)
marking, shapes, − Put ‘OK’ or hold marks
colours, etc. on product.
Standardizing also
helps to do the right − Put transparency control
thing the rightway − Make transparent covers
every time thus of drawers.
improving product
quality spending lesser − Put inspection windows
time and money. in themetal covers.
− Use location maps with
176
 emergency exits, fire House Keeping (5S
Concepts)
fighting equipment, etc.
visible from a distance.

7.5.6 Sustain – SHITSUKE

Shitsuke places emphasis on being able to forge a workplace with good
habits and discipline. Demonstrating to others what needs to be done and
encouraging practice amongst them. This is mainly a management
responsibility.

Meaning Methods Benefits

Sustain also means  Create awareness and Promotes habit for

‘Discipline’. publicize the system. For complying with
It denotes your example develop 5S workplace rules and
commitment to News, 5S Posters, 5S procedures.
maintain orderliness Slogans, observe 5S Day,
and to practice first etc.
 Create a structure of how Creates healthy
3S as a way of life. atmosphere and a
This also requires and when 5S activities
will be implemented. good workplace.
that your employees
show positive  Formulate guidelines for
interest and audit/evaluation of 5S
implementation. Helps you to develop
overcome resistance teamwork.
to change.  Provide management
support by providing
resources and leadership.
 Reward and recognize Provides you with
best performers. data for improving
5S.

SAQ 2
a) Why should we implement 5S?
b) What is SEIRI and what are the benefits an industry can derive from
practicing it?
c) What does SEITON mean and what are the steps in SEITON?
d) Explain SEISO and its benefits.

7.6 ROLE OF MANAGEMENT IN

IMPLEMENTING 5S
It is important to note that the implementation of 5S concerns and benefits
everyone in the organisation. Figure 7.5 and 7.6 shows Before Implementing
and after Implementing respectively. 5S Like any other initiative,
management has the important role to facilitate and support the process by:
177
Introduction to  Acknowledging the importance of 5S for the organization;
Industrial Safety
Engineering  Allowing employees time for 5S;
 Providing resources and infrastructure for 5S implementation;
 Personal involvement in implementation of 5S;
 Creating tangible and intangible rewards and recognition for
improvements; and
 Promoting the ongoing 5S efforts

Figure 7.5: Before Implementing 5S

Figure 7.6: After Implementing 5S

7.6.1 Additional Guidelines for Implementing 5S

The methods of implementing each of the 5S have been indicated in the
tables above. An ITC diagnostic tool is included in Annex I to enable you to
assess and score the implementation of your 5S. It would be advisable to start
the implementation with one selected area in the organisation and then after
getting positive results to extend gradually to other areas. However, for
effective implementation, it would be important to:

178
 Sensitize the management and all employees concerned about the House Keeping (5S
Concepts)
importance and benefits of 5S and get their commitment;
 conduct a status audit with photographs ‘as is state’. The diagnostic tool
given in the appendix may be used;
 measure throughput, time in materials handling, floor space, flow
distance, rack storage, engineering cycle times, annual physical
inventory time, and defect ratios before and after the 5S implementation.
 develop an implementation plan, with clear responsibilities and deadlines,
in consultation with management and all employees concerned;
 implement the 5 S plan;
 take photographs after the implementation and assess the
difference;
 share the experience and extend the implementation to other
areas;
 conduct periodic 5S Internal Audits with ratings to monitor progress.

SAQ 3
a) Which aspect of 5S does SEIKETSU deal with? Describe in
detail.
b) What do you understand by SHITSUKE? What are the benefits of
practicing SHITSUKE?
c) Why is it important to measure throughput, time in materials
handling, floor space, flow distance, rack storage, engineering
cycle times, annual physical inventory time, and defect ratios
before and after the 5S implementation?

7.7 LET US SUM UP

There is no shortage of workplace organization and improvement methods
available today, but few are better known and more proven than 5S. This
system has been around as a formal system for decades and has been proven
effective at improving virtually every aspect of nearly any business across all
industries.
5S gets its name from the five Japanese words, Seiri, Seiton, Seiso, Seiketsu,
and Shitsuke, which translate in English to Sort, Set in Order, Shine,
Standardize, and Sustain. Anyone who is looking for a way to cut waste,
improve efficiency, improve product quality and generally improve the way
everything is done in the workplace, will benefit from the 5S methodology.

7.8 KEY WORDS

5S gets its name from the five Japanese words, Seiri, Seiton, Seiso, Seiketsu,
and Shitsuke, which translate in English to Sort, Set in Order, Shine,
Standardize and Sustain.

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Introduction to
Industrial Safety
5 S: is a process designed to organize the workplace, keep it clean, maintain
Engineering effective and standard conditions.
Seiri (Sort): Distinguish between necessary and unnecessary items.
Remove the latter.
Seiton (Set in order):Enforce the dictum ‘a place for everything and
everything in its place’.
Seiso (Shine): Clean up the workplace and look for ways to keep it clean.
Seiketsu (Standardise): Maintain and monitor adherence to the first three Ss.
Standardise the way of maintaining cleanliness.
Shitsuke (Sustain): Stay committed to practicing the 5S daily make it a way
of life.

