Sector : CONSTRUCTION

Qualification : MASONRY NC I
Module Title : Prepare Masonry Materials
TECHNICAL EDUCATION AND SKILLS DEVELOPMENT
AUTHORITY
CABUGAO SCHOOL OF HANDICRAFT AND COTTAGE INDUSTRIES

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MASONRY NC
I
COMPETENCY - BASED LEARNING MATERIAL

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 MASONRY NC I

COMPETENCY - BASED LEARNING MATERIAL

LIST OF COMPETENCIES

No. Unit of Competency Module Title Code

01 Prepare Masonry Preparing of Masonry CON712301
Materials Materials
02 Perform Basic Masonry Performed Basic Masonry CON712302
Work Work

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 HOW TO USE THIS COMPETENCY BASED LEARNING
MATERIAL

Welcome!
The Unit of competency “Prepare Masonry Materials” in This module contains
training materials and activities for you to complete.

The unit of competency “Prepare Masonry Materials” contains knowledge, skills

and attitudes required for Masonry NC I. It is one of the specialized modules at
National Certificates Level (NC I).
You are required to go through a series of learning activities in order to
complete each learning outcome of the module. In each learning outcome are
Information Sheets and Resources Sheets (Reference Materials for further reading
to help you better understand the required activities). Follow these activities on your
own and answer the self-check at the end of each learning outcome. You may
remove a blank answer sheet at the end of each module (or get one from your
facilitator/trainer) to write your answers for each self-check. If you have questions,
don’t hesitate to ask you facilitator for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in
this learner’s guide because you have:

 been working for some time

 already completed training in this area

If you can demonstrate to your trainer that you are competent in a particular
skill or skills, talk to him/her about having them formally recognized so you don’t
have to do the same training again. If you have a qualification or Certificate of
Competency from previous trainings, show it to your trainer. If the skills you
acquired are still current and relevant to the unit/s of competency they may become

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part of the evidence you can present for RPL. If you are not sure about the currency
of your skills, discuss this with your trainer.

At the end of this module is a Learner’s Diary. Use this diary to record
important dates, jobs undertaken and other workplace events that will assist you in
providing further details to your trainer or assessor. A Record of Achievement is
also provided for your trainer to complete once you complete the module.

This module was prepared to help you achieve competency, in Masonry NC

I . This will be the source of information for you to acquire knowledge and skills in
this particular trade independently and at your own pace, with minimum supervision
or help from your instructor.

 Talk to your trainer and agree on how you will both organize the Training of this
unit. Read through the module carefully. It is divided into sections, which cover all
the skills, and knowledge you need to successfully complete this module.

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 MODULE CONTENT

QUALIFICATION : MASONRY NC I

UNIT OF COMPETENCY : Prepare Masonry Materials

MODULE TITLE : Preparing Masonry Materials

INTRODUCTION : This module covers the knowledge, skills and

proper attitude in preparing materials in masonry.

NOMINAL DURATION : 104 HOURS

LEARNING OUTCOMES:

Upon completion of this module, the trainee/student must be able to:

1. Select materials, tools and equipment needed

2. Haul materials
3. Mix mortar / concrete

ASSESSMENT CRITERIA:
At the end of this module the trainees or the student must be able to :
1. Materials are listed as per job requirements Quantity and description of
materials conforms with the job requirements Tools and accessories are
identified according to job requirements
2. Materials and tools needed are requested according to the listed prepared
Required is done as per company standard operating standard procedures
(SOP) substitute materials and tools are provided without sacrifing cost and
quality of work
3. Materials and tools issued are inspected as per quantity and specification
tools, accessories and materials are checked for damages according to
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 enterprising procedures, materials and tools are set aside to appropriate
location nearest to workplace.
4. Workplace location, Materials relevant to the unit of competency, technical
plans, drawing and specifications relevant to the activities
5. Direct observation and oral questioning

LEARNING OUTCOME NO. 1

Content:
 types and uses of hauling tools, equipment and PPE
 procedures in handling construction materials
 storage of construction materials

Assessment Criteria:
1. Appropriate personal protective equipment (PPE) are used and demonstrated
according to job requirements.
2. Availability and serviceability of appropriate hauling equipment are checked
and specified.
3. Materials are hauled based on work schedule as specified.
4. Required materials are stockpiled base on instruction
5. Safe handling of materials, tools and equipment are observed.
6. Instructions, safety signs and symbols are properly interpreted and followed.
7. Quantity and type of materials are hauled and delivered timely.

