In January of 2012 the Safety and Health Department launched several new initiatives designed to “target the deadly dozen hazardous activities that lead to fatalitiesand disabling injuries."  The focus of this article is to highlight some of the common material handling activities and hazards that commonly occur on the job site.  Fatality and incident reports obtained from the Occupational Safety and Health Administration (OSHA) and The International Association revealed that material handling and staging operations are one of the deadly dozen hazardous activities.  Following are illustrations of common job site material handling activities and OSHA standards for our members to recognize.  As part of our 2012 Zero Fatality Campaign, remember, “You See Something…You Say Something.”

Job Site Access and Layout Conditions– Preventing material handling and staging incidents begins with safe job site conditions to allow crane set-up for off-loading material and staging structural members.  The International Association pursued specific OSHA standards to prevent unsafe job site conditions during the material handling and staging process.  These Subpart R – Steel Erection standards contain controlling contractor requirements, and it is important to recognize these standards and avoid unsafe conditions.  OSHA has defined a controlling contractor as “a prime contractor, general contractor, construction manager or any other legal entity which has the overall responsibility for the construction of the project, its planning, quality and completion.” Following is the applicable OSHA Subpart R – Steel Erection standard that requires the controlling contractor to provide and maintain site conditions for the steel erection contractor.    

1926. 752(c)(1) Site Layout Conditions - The controlling contractor shall ensure that the following is provided and maintained: Adequate access roads into and through the site for safe delivery and movement of equipment, materials and pedestrians.

The photograph below illustrates proper job site access for crane assembly and safely off-loading materials.  Whenever access roads are not provided to allow for safe access and delivery of equipment, trucks and materials, the steel erection contractor must notify the controlling contractor to comply with this standard.  The assembly of cranes and use other hoisting equipment requires preplanning between the controlling contractor and the steel erection contractor.

Access Roads for Off-Loading Iron– Adequate access roads and site conditions allow for the safe delivery of trucks with structural members.  Serious material handling incidents have occurred due to adverse site conditions that cause delivery trucks to sink and the structural steel to shift or slide.  The photograph below illustrates good job site access and site conditions that were provided and maintained by the controlling contractor.

Site Condition Requirements for Staging Areas - Staging and shaking-out structural members requires adequate site conditions to prevent beams from rolling over and subjecting Ironworkers to crushing hazards and incidents.  In addition to controlling contractor requirements to ensure safe access roads into and through the job site, following is another OSHA standard that requires the controlling contractor to ensure adequate site conditions for staging and shaking-out structural members.

1926. 752(c)(2) Site Layout Conditions - The controlling contractor shall ensure that the following is provided and maintained: a firm, properly graded, drained area, readily accessible to the work with adequate space  for the safe storage of materials and safe operation of the erector’s equipment.

The two photographs below illustrate a firm and properly graded job site for staging and shaking-out field beams and columns.  These job site conditions allow Ironworkers to safely work between the field beams and columns to mark centers and install wire ropes.  Many controlling contractors have recognized their regulatory responsibility to ensure that adequate site conditions are provided to the steel erection contractor.  Good job site conditions not only prevent material handling incidents but increase productivity on the project.  

Material handling, hoisting and rigging of structural components require a “qualified rigger” to perform these activities.  The OSHA standard 1926.753(c)(2) states:“A qualified rigger (a rigger who is also a qualified person) shall inspect the rigging equipment prior to each shift in accordance with CFR 1926.251.”

OSHA’s definition of a “qualified rigger” is the same as a “qualified person” and states: “one who by possession of a recognized degree, certificate, or profession standing, or who by extensive knowledge, training, and experience, has successfully demonstrated the ability to resolve problems relating to the subject matter, the work, or the project.” NOTE:  State Approved OSHA Plans or project requirements may impose more stringent inspection and removal requirements for hoisting slings and rigging equipment. 

Basic Hoisting and Rigging Considerations

• Determine the net load for the total weight of the lift.
• Determine the gross load – sum of the weights of all attachments, lift, rigging, etc.
• Determine working range and operating radius of crane.
• Verify job site and soil conditions.
• Refer to crane manufacturer’s load charts and technical publications on equipment.
• Determine sling angle and select the proper slings for hoisting.
• Refer to rated capacity chart for slings and rigging devices.
• Preplan locations for crane set up.
• Ensure a “competent and qualified person is on site to inspect rigging equipment on a “frequent and regular” basis.
• Refer to Appendix B for specific ANSI B30.9 requirements for wire rope sling requirements.

