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[PDF] Mechanical Material Handling Safety

 Mechanical Material Handling: - Is defined as the movement of goods by 
mechanical force for the purpose of feeding, Loading, or unloading to or from a machine, 
Plant, or storage place, to or from a means of transport such as vehicles, ships or air 

Hazards in Mechanical Material Handling:- 

  Wrong selection of equipment 
  Design defect / unsafe construction or 
  Lack of space for operation 
  Lack of skill, training and correct attitude  operation of equipment   on the part of operator 
  Overloading of equipment 
  Wrong position of material or equipment 
  Working at excessive speed 
  Unauthorized Operator 
  Improperly guarded or unguarded machinery 
  Electrical faults 
  Poor maintenance or no testing 

Mechanical Material Handling Safety
Only skilled and authorized person to be allowed for doing Mechanical Material handling 
by using Various Lifting Machines. 
Wear work specific PPE while doing various operations. 
Use proper lifting tools and tackle having adequate capacity. 
Each tool, tackle, or equipment should have identification number and Safe Working 
Load (S.W.L.) marked on it. 
Assess weight of material, distance to be carried, and hazards etc. before lifting the load. 
Inspect and test all the lifting tools and tackles regularly and before taking in use. 
When placing a sling on a load, ensure all sharp corners are covered with pad or soft 
Keep Remote Control away from heat/Vibration & Welding Machines. When not in use 

keep Remote control in wooden box as far as possible. 
Ensure no damage to remote control due to falling/jerks/mishandling. 
Ensure no damage occurs to other machines/fixtures/DSL/railings due to improper 
operation of crane. 
Use only inspected and safe lifting tools-tackles. 
Always use slings/D’s hackles /Clamps etc. of proper rating. Consider SWL at different 

boom level / load position. 
Get the crane inspected from Maintenance dept. If overloading of crane can’t be 

avoided. Also fill the Critical Material Handling permit form properly. 

Always operate cranes in lower steps/speed, when approaching end of long/cross travel. 
Use guide rope way while load shifting. 
Maintain eye contact or means of any direct contact between all team members while 

handling operation for better communication. 


× Don’t use the equipment for the purpose other than its design intention. 

× Don’t allow personnel to move underneath lifted load. 

× Don’t load the equipment above its safe working load. 

× Don’t use makeshift arrangement for lifting the material. 

× Don’t use defective tolls and tackles. 

× Don’t use altered or repaired lifting equipment without inspection or test. 

× Don’t drag chains, ropes, or cable etc. on the floor. 

× Keep tools & Tackles free from adverse effect of atmosphere by applying suitable 
protective coating. 

× The angle between the legs of two leg sling should not exceed 90 degree. 

× Don’t pull any machine/fixture/job/item by long/cross travel. This can cause de- 
wounding of wire rope from rope drum/pulley. 

× While operating higher level cranes (200T/500T/150T) ensure that the hook doesn’t 
fouls with lower level cranes (50T/15T). 

× Never use damaged slings and other accessories required for lifting. 

× Don’t move ahead with remote w.r.t. actual crane movement. 

Don’t allow to operate crane to unauthorized person. 

× Avoid inching & overload operation as far as possible. 

× Don’t stop or start loading of crane suddenly to prevent shock 

× Don’t handle suspended load over person. 

× Don’t allow unauthorized person on the gantry or crane girder while the crane is in 

× Don’t pull or drag the suspended load while it is hanging at height. 

× Don’t pull free, fixed, or obstructed load. 

× Don’t exceed the safe working load specified on the capacity plate. 

× Don’t leave suspended loads unsupervised. 

× Don’t allow the chain / rope to pass over edges. 

× Do not use the hoist chain / rope as a load bearing sling. 

× Don’t allow the loads to drop when the chain rope is in slack condition. 

× Don’t perform inching operation when not required. 

× Don’t use the emergency limit stop device (slipping clutch or emergency limit switch) as 

an operating limits stop. 

× Don’t bypass safety latch of hook 

× Never pull the hook in inclined direction for loading.

For download this document please click on given below button 

                                                           safety downloads


  1. All this material is very useful. Also, I am so glad, that you have shared a PDF file. Thus, it will be easier to read. I will be waiting for more posts.

  2. This comment has been removed by the author.

  3. Lifting Gear London I would like to say that this blog really convinced me to do it! Thanks, very good post.


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