7.9 ANSWER TO SAQs

SAQ 1
a) The 8 forms of waste usually noticed in the industries are,
i) Over production
ii) Excessive Inventory
iii) Inappropriate or Non Value Added Processing
iv) Waiting
v) Transportation
vi) Unnecessary Motion
vii) Defects
viii) Untapped Employee Creativity (potential)
b) 5S is amongst the first and fundamental steps implemented by an
enterprise towards the path of accomplishing Total Quality Management
and continuous improvement at the operation level. 5S is a process
designed to organize the workplace, keep it clean, maintain effective and
standard conditions. It instils the discipline required to enable everyone
to achieve and maintain a world-class working environment.
c) 5S is needed if the workplace is messy and unorganized. It is also be
needed if employees spend extra time in searching for tools, papers,
information, etc.
Basically to implement 5S you will have to find out the following eight
wasteful items/procedures and eliminate them.
 Over production
 Excessive Inventory
 Inappropriate or Non Value Added Processing
 Waiting
 Transportation
180  Unnecessary Motion
  Defects House Keeping (5S
Concepts)
 Untapped Employee Creativity (potential)
SAQ 2
a) We should implement 5S because it is a simple and practical method to
instil a quality culture at the workplace.
Among the main benefits of implementing 5S are:
 the workplace becomes cleaner, safer, well-organized and more
conducive for working
 floor space utilization is improved
 workflow becomes smoother and more systematic and non-value-
added activities are reduced
 time for searching tools, materials and document is minimized
 machine breakdowns are reduced since clean and well-maintained
equipment breaks down less frequently and it also becomes easier to
diagnose and repair before breakdowns occur, therefore extending
equipment life
 errors are minimized leading to making defect-free products
 consumables and material wastage are minimized
 the morale and satisfaction of employees improves
 the productivity of the organization improves together with the
quality of products and services.
b) The Japanese word ‘SEIRI’ means sorting. It is basically identifying and
categorising the necessary and unwanted items/equipment/processes in a
workplace.
Benefits of practising SEIRI in an industry are,
 Useful floor space is saved.
 Searching time for tools, materials, and papers is reduced.
 Flow of work is better.
 Inventory cost is reduced.
c) SEITON means set in order. While Seiri helps one to decide what items
are needed, Seiton helps to decide the way things are to be placed.
Following are the steps to be taken to implement SEITON
 If necessary, reassign spaces, racks, cabinets, etc.
 Decide the right places for everything.
 Put all materials and equipment at a place allocated to them with
proper label or signalization. Use alerts or indications for out-of-
stock situations.
 Use floor paint marking to define working area, path, entrance/exit,
safety equipment, cart/ trolley locations, etc.
 Use standard colour coding for pipelines for steam, water, gas,
drainage, etc.
 Use display cautions, messages and instructions, written clearly at
proper places and at a proper height.
d) SEISO means shining, but not in the literal sense. It is cleaning as a form
of inspection i.e. getting rid of waste, and foreign matter.
181
Introduction to The benefits of SEISO are,
Industrial Safety
Engineering  The workplace becomes free of dirt and stains which is the starting
point for quality.
 The equipment lifespan is prolonged, and breakdowns are less.
 It creates a pleasant work environment.
 It prevents or minimises accidents.
SAQ 3
a) SEIKETSU deals with standardisation, making the first three S’s, SEIRI,
SEITON, and SEISO a constant routine. This means ensuring that
whatever cleanliness and orderliness is achieved should be maintained.
That is one has to develop a work structure that will support the new
practices and turn them into habits. The purpose of standardisation is to
make sure that everyone in the company follows the same procedure, the
same names of items, the same size of signalisation/floor marking,
shapes, colours, etc. Standardising also helps to do the right thing the
right way every time thus improving product quality, spending lesser
time and money.
b) SHITSUKE means discipline. It places emphasis on being able to forge a
workplace with good habits and discipline. Demonstrating to others what
needs to be done and encouraging practice amongst them. This is mainly
a management responsibility.
The benefits of practising SHITSUKE are,
 It promotes habit for complying with workplace rules and procedures.
 Creates healthy atmosphere and a good workplace.
 Helps to develop team work.
 Provides data for improving 5S.
c) To assess the benefits of 5S in cognisable terms we need to measure
throughput, time in materials handling, floor space, flow distance, rack
storage, engineering cycle times, annual physical inventory time, and
defect ratios before and after the 5S implementation.
This will provide an impetus to all concerned from the top management
to the workmen to strictly adhere to practising 5S. The workmen will
find a better working environment, get less fatigued during work and a
safer workplace. This in turn will improve product quality, decrease
rejection and machine down-time and increase productivity.
By keeping records of throughput, time in materials handling, floor space,
flow distance, rack storage, engineering cycle times, annual physical
inventory time, and defect ratios before and after the 5S implementation
the effects of 5S can be shown to the management in tangible terms. The
improvement in the company bottom line will induce the management
also to follow 5S.

7.10 REFERENCES AND FURTHER READINGS

[1] https://safetyculture.com/topics/5s-lean/
[2] https://en.wikipedia.org/wiki/5S_(methodology
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[3]https://www.jica.go.jp/activities/issues/health/5S-KAIZEN-TQM- House Keeping (5S
02/ku57pq00001pi3y4-att/5S_Principle.pdf Concepts)

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Introduction to
Industrial Safety
Engineering
UNIT 8 SAFEGUARDING OF MACHINERY
Structure
8.1 Introduction
Objectives
8.2 Mechanical Operations and Safety
8.3 Hazards of Working With Cranes
8.4 Types of Cranes
8.5 Safety Factors to be Observed in Crane Operation
8.6 Safe Loading and Operation of Cranes
8.7 General Guideline for Cranes
8.8 Let Us Sum Up
8.9 Key Words
8.10 Answers to SAQs
8.11 References and Further readings

8.1 INTRODUCTION
Machines can significantly improve production and efficiency. But they do not
come without risks. This unit is designed to focus on what mechanical
operations mean and the various hazards connected to mechanical operations.
We shall then take up the study of one mechanical operation - cranes in detail,
to provide an overall insight on safety in mechanical operations.
Objectives
After studying this unit, you will be able to:
 categorise mechanical operations;
 appreciate the need for safety in mechanical operations;
 enlist the types of cranes
 describe the safety factors to be observed in crane operations;
 recognise the importance of safe loading in operations of cranes

8.2 MECHANICAL OPERATIONS AND SAFETY

Mechanical operations can be broadly categorised into the following
sections:
 Mechanical Design.
 Manufacturing.
 Biomedical and Engineering Fluid Mechanics.
 Combustion and the Environment.
 Ground Vehicle and other transportation Systems.
 Heat Transfer, Thermodynamics and Energy Systems.
 System Dynamics and Control.

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 Safeguarding of
The hazards involved in the various types of mechanical operations mentioned Machinery
above cannot be individually tagged to each operation and often overlap. For
example the hazard of a moving machine part not provided with proper guard,
can come under the categories of Design, Manufacturing and Transportation.
So we shall broadly mention the hazards that may occur in general during
mechanical operations and the safety measures needed for them. To provide
further insight on safety of mechanical operations we shall discuss one
operation in particular and safety measures connected to it, in detail.
Key risk areas in mechanical operations and safety measures needed for them
can be broadly categorised as follows:
 Winding equipment – Safety precautions for winding euipment include
suitable guards covering high speed rotating parts and general electrical
safety.
 Diesel engine systems – Safety measures for diesel engine systems include
safety against toxic fumes, heated pipes and parts and high speed rotating
parts.
 Welding– Wearing protective gloves and clothing, using proper screen and
protection from electrical hazards is required for safe operations during
welding.
 High pressure hydraulic equipment – Making sure that safety valves in the
system are always in working order, few routine checks like oil level, leak,
clogging filters, hoses defects, hydraulic piping and connections, abnormal
noise pump etc. should be the primary safety measures.
 Metal cutting operations - To ensure safety avoid wearing loose garments
and using rags near running machines, wear goggles to avoid flying metal
chips, stop the machine before cleaning chips or when you are away and
never try to free a stalled cutter without turning the power off first.
 Mobile and transportable equipment – We shall discuss the safety
measures for mobile and transportable equipment in detail with the help of
the example of cranes.

8.3 HAZARDS OF WORKING WITH CRANES

Cranes are the typical example of mobile and transportable equipment used in
the industry for lifting and shifting heavy loads and are quite prone to accidents.
Many a times, accidents involving tower cranes have resulted in serious
injuries and even deaths. Hence, while using cranes and other lifting equipment
at work, being aware of the hazards and knowing what steps one can take to
reduce risk is crucial to ensuring safety of the workmen, equipment and
workplace.
Common Crane Hazards:
Working with cranes poses many hazards, and unsafe working practices can
result in injuries, fatalities and costly damage to buildings, equipment and
materials. Therefore, it’s important to be aware of the main hazards and how to
avoid them.
Some of the main hazards include:
i) Falling Loads

185
Introduction to
Industrial Safety When working with overhead cranes, falling loads are one of the most
Engineering common, and most dangerous, hazards. A falling load can result in several
injuries, fatalities and significant structural damage to buildings and
property. Additionally, it will also lead to significant time and money costs.
Falling loads from an overhead crane could be the result of:
 Operator incompetency. One must ensure that the workmen are
adequately trained so that they are able to carry out their roles
competently and safely.
 Slipping. If the loads are not secured properly it can result in slipping
of material.
 Mechanical failure. The risk of mechanical failure can be reduced if
a competent person carries out routine inspections, maintenance and
repairs at suitable intervals.
 Two blocking. Two blocking occurs when an uppermost hoist line
component (i.e the load block, hook block, overhaul ball) touches the
upper block, boom tip or similar component. When two blocking
occurs, increased tension is placed on the line which can result in
falling of loads or crane components.
ii) Electrical Hazards
Around 50% of accidents involving overhead cranes are a result of a metal
part of a crane coming into contact with a power source (i.e a high-voltage
power line). There’s a risk of a crane’s hoist line or boom touching
energized power lines when moving materials nearby or underneath.
While those directly touching the crane are the most likely to be
electrocuted, anything in the vicinity is also at risk. Therefore, one
accident can result in multiple deaths and injuries. Fatalities are also the
result of contact with power lines, so it’s crucial that pre-job planning is
carried out prior to starting work.
iii) Crane Overload