Considerations for using “Below the Hook Lifting Devices”- The process of hoisting pre-built rebar wall sections or panelized joists requires the employer to use a specially designed “below the hook lifting device.”  This device must be designed by a qualified person to accommodate the intended load of panelized bays.  When designing and fabricating lifting devices, the employer must refer to the ANSI B30.20 Standards.  These standards provide specific requirements for “below the hook lifting devices.”   The two photographs below illustrate a typical pre-built rebar curtain wall and a panelized joist bay being hoisted by a “below the hook lifting device.”

The following items are some of the ANSI B30.20 requirements the erector should address when designing the lifting device.

RATED LOAD MARKING– Structural and mechanical lifting devices are required to be marked on the main structure where it is visible.  A nameplate or other permanent marking must display the following information:

• Manufacturer’s name
• Serial number
• Lifter weight
• Rated load

GENERAL CONSTRUCTION– The ANSI standards require the lifting device “to withstand the forces imposed by its rated load, with a design factor of 3, based on yield strength, for load bearing structural components.  All welding on components of lifting devices must be in accordance with ANSI/WS D1.1 Standards.  Modifications performed on these devices must be analyzed and re-rated by a qualified person or the manufacturer of the device.  In some cases, the lifting device must change configuration to accommodate different joist bay sizes and weights.  When support lugs and components are “field washed” with cutting torches and re-welded to new locations, the Ironworker must ensure these modifications are analyzed.  The change in concentrated loads and distributed loads may alter the load capacity of the lifting device.

INSPECTIONS– Prior to initial use, the erector must inspect all new, altered, modified or repaired lifting devices by a designated person to recognize deficiencies and ensure compliance with applicable ANSI Standards.  Inspection procedure for lifting devices in regular service is divided into two general classifications.  The two general classifications are designed as “frequent and periodic,” with respective intervals between inspections as defined below.

MAINTENANCE– The erector should establish a preventative maintenance program that is based on the frequency of use and recommendations of a qualified person or the manufacturer of the lifting device.  When making adjustments and repairs to the lifting device, a qualified person must be consulted to verify service procedures and modifications.

INSPECTIONS – Frequent and Periodic for below the hook lifting devices

1.  Frequent inspections:  These consist of visual examinations by the operator or other designated personnel with records not required

• normal service – monthly
• heavy service – weekly to monthly
• severe service – daily to weekly
• special or infrequent service – as recommended by a qualified person before and after occurrence.

Items to Look For:

• structural deformation, cracks, excessive wear
• lose or missing components
• maladjustments interfering with operator

2.  Periodic inspections:  These consist of visual inspections by an appointed person who makes records of apparent external conditions to provide the basis for continuing evaluation.  In lieu of written record keeping, the erector may elect to use an external code mark on the lifting device that is an acceptable identification.

• normal service – equipment at site of use – yearly
• heavy service – as in (a) above, unless external conditions indicate that disassembly should be done to permit detailed inspection – semi-annually
• severe service – as in (b) above, quarterly
• special or infrequent service – as recommended by a qualified person before the first such occurrence and as directed by the qualified person for any subsequent occurrences.

Items to Look For:

• loose bolts, fasteners and adjustments
• cracks in lugs, welds and components
• excessive wear of components hardware
• excessive wear at hoist hooking points and load support devices or pins

RATED LOAD TEST– Prior to initial use, all new, altered, modified, or repaired lifting devices should be tested and inspected by or under the direction of a qualified person and a written report be furnished by such person confirming the load rating of the lifting device.

The “2012 Zero Fatality” campaign will challenge all members to “intervene and prevent unsafe conditions and unsafe acts” in the workplace.  Material handling and staging hazards created by unsafe job site conditions have contributed to fatalities and serious incidents.  This campaign will include hard-hat stickers, gang-box stickers, and posters for training facilities and local unions.  I will continue to work closely with District Councils, local unions, and IMPACT Regional Advisory Boards throughout the United States and Canada to promote the “2012 Zero Fatality."

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Contact: Steve Rank, Executive Director of Safety and Health, Iron Workers International; srank@iwintl.org or (800) 368-0105