The majority of crane structural failures and upsets are the result of
somebody overloading a crane. Exceeding a crane’s operational capacity
may subject it to structural stresses and cause irreversible damage.
Crane overload may be caused due to the following reasons:
 Swing or suddenly drop loads - Sudden swinging of heavy loads at a
height can topple the crane altogether and cause serious damage to life and
property. Dropping of heavy loads from a height can also cause damage.
 Hoist loads beyond the cranes capacity - Electric Overhead Traction (EOT)
cranes are mostly used in shop-floors. Often weight of the load to be lifted
and moved is not known and people tend to overload the crane in an
attempt to maintain the workflow. Such practises often lead to disaster.
 Mobile cranes are largely used outdoors. Again the tendency to manage
with the available resources at site leads to overloading of cranes, often
with fatal consequences. One may follow the cranes’ rated load while
loading but may find the hanging hook to be under-rated and may take the
risk which may soon turn into a disaster.

186
 Safeguarding of
 Use defective components – Sometimes there may be a tendency to Machinery
manage things in any possible way often ignoring the safety aspect. It is
the responsibility of a safety engineer to change such habits and provide
the right resources. A simple defective component in a crane, like a worn
out tyre or a badly welded joint in the lifting system can be dangerous.
 Dragging or side-pulling loads – Loads are always meant to be lifted
vertically by cranes. However, to accommodate working conditions
operators sometimes drag or side-pull loads. This is a very dangerous
practise as when the load finally leaves the ground it can swing and cause
a lot of damage to life and property including toppling of the crane itself.
 Not paying enough attention to the loading chart provided on the body of
the crane – That crane operations require a lot of safety precautions is
established by the fact that all cranes have very clear loading chart and
instructions fixed to the body of the crane in a visible location where it is
least likely to be damaged. This chart is particularly important for mobile
cranes. One needs to pay enough attention and study the chart before
loading the crane.

SAQ 1
a) Name and explain the key risk areas in mechanical operations.
b) What are the main hazards in crane operation?

8.4 TYPES OF CRANES

A crane is a tower or derrick that is equipped with cables and pulleys that are
used to lift and lower material. They are commonly used in the construction
industry and in the manufacturing of heavy equipment. The top 7 types of
cranes are normally temporary structures, either fixed to the ground or
mounted on a custom-built vehicle.
They can either be controlled from an operator in a cab that travels along with
the crane, by a push button pendant control station, or by radio type controls.
Types of Cranes Used in Industry
i) Mobile Cranes
Mobile Cranes are the most standard and versatile type of cranes used in
construction and other industries. The Figure of mobile crane is shown is
Figure 8.1. The mobile hydraulic crane consists of a steel truss or
telescopic boom mounted on a mobile platform, which could be a rail,
wheeled, or even on a truck. The boom is hinged at the bottom and can be
either raised or lowered by cables or hydraulic cylinders.

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Introduction to
Industrial Safety
Engineering

Figure 8.1: Mobile Cranes

What makes this crane so versatile is its footprint and mobility. In

construction situations, it can sometimes be difficult to get close to where
you need to hoist the materials. Moving a crane into a position that allows
it to lift the material with the correct crane capacity is effected by the
footprint of the crane. The foot print is the area required to have the crane
set up its outriggers into position that allows it to hoist the material while
remaining inside the crane chart requirements.
ii) Telescopic Crane
Telescopic cranes offer a boom that consists of a number of tubes fitted
one inside the other. Telescopic crances are shown in Figure 8.2.

Figure 8.2: Telescopic Cranes

188
 Safeguarding of
A hydraulic mechanism extends or retracts the tubes to increase or decrease the Machinery
length of the boom. Most construction cranes today are in some form, a
telescopic crane, except for the Lattice boom crane (picture below) that has a
frame of steel structure which is bolted together to get the right height for the
hoist. The Lattice Boom Crane is shown in Figure 8.3.

Figure 8.3: Lattice Boom Crane

iii) Tower Crane

The tower crane is a modern form of a balance crane. Tower crane is
shown is Figure 8.4. When fixed to the ground, tower cranes will often
give the best combination of height and lifting capacity and are mostly
used when constructing tall buildings.

189
Introduction to
Industrial Safety Figure 8.4: Tower Crane
Engineering
Some large tower cranes reach up to 1000 meters high. With an average
floor dimension of a high rise equalling 3.5 meters/floor, it equals to a
285 story building! One important thing to note about tower cranes, as
they construct past a specific height is that it is mandatory to have the
tower crane secured to the building to help prevent crane sway and crane
tipping.

iv) Truck Mounted Crane (Also Known as Boom Truck or Picker Truck)
Boom trucks (Figure 8.5) or picker trucks are cranes mounted on a truck
with rubber tires and provide great mobility. Outriggers that extend
vertically or horizontally are used to level and stabilize the crane during
hoisting. The capacity of these cranes rarely exceed 50 tons. As mentioned
above, their versatility is found in their mobility and reach.

Figure 8.5: Boom Trucks

v) Rough Terrain Crane
A rough terrain crane (Figure 8.6) is a crane that is mounted on an
undercarriage with rubber tires, designed for operations off road.

Figure 8.6: Rough Teerrain Craine

The outriggers extend vertically and horizontally to level and stabilize the
crane when hoisting. These types of cranes are single engine machines
where the same engine is used for powering the undercarriage as it is for
powering the crane. These cranes are ideal for construction sites that have
uneven, dirty and rocky terrain. The mobility and ability of the crane to

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travel around the site make it an effective support crane for lighter hoists Machinery
on highway, construction and infrastructure projects.
vi) Loader Crane (Also Known as a Folding Boom Crane)

A loader crane (Figure 8.7) or a folding boom crane is a hydraulic

powered articulated arm fitted to a trailer, used to load equipment onto a
trailer.

Figure 8.7: Loader Crane

The numerous sections can be folded into a small space when the crane
isn’t in use. Capacity of these cranes have increased dramatically over the
years. Presently there are 200 ton capacity loader folding boom cranes in
the market today.

vii) Overhead Crane

Figure 8.8: Overhead Crane

An overhead crane, also referred to as an Electric Overhead Traction (EOT)

crane, is normally used in a factory, with some of them being able to lift very
heavy loads. Larger overhead cranes (also known as goliath cranes or gantry
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Introduction to
Industrial Safety cranes) can be found in use in shipyards and large outdoor manufacturing
Engineering plants. The hoist is set on a trolley which will move in one direction along one
or two beams, which move at angles to that direction along elevated or ground
level tracks, often mounted along the side of an assembly area.

8.5 SAFETY FACTORS TO BE OBSERVED IN

CRANE OPERATION
When working with cranes, there will always be hazards. However, one can
minimise the risks by taking appropriate precautions while undertaking all
operations safely.
To carry out your crane operations safely, you should:
 Appropriately train all employees. As an employer or the man-in-charge,
one has a legal responsibility to provide appropriate health and safety
training to all employees so that they are competent at their jobs. This will
increase workplace safety, satisfaction and profits and reduces the chances
of injuries, fatalities, accidents and sickness, absence, machine down-time
and repair costs.
 Have a certified operator. A crane in the hands of an unqualified
operator can be a deadly weapon. Riggers should also be properly trained
on setting the crane up for the specific load and circumstances.
 Know what’s below. The most powerful, carefully rigged crane is only as
strong and stable as the surface upon which it stands. One should know the
classification of soil or other material under the crane, and adjust the
setup and load limits accordingly. While many cranes are equipped with
outriggers, extending them doesn’t necessarily mean that the surface
underneath is stable . The pad and float at the end of the outrigger carry a
great deal of compression force when the crane is under load. Too much
force can cause them to punch through the ground, causing the entire crane
to tip.
 It’s important to know the load weight and how that is affected by the
conditions of the job site. The crane’s load chart can help in determining
whether the lift will be safe. The allowable load will depend on whether
the tires or outriggers are being used, along with other factors. For
example, asphalt may seem to be a stable surface, but on a warm day, it
may become very flexible. Even concrete may not provide enough
strength if there is a void beneath it.
 Plan for swing. For cranes, there is something called a swing radius.
Swing radius is the distance fom the hanging point to the farthest edge of
the mobile. It is this distance atleast that a mobile must be hungfrom a wall
or other objects so that the mobile can rotate freely.The counterweight and
boom travel within a specific arc is also called the swing radius. It’s
important to ensure that the area within that radius is barricaded off, and to
establish a control zone for those authorized to work in the immediate area.
It prevents personnel from being struck or crushed by the crane. The
barricade must include the maximum swing radius of the counter weight
which is past the main body of the crane. Also check the area every day to
ensure that there are no objects that the boom may fowl with, such as

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power lines. If such obstacles exist, one needs to ensure that the operator Machinery
and other workmen are aware of the plan for avoiding them.
 Use cranes properly. Cranes are engineered for vertical lifting. That
doesn’t stop some crews from trying to use them for side loading or other
improper activities. Using a crane to drag something across the ground or
from under an obstacle puts extreme stress on the boom, the turn table, and
all the structural members. It could potentially weaken key components
and lead to their failure. If someone on the site has used a crane
improperly, one should ensure that it has been inspected thoroughly to
check for damages and impairment.
 Stay in touch. Whether one uses radios, air horns, or hand signals, there
needs to be clear communication between the operator and other workmen.
That’s especially critical when a crane is making a lift in which the
operator cannot see the load, such as when air handling equipment is being
delivered through an opening on another side of a structure. One should
not assume that everyone will know how instructions will be
communicated. One should build specific guidelines, and make sure that
everyone on the site knows exactly what each signal means.
 Avoid man-baskets. Sometimes the easiest way to put employees where
they’re needed is to lift a man-basket to the work area. However, that
approach creates hazards that must be tested and addressed before work
begins, such as providing proper fall protection, verifying basket capacity,
and checking that the basket is properly attached. In addition, the safety of
the employees in the basket is entirely dependent on the skill of the
operator, and a simple mistake could have tragic consequences. Before
using a man-basket, consider whether an articulating boom lift or a scissor
lift might provide a safer alternative.
 Start with a plan. Each lift is different from another, and it’s important to
review load weight capacities, the integrity of the equipment, the possible
effect of wind, and other factors. The operator, riggers, and other workmen
involved with the lift should be part of that planning process.
 Standing under a crane: One must ensure that employees know they
must not stand under loads and ensure that operators never lift a load over
an employee. One must never stand under a crane or have a load lifted
over oneself. It’s crucial that the employees are aware of this and avoid
walking through any zones where cranes are overhead.
 Know, understand and comply with the Lifting Operations and Lifting
Equipment Regulations 1998 (LOLER). After all, the standards requiring
tag lines on loads, capacity limits, ground stability, and similar factors
have all been adopted because incidents, injuries and fatalities
demonstrated a need for them. Following those rules and ensuring that the
operators and other workmen have the right education, training, and
experience will protect everyone involved.
 Carry out routine maintenance and repairs of all on-site equipment at
appropriate intervals. Part of one’s legal responsibility under LOLER
involves carrying out routine, periodic maintenance and repairs to ensure
your machinery is in safe working condition. The concerned authorities in
the Government issue a fitness certificate to each crane in operation, once
a year. It is grossly illegal to operate any crane without this Fitness
Certificate.

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Introduction to
Industrial Safety  Checking the operating functions daily: It’s important to check the
Engineering operating functions daily to ensure that everything is working properly and
that there are no defects or cracks in the support chambers. The cranes of a
generation ago were made with alloys that could handle overloading and
other abuse. Today’s cranes use materials that are less tolerant of
mishandling. Long time operators are often surprised to discover that the
tricks they used to push cranes beyond the limits in the past can easily
create very dangerous situations with newer cranes.
 Overhead cranes used in heavy industrial applications such as steel
making need to be inspected even more carefully. Many of these cranes
spend decades working in extreme environments such as melt shops. That
constant exposure to intense heat and temperature swings can cause the
beam and other structural members to become brittle and lose strength or
even fail.
 Ensure a supervisor is present on site at all times when cranes are in
operation.
 Make employees aware of, and strictly enforce your loading and lifting
limits.
 Ensure clear warning signals are displayed on-site when needed. One must
display the relevant hazard signs in all danger zones on-site to warn your
employees of the potential hazards. All the employees must know and
understand all the warning signs so that they are aware of when they are
entering a danger zone.
 Select appropriate PPE for all employees. Ensure that employees wear
appropriate foot, head and eye protection, along with any other PPE that
has been identified during risk assessment.

SAQ 2
a) What are the different types of cranes used in the industry?
b) Name and explain the safety factors to be observed during crane
operation.

8.6 SAFE LOADING AND OPERATION OF

CRANES
A crane capable of operating at variable radii, for example a tower or mobile
crane, will have a crane-specific load chart (also known as a ‘rated capacity
chart’) explaining how the crane lifting capacity varies depending on how the
crane is set up i.e. how far the boom is extended and the angle of the boom.
Using the load chart correctly is critical in ensuring that the crane is used
safely.
Where the crane has one main load chart it should be fixed in the operator’s
cabin in a place that is easy to see and read. Where the crane has more than one
load chart, for example for different boom and fly jib configurations, the charts
should be easily accessible for the operator to verify that the crane will not be
over loaded. The charts may be kept electronically or in hard copy.
The lifting capacity of a crane is generally limited by:

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 the structural strength when the working radius is small, and Machinery
 its stability when the working radius is greater.
However, there are structural limits at both the minimum and maximum
working radius. If a crane is over loaded, a structural or mechanical component
of the crane may fail, or the crane may overturn. The lifting capacities
specified on a load chart should not be exceeded except during testing of the
crane by a competent person under controlled conditions.
Each load chart should include enough information to identify the crane
configuration it applies to.
For example:
 the safe working zone
 the counter weight mass
 whether a fly jib is fitted, in use, in place or stowed
 outrigger extension or pick-and-carry mode
 maximum speed for making a load mobile
 rope and reeving details, including number of falls of rope in the hook
block
 main or auxiliary hoist in use, and
 whether the hook block is included or excluded.
Some important factors which are often overlooked when reading load charts
are:
 Subtracting the mass of the hook block and lifting slings from the capacity
of the crane at the particular radius. This should be noted on the load chart.
For example, if the load chart states the crane can lift 20 tonnes at a given
radius but the hook and lifting gear have a combined mass of a ton, the
load to be lifted cannot be more than 19 tonnes. This issue is critical for
heavier hook blocks and lifting gear, for example spreader beams.
 Subtracting the mass of the fly jib (adjustment mass) from the capacity of
the main hook when lifting from the main hook on the main boom with a
fly jib attached to the boom head. This adjustment mass should be noted
on the load chart—there may be two different masses for some cranes with
swing around fly jibs—one for the fly jib in place and another for the
stowed position. Capacities of the main boom are generally based on the
fly jib being removed. If this issue is ignored, the crane is likely to
overturn.
 The increased maximum working radius that may result when using a fly
jib.

8.6.1 Limiting and Indicating Devices

Limiting and indicating devices, for example rated capacity limiters, motion
limiting devices, load indicators and radius indicators are intended to prevent a
crane moving beyond its safe operating limits or to aid crane operators. The
devices should not be relied on in place of using the crane’s load chart and
operating instructions. Sole reliance on these devices, especially indicating
devices, in place of safe operating practices may cause an incident. Where
limiting and indicating devices are to be installed on a crane the safety circuits
of these devices should generally meet either:

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Introduction to
Industrial Safety  a reliability level of Category 4 under AS 4024.1-2006: Safety of
Engineering machinery, or
 a safety integrity level (SIL) of 3 under AS 61508-2011: Functional safety
of electrical/electronic/programmable electronic safety-related systems.
These categories of reliability level and SIL are related to the concept of ‘fail
safe’.

8.6.2 Free Fall Lock-Out

When a crane is fitted with a free fall facility this function should be able to be
positively locked out and not able to be unintentionally activated.

8.6.3 Operator Protective Devices

Suitable operator protective devices must, so far as reasonably practicable, be
provided for powered mobile plant including cranes. Typically these include
FOPS and operator restraints e.g. seat belts. A roll-over protective structure
(ROPS) may also be an appropriate device for some types of cranes.

8.6.4 Choosing the Right Location

You should choose where to site a crane during the planning phase after
considering relevant factors including:
 the risk of the crane overturning or collapsing from the foundations or
supporting structure failing
 crane and foundations/supporting structure combination not being able to
withstand the forces likely to be imposed on it after loading
 the risk of the crane colliding with other plant, structures or objects at the
workplace, and
 the loads and lift paths including the load pickup and drop off or
installation locations.

8.6.5 Crane Standing Area

The crane standing design should conform to the crane manufacturer’s
instructions or a competent person’s recommendations, for example an
engineer. The crane standing should be designed to withstand the forces likely
to be imposed on it by the crane while in-service, out-of-service and during
erecting and dismantling. These forces include:
 the dead weight of the crane
 the dead weight of the load and lifting attachments
 dynamic forces caused from the crane moving
 bearing pressure being applied by the crane’s outriggers and/or
tyres/tracks
 wind loadings, and
 other loads identified by the designer of the crane standing area.
When a crane is to be supported on, or tied to a permanent or temporary
structure, the design of the structure should be capable of with standing the
forces designed to be imposed on it by the crane. Precautions should also be
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taken to ensure the stability of the crane when the crane will be sited near Machinery
underground services, excavations or embankments.

8.6.6 Collision Between the Crane and Other Plant and

Structures
If there is a possibility of cranes colliding with other plant or structures they
should be positioned so the clearance between the crane and its load and other
plant, structures and workmen minimises the risk of collision. Where cranes
are operating near one another they may share the same air space. The people
in each work area should consult and develop safe systems of work to make
sure there is enough space between the cranes and where they work. Each
work area should nominate a person to implement the safe system of work. A
safety observer (also known as a ‘spotter’) should be used where a collision
between a crane and other plant or structures are likely to occur.
Where cranes are set up in or near flight paths, one should contact the local
airport operator to find out where these are in the area where the crane is
operating. Where necessary, aircraft warning lights should be fitted to the
highest part of the crane.

8.6.7 Working Near Electric Lines

It must be ensured, so far as is reasonably practicable, no person or crane at the
workplace comes within an unsafe distance of an overhead or underground
electric line. If this is not reasonably practicable then one must carry out a risk
assessment and implement control measures to manage the risks. The control
measures must be consistent with requirements of the Electricity Supply
Authority.
A safety observer should be used when the crane, its load, or any one working
from the plant are in motion and likely to enter a restricted work zone
established around electric lines. Electric lines can have significant risks
including electrocution, arcing, explosion or fire causing burns, unpredictable
cable whiplash and other objects being electrified like signs, poles, trees or
branches. Contact with energised overhead or underground electric lines can be
fatal regardless of the voltage they carry. It is not necessary to touch an
overhead electric line to be electrocuted. A ‘flash over’ or ‘arc’ can electrocute
when one is close to a live line.
Most risks can be controlled by observing safe working distances for people
and cranes working near electric lines. Safe working distances will depend on
the type of work being carried out and the voltage of the electric lines. One
should contact the relevant Electricity Supply Authority to determine the type
of control measures required. This may include isolating the electric line for
the duration of the work.
Contact with energised overhead electric lines may have an impact on parts of
the crane, for example tyres, hydraulic and electrical systems. If contact occurs,
the crane should be immediately placed out-of-service until it has been
inspected by a competent person and proven to be safe to resume operation.

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Engineering
8.6.8 Working at a Height
People installing, erecting and dismantling some types of cranes may be
exposed to the risk of falling when working at a height. An activity carried out
in relation to construction work where a person could fall more than 2 metres
is defined as high risk construction work and requires a safe work method
statement (SWMS).
To minimise the risk of workmen falling from a height control measures may
include:
 temporary work platforms e.g. an elevating work platform
 travel restraint systems
 fall-arrest harness systems, and
 edge protection systems.

8.6.9 Managing the Risk of Falls at Workplaces

Pick and carry activities occur when a mobile crane carrying a suspended load
travels with the load (also known as mobiling). Pick and carry activities are
only to be carried out with cranes designed for this purpose and in accordance
with the manufacturer’s instructions. The rated lifting capacity of pick and
carry cranes is de-rated by design to take into account the reduced stability
when the crane moves across various terrain types. Pick and carry crane
manufacturers may also provide a de-rating chart to help determine a crane’s
rated lifting capacity when working on specified side slopes. Operational risks
such as ground conditions, intended travel pathway, and wind speed also need
to be considered. Unless otherwise specified by the manufacturer, cranes
designed to remain in one location during the lift, for example vehicle loading
cranes, are not to be used in a pick and carry mode. When other cranes, for
example earthmoving equipment or telescopic handlers are used for pick and
carry activities, the manufacturer’s instructions or those of a competent person
must be followed.

8.6.10 Crane Stability

Failure to maintain stability is one of the key factors associated with serious
crane incidents.
Things to consider are:
 crane operation parameters resulting in an overturning moment greater
than the stabilising moment of the crane. The crane counterweight
generally provides the primary stabilising moment
 the ground conditions and means of supporting the outrigger pads or the
crane tyres
 the slope of the ground including both the side slope and the slope of the
ground in the direction of the crane travel if the crane has mobile ratings.
 varying wind conditions depending on the size and shape of the suspended
load and crane boom, and
 the way loads are lifted or moved e.g. a sudden stop when mobiling a load
may cause the load to swing and destabilise the crane. If the crane moves

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unexpectedly while mobiling or slewing (moving the load in a radius), the Machinery
load may swing unexpectedly. Cranes should only be positioned and
operated on stable surfaces, designed by a competent person, with the
correct bearing pressure and without significant holes or indentations that
may cause the crane and load to move unexpectedly due to being unstable.
Further information on crane stability is in the Guide to mobile cranes.

8.6.11 Wind Conditions

Winds impose extra loads on a crane and affect the crane’s stability. Where
wind speeds are greater than those recommended by the manufacturer, crane
operations should be stopped and if necessary, the crane should be stowed
(retracted to the most stable position).The design wind speed for the crane
should be listed in the manufacturer’s instructions and marked on the load
chart(s). Crane operators should recognise that dependent on the boom length
and luffing angle (boom is the long, telescopic or fixed arm that is used to
move objects. Luff is the movement of jib of crane vertically to lift a load), the
wind speed may be greater at the height of the load compared to the wind
speed at the height of the crane’s cabin. Also wind gusts have a different effect
on the crane than a constant wind. Given these variables, crane operators
should make their decision to conduct a lift based on the information provided
by the crane manufacturer, advice provided by competent people like an
engineer, dogger or rigger.
If the crane operator considers it unsafe to lift the load it should not be lifted
until:
 a written authorisation is provided by a competent person confirming the
load is safe to lift and how it is to be lifted, or
 the conditions change and the crane operator decides it is safe to make the
lift.

8.6.12 Licences to Operate Cranes

A person who operates a crane does not need to be licensed if the work carried
out is:
 as a trainee being supervised by a licensed crane operator
 solely for manufacturing, testing, trialling, installing, commissioning,
maintaining, servicing, repairing, altering or disposing of the crane
 solely for moving the crane in the workplace where the crane is operated
or used without a load except when standard weights with predetermined
fixing points are used for calibration and other testing
 limited to setting up or dismantling the crane and the person carrying out
the work holds a high risk work licence for rigging which qualifies the
person to carry out the work, or
 limited to loading or unloading plant from a vehicle or equipment used to
move plant. The person that slings a load, including selecting and
inspecting the lifting gear, and/or directs the crane operator in the
movement of a load when it is out of the crane operator’s view must hold a
dogging or rigging licence (excepting for a licensed vehicle loading,
bridge or gantry crane operator who can sling loads for the type of crane
they are licensed to operate). Regular refresher training is important to
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Industrial Safety ensure licensed crane operators, doggers and riggers maintain the
Engineering competencies gained when they undertook their high-risk work licence
and understand the cranes they are working with. Refresher training
should be conducted as often as necessary to ensure the crane crew
continues to work safely.

8.6.13 Driver’s Licence Requirements

A mobile crane may be a registered vehicle under state and territory road laws.
Like a truck driver, a person must hold a current driver’s licence for the class
of vehicle before driving a mobile crane on a public road.

8.6.14 Operating and Lifting Procedures

Documenting operating and lifting procedures can help define responsibilities
and manage crane activities in a logical and systematic way. Lifting procedures
should be prepared to suit the crane, the work and the working conditions. A
SWMS will be required for crane work, including work defined as high risk
construction work.
Documented lifting procedures may include:
 hazards and risk controls to be applied e.g. for electric lines
 the type of crane or cranes to be used
 the loads to be lifted including the mass of the lifting equipment e.g. slings
and spreader beams
 verification that the crane standing will support the maximum ground
bearing pressure to be imposed by the crane during operations
 the position of the crane, loads to be lifted and where e.g. a diagram
showing a plan view of the site
 the maximum wind speed for the crane and lower wind speeds for
specified loads e.g. where the load has a large surface area, for example
large pressure vessels and tanks.
 the load working radius range with confirmation the loads are within the
crane’s capacity at the maximum radius
 allowance for the factors that may require de-rating of the crane e.g. for
multiple crane lifts, extra radius caused by tilting of tilt-up panels
 when a spotter is needed e.g. to prevent a collision or contact with
overhead electric lines—the tasks required, who is responsible for
performing them and what communication system is to be used should
also be documented
 the slinging and lifting sequence, and
 the rigging requirements of the job.

8.6.15 Communication
Lack of reliable communication between a crane operator and dogger or rigger
may lead to unsafe crane operations and contribute to injury to people from
dropped loads and collision with other plant and/or structures. Only one dogger
should give signals at a time. Signals may be visual, audible or a combination
of both. When more than one dogger is involved in a lift, each dogger should
understand when responsibility for their part of the lifting operation should be
handed over to another dogger.

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Effective communication is particularly important where the crane operator Machinery
cannot see the load, the load’s landing area or the path of travel of the load or
the crane make an accurate judgement of distance and see if the crane or the
load may contact overhead electric lines or other obstacles. People using radio
equipment should be familiar with the manufacturer’s operating instructions. A
secure dedicated radio frequency should be selected for the duration of the
crane operations to prevent interference with other radio equipment being used
in the vicinity of the crane. A constant talk method should be used so the
people involved are aware of the progress of the lifting operations. Work
should stop immediately if there is a loss of radio communication.
Where radio communication cannot be used other ways to communicate
including hand signals, bell, buzzer and whistle signals should be used. Mobile
phones should not be used for directing mobile crane operations.

8.6.16 Lifting Gear

Lifting gear should be checked before and after use and inspected regularly by
a competent person to determine whether it is suitable to keep using.
Checks should ensure:

 the lifting gear is tagged and relevant information listed e.g. relevant
information for a chain sling includes grade of chain, rated capacity,
manufacturer, chain size and the relevant standard marking.
 lifting hooks are provided with operable safety latches unless a safety latch
would increase the risk e.g. a hook on a tea pot ladle at a smelter.
 shackles used as terminal fittings are prevented from unscrewing e.g.
mousing.
 lifting eyes and inserts are compatible.
 lifting slings are not damaged e.g. excessive wear, damaged strands,
cracks, deformation or severe corrosion, and
 the sling is suitable for the load being lifted including capacity and
protection from sharp edges. The manufacturer’s requirements for lifting
gear should be followed including using protective sleeves and corner
pieces. Although the edges of the load may not appear sharp a sling may
be damaged when it is placed under tension.

8.6.17 Lifting Materials

Crane-lifted loads should be slung and secured so the load or part of it cannot
fall. Tag lines or similar control devices should be used to control loads while
being lifted or suspended.

8.6.18 Material Boxes

Material boxes should.
 have the tare mass and working load limit (WLL) clearly marked
 be suitable for the material being lifted and be engineer-designed and
certified
 have four slings—one in each corner—attached during lifting

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Industrial Safety  have enclosed sides or robust mesh with openings less than the minimum
Engineering size of materials being lifted (specifically designed material boxes should
be used to lift smaller components)
 be inspected and maintained and inspection records should be properly
kept.
 have loads secured against movement, and not have materials stacked
higher than the side of the material box unless they are secured—but at no
time should the material box become top heavy.

8.6.19 General Lifting

The following principles should be observed when using cranes for general
lifting work:
 Formwork frames should be either tied together, secured in a lifting frame,
or lifting slings should be wrapped around the load.
 Loads of pipes, joists, timber or sheeting should be strapped together and
lifted in a flat position to prevent individual items from slipping.
 Sheets of plasterboard may be lifted in a specifically designed material
box. If a material box is not used then the lifting system should
 be certified by an engineer or a person who holds an intermediate or
advanced rigging licence
 specify the minimum and maximum number of sheets
 specify the number and locations of lifting slings, and
 specify the capacity of lifting slings.
 Tag lines should be used as needed to control loads.
 Loads should be supported where possible with dunnage (loose wood,
matting, or similar material) and with the load distributed over the
supporting surface.
 Wherever basket hitches are used the sling needs to be positively
restrained from sliding along the load.

8.6.20 Lifting People

Except where exempted by the WHS regulations, people should only be lifted
by implements designed specifically to lift people, for example elevating work
platforms or man-baskets. If it is not reasonably practicable to use implements
specifically designed to lift people, a crane-lifted work box may be used to lift
workmen to perform minor work for a short amount of time in an elevated
work area.

8.6.21 Crane Overload

A crane should never be overloaded. The crane operator or dogger should:
 verify if the marked load mass is correct and not lift a load in excess of the
crane’s rated capacity
 verify the correct counter weight is correctly mounted and the outrigger
settings are in accordance with the load chart being used, and
 control crane movement including mobiling to stop excessive load swing
that may overload or topple the crane.

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 Safeguarding of
Before lifting a load, the crane operator or dogger should ensure that the hoist Machinery
rope hangs vertically over the load. Care should be taken to stop the load
swinging when lifting the load. The crane operator should always have the load
under control when lowering loads or when the load is suspended.

8.6.22 Falling Objects

The risk of falling objects causing injury to workmen and other people must be
eliminated, or minimised, including preventing objects from falling freely, or
providing a system to arrest the fall of the object. Loads should not be lifted
over public access areas including footpaths, roads, highways, railways,
waterways and buildings. If there is a risk of people being hit by falling objects
control measures like exclusion zones or suitably designed gantries should be
used to prevent people being hit by falling objects during lifting operations.
Where possible, site access should be restricted to people who are directly
involved with crane activities. Movement of people and other mobile
equipment at the workplace should be minimised while lifting is taking place.

8.6.23 Exclusion Zones

Exclusion zones should be established around cranes and adjoining areas to
stop people entering the area and risk being injured by the crane or falling
objects. The size of the exclusion zone should be based on risk assessment.
Where the exclusion zone crosses a public footpath or roadway that needs to be
closed or an overhead protective structure should be erected. Approvals should
be taken from the relevant authority. People should be safely directed to an
alternative footpath. Lane closures and other operations requiring barricades
and signs to be erected should meet local road authority, local government
authorities and relevant building or local laws.

8.7 GENERAL GUIDELINES FOR CRANES

8.7.1 Single Crane Multiple Winch Lifts:
Some single cranes are designed to lift a load using both the main and auxiliary
winches. Single crane multiple winch lifts can be undertaken on these cranes in
accordance with the manufacturer’s instructions. This can occur for example,
to rotate a prefabricated concrete panel into its vertical position from a
horizontal storage or a position suitable for transport by using two hoist ropes.
Even though the concrete panel will be suspended by two hoist ropes, each
rope usually needs to support more than 50 per cent of the load during the
rotation and one rope will have to support the full weight. Therefore unless
each hoist is capable of supporting the full load it is important to use the main
hoist to support the full load.
The actual load to be carried by each winch and rope should be calculated and
documented by a competent person before the lift commences.
Where a single crane is used for mid-air rotation one should:
 use a crane designed and manufactured for simultaneous multiple winch
use
 follow the crane manufacturer’s instructions

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Introduction to
Industrial Safety  if needed, reconfigure the crane before it can be used in this way
Engineering  make sure the main winch and auxiliary winch drives are independent
 not exceed the rigging maximum design fleet angle
 rotate as near as possible in line with the plane of the boom to prevent side
loading the sheaves
 monitor the load on the main and auxiliary winches separately and
simultaneously to avoid overloading either rope and to make sure the
combined load of both ropes does not exceed the rated capacity
 not exceed the included angle between the main hoist rope and auxiliary
hoist rope by more than 10 degrees, or as determined by the manufacturer
or a competent person, unless otherwise specified by the manufacturer,
and rotate with enough clearance to make sure the load does not strike the
ground, crane or other objects.
 A competent person, for example an engineer should confirm the
minimum required capacity of each hoist rope, that is the maximum load
placed on each rope during the rotation. Sometimes the auxiliary winch
line passes over the ‘rooster sheave’, the sheave mounted on a short boom
extension. Do not overload the rooster sheave as some are not rated for the
full line pull of the auxiliary winch and are not suitable for this purpose.
Rooster sheaves and the associated rigging on the boom head should be
designed and certified by an engineer.

8.7.2 Multiple Crane Lifts

Lifting a load with two or more cranes requires detailed planning and
supervision because the movement of the load between the cranes may create
extra loadings on the cranes, the load and the lifting gear. The design capacity
of a crane will not be the maximum rated capacity but the de-rated capacity
relevant to the multi-crane lift to be carried out. The cranes to be used in the
lift will need to be de-rated. No load should be lifted simultaneously by more
than one crane unless a single crane lift is not practical and the multiple crane
lifting method ensures the load placed on each crane does not exceed its de-
rated design capacity. Where multi-crane lifts are carried out, a documented lift
plan and procedure should be prepared by a competent person, for example an
engineer, and followed. The crane de-ratings for each of the cranes used for the
multi-crane lift should be identified in the plan. Where it is necessary to lift a
load using more than one crane, the person in control of the lift must hold at
least an intermediate rigging high risk work licence.

8.7.3 Cranes Used for Demolition

Cranes should not be used for demolition (or wrecking) ball work. If a crane is
used for demolition ball work it should be thoroughly inspected and verified by
a competent person after the work is complete as being in a satisfactory
condition before it is used for general lifting. The results of the inspection must
be recorded in the crane’s service logbook. Cranes used for demolition work
must be fitted with suitable operator protective devices, for example a FOPS,
to protect the crane operator. The hoist rope should be prevented from leaving
the boom point sheave. This may include fitting heavy duty rope guards to the
sheave to control the slack rope condition that may occur as the ball falls—
damage is likely where the demolition ball is attached to the hoist rope. Hoist
ropes should not be fixed directly to the demolition ball. A length of chain
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 Safeguarding of
should be used to join the hoist rope to the demolition ball. The chain should Machinery
be at least 16 mm and at least 2 metres in length.

8.7.4 Cranes not in Use

A crane may not be in use if it is unattended, parked or stored. You must make
sure, so far as is reasonably practicable, a crane that is not in use is left in a
state that does not create a risk to the health or safety of a person.
Except in an emergency due to fire or other life threatening reason, the crane
operator should never leave the crane cabin or controls while a load is
suspended from the crane. A crane should not be left unattended unless:
 loads are removed from the hook or lifting device
 the hook has been secured or raised to a position where it is clear of other
operations
 the crane is properly stowed
 powered movements have been disabled, and
 the keys removed or the starting device locked out.
When leaving a mobile crane unattended for a period of time ensure the
crane’s boom is retracted and lowered as far as possible.
Where there is no risk of a tower crane boom contacting other structures, the
crane should be left to weathervane when unattended according to the crane
manufacturer’s instructions. Where it is necessary to restrict the movement of
the boom of a tower crane the method of tethering, that is securing the boom to
prevent slewing, should be according to the crane manufacturer’s instructions
or as determined by an engineer. If a crane is to be stored, it should be
prepared to be left unattended and:
 the manufacturer’s storage instructions followed
 remote control equipment isolated
 the power supply and controls isolated and locked off
 storm anchors applied, if fitted, and
 doors and windows locked to prevent unauthorised access.

8.7.5 Decommissioning and Dismantling

A crane must be decommissioned or dismantled by a competent person and
inspections must be undertaken during the process. A crane should be
decommissioned and dismantled according to the manufacturer’s instructions.

SAQ 3
a) Briefly state the check points to ensure safe loading of a crane.
b) What precautions are needed when loads are lifted with multiple
cranes?
c) Explain the safety measures to be taken when a crane is not in use.

8.8 LET US SUM UP

205
Introduction to
Industrial Safety We have touched upon safety requirements in mechanical operation in general
Engineering and studied the safe operations of cranes in detail.
We have learnt that:
 Commonly 7 types of cranes are used in the industry, namely,
 Mobile cranes
 Telescopic crane
 Tower crane
 Truck mounted crane (also known as boom truck or picker truck)
 Rough terrain crane
 Loader crane (also known as a folding boom crane)
 Overhead crane
 The usual hazards of working with cranes are,
Falling Loads can be caused by,
 Operator incompetency
 Slipping
 Mechanical failure
 Two blocking
Crane Overload
 Swing or suddenly drop loads
 Hoist loads beyond the cranes capacity
 Use defective components
 Dragging or side-pulling. Do not pay enough attention to the loading
chart provided on the body of the crane
 Not following the cranes’ rated capacity/loading chart
Electrical Hazards
 The safety precautions to be taken during crane operations can be summed
up as,
 Have a certified operator
 Know what’s below
 Plan for swing
 Use cranes within rated capacity
 Stay in touch
 Avoid man-baskets
 Start with a plan
 How to safely load and operate cranes
To ensure safe loading of cranes various factors to be considered are,
 the safe working zone
 the counterweight mass
 whether a fly jib is fitted, in use, in place or stowed and the increased
mass and maximum working radius that may result when using a fly
jib.
 outrigger extension or pick-and-carry mode
 maximum speed for mobiling a load
 rope and reeving details, including number of falls of rope in the hook
block
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 Safeguarding of
 main or auxiliary hoist in use, and Machinery
 whether the hook block is included or excluded.
 limiting and indicating devices in working condition
 suitable operator protective devices
 crane positioned in right location
 crane standing area
 electric lines near operation area
 working at a height
 wind conditions
 communication between operator and ground staff

8.9 KEY WORDS

Crane Hazards: while with cranes poses many hazards, and unsafe working
pratices can result in injuries, fatalities and costly damage to buildings,
equpment and materials.
Falling Loads: while working with overhead cranes, falling loads are one of
the most comon, and most dangerous, hazards.
Electric Overhead Traction (EOT) : an overhead crane, also referred as an
crane, is normally used in factory, with some of them being able to lift very
heavy loads.
Crane overload: the majority of crane structural failures and upsets are the
result of somebody overloading a crane.
Mobile crane: the most standar and versatile type of cranes used in
construction and other industries.
Telescopic cranes: offer a boom that consists of a number of tubes fitted one
insdie the other.
Tower crane: it is a modern form of a balance crane.
Boomtrucks or picker trucks: these are cranes mounted on a truck with
rubber tires and provide great mobility.
Rough terrain crane: it is crane that is mounted on an undercarriage with
rubber tires, designed for operations off road.
Loader crane: a folding boom crane is a hydraulic powered articulated arm
fitted to a trailer, used to load equipment onto a trailer.
Overhead crane: referred to as an Electric Overhead Traction (EOT) crane, is
normally used in a factory, with some of them being able to lift very heavy
loads.

8.10 ANSWERS TO SAQs

SAQ 1
a) Key risk areas in mechanical operations and safety measures needed for
them can be broadly categorised as below;
 Winding equipment – Safety precautions include suitable guards
covering high speed rotating parts and general electrical safety.
 Diesel engine systems – Safety measures against toxic fumes, heated
pipes and parts, high speed rotating parts need to be taken.

207
Introduction to
Industrial Safety  Welding – Wearing protective gloves and clothing, using proper
Engineering screen and protection from electrical hazards is required for safe
operations.
 High pressure hydraulic equipment – Making sure that safety valves
in the system are always in working order, few routine checks like oil
level, leak, clogging filters, hoses defects, hydraulic piping and
connections, abnormal noise pump etc. should be the primary safety
measures.
 Metal cutting operations - To ensure safety avoid wearing loose
garments and using rags near running machines, wear goggles to
avoid flying metal chips, stop machine before cleaning chips or when
you are away and never try to free a stalled cutter without turning the
power off first.
 Mobile and transportable equipment – We shall discuss the safety
measures for this type of mechanical operation in detail below taking
the example of cranes.
b) The usual hazards of working with cranes are,
Falling Loads can be caused by,
 Operator incompetency
 Slipping
 Mechanical failure
 Two blocking
Crane Overload
 Swing or suddenly drop loads
 Hoist loads beyond the cranes capacity
 Use defective components
 Dragging or side-pulling Do not pay enough attention to the loading
chart provided on the body of the crane
 Not following the cranes’ rated capacity/loading chart
SAQ 2
a) Commonly 7 types of cranes are used in the industry, namely,
 Mobile cranes
 Telescopic crane
 Tower crane
 Truck mounted crane (also known as boom truck or picker truck)
 Rough terrain crane
 Loader crane (also known as a folding boom crane)
 Overhead crane
b) The safety precautions to be taken during crane operations can be summed
up as,
 Have a certified operator
 Know what’s below
 Plan for swing
 Use cranes within rated capacity
 Stay in touch
 Avoid man-baskets
 Start with a plan

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 Safeguarding of
SAQ 3 Machinery
a) To ensure safe loading of cranes various factors to be considered are,
 the safe working zone
 the counterweight mass
 whether a fly jib is fitted, in use, in place or stowed and the increased
mass and maximum working radius that may result when using a fly
jib.
 outrigger extension or pick-and-carry mode
 maximum speed for mobiling a load
 rope and reeving details, including number of falls of rope in the hook
block
 main or auxiliary hoist in use, and
 whether the hook block is included or excluded.
 limiting and indicating devices in working condition
 suitable operator protective devices
 crane positioned in right location
 crane standing area
 electric lines near operation area
 working at a height
 wind conditions
 communication between operator and ground staff
c) Lifting a load with two or more cranes requires detailed planning and
supervision because the movement of the load between the cranes may
create extra loadings on the cranes, the load and the lifting gear. The
design capacity of a crane will not be the maximum rated capacity but the
de-rated capacity relevant to the multi-crane lift to be carried out. The
cranes to be used in the lift will need to be de-rated.
Where multi-crane lifts are carried out, a documented lift plan and
procedure should be prepared by a competent person, for example an
engineer, and followed. The crane de-ratings for each of the cranes used
for the multi-crane lift should be identified in the plan. Where it is
necessary to lift a load using more than one crane the person in control of
the lift must hold at least an intermediate rigging high risk work licence.
c) If a crane is to be stored it should be prepared to be left unattended and:
 the manufacturer’s storage instructions followed
 remote control equipment isolated
 the power supply and controls isolated and locked off
 storm anchors applied, if fitted, and
 doors and windows locked to prevent unauthorised access.
Except in an emergency due to fire or other life threatening reason, the
crane operator should never leave the crane cabin or controls while a load
is suspended from the crane. A crane should not be left unattended unless:
 loads are removed from the hook or lifting device
 the hook has been secured or raised to a position where it is clear of
other operations
 the crane is properly stowed
 powered movements have been disabled, and
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Introduction to
Industrial Safety  the keys removed or the starting device locked out.
Engineering

8.11 READINGS AND FURTHER READINGS

[1] https://www.ccohs.ca/oshanswers/safety_haz/safeguarding/general.html
[2]https://books.google.co.in/books?id=91mBNcrrX3AC&printsec=frontcover
&source=gbs_ge_summary_r&cad=0#v=onepage&q&f=false

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