CONDITIONS:

Students/trainees must be provided with the following:

 Helmet, safety shoes, proper uniform, gloves, dust masks, safety glasses.
 Buggy, wheel barrow, pallet, pallet track, pail, measuring box, shovel/spade,

METHODOLOGIES:

 Demonstration
 Classroom discussions

ASSESSMENT METHODS:

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  Practical examination
 Direct observation
 Written test/questioning

Table of Content

Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
List of Competency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
How to use this CBLM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Module Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Learning Outcome No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8
Table of Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Learning Experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Information Sheet 1.2.1. . . . . . . . . ... . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Self Check 1.2.1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Answer Slef Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
Information Sheet 1.2.2. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. .. . . .. . . .. . . . . . . . . .
Self Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .
Answer Self check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Information Shee 1.2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 Learning Outcome 1

LEARNING EXPERIENCE
PREPARING MASONRY MATERIALS

Learning Activities Special Instructions

Read Information Sheet 1.2 – 1 The trainer will conduct a lecture regarding
the materials used in basic masonry works
Answer Self – Check 1.2-1 Try to answer the Self – check without looking at
the answer key
Compare Answer key 1.2-1 Check and Double check the answer correctly
through self – check
Read Information sheet 1.2.2a Identify and The trainer will conduct a lecture regarding the
interpret drawing symbols and plans TOPIC
Answer Self – check 1.2-2a Try to answer the Self – check without looking the
answer key
Compare Answer key 1.2-2a Check and Double check the answer correctly
through self – check
Answer Self – check 1.2-2a Answer the self – checked without looking at the
answer key

Read Information Sheet 1.2 –3 Identify and The trainer will conduct a lecture regarding the
describe safety practices and first aid regulations kinds of masonry materials
in basic masonry works
Answer Self – Check 1.2-3 Try to answer the Self – check without looking at
the answer key
Compare Answer key 1.2-3 Check and Double check the answer correctly
through self – check
Read Information Sheet 1.2-4 on  Listen attentively so you may be able to
perform a demonstration

 Ask question if you are in doubt for

clarification or verification
Answer Self – Check 1.2 -4 (Written Read the information sheet carefully
Test)
Compare to answer key 1.1-5
Guided by information sheet 1.2-6 , Jot Down and Observation

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 Information Sheet 1.2.1
Haul Materials

Learning Objective
After reading information sheet, you must able to:
1. What is the process of mixing concrete?
2. Types and uses of hauling tools and its equipment and PPe
3. And its storage of construction materials

This Information sheet or learning outcome will provided a basic information about the
different types of Hauling Mixture and others.

INTRODUCTION
The successful placement of concrete is dependent upon careful mixing, the
proper equipment, and adequate transportation. This site will define, analyze, and
demonstrate the importance of each in the overall process of placing concrete.

Batching and Mixing Concrete

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 Mixing concrete is simply defined as the "complete blending of the materials
which are required for the production of a homogeneous concrete" (Young, 267). This
can vary from hand to machine mixing, with machine mixing being the most common.

However, no successful mixture can be achieved without the proper batching of all
materials. Batching is the "process of weighing or volumetrically measuring and
introducing into the mixer the ingredients for a batch of concrete" (Kosmatka, 94).
Quality assurance, suitable arrangement of materials and equipment, and correct
weighing of the materials are the essential steps that must be completed before any
mixing takes place.

The types and volume of materials, the mix design, and the end result (i.e. strength) are
normally provided in the design specifications. The design specifications must be
consulted before any batching or mixing takes place.

1. Components of Mixing

There are many components of mixing that need to be considered in order

to ensure that a uniform concrete mixture can be achieved. Location,
shape and angle of the mixing blades, shape of the mixing chamber, speed
of rotation, and horsepower must all be taken into account. It is paramount
that each batch is consistently mixed to design specifications so the
concrete’s final strength is not compromised.

2. Classifications of Mixers

There are essentially three classifications of mixers: the drum mixer, pan
mixer, and continuous mixer. Each of these mixers can be further
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 classified as batched or continuous, free-falling or forced movement, and
stationary or portable.

3. Mixing Time

Once the appropriate mixer has been chosen, it is necessary to determine

the mixing time. This is the duration of
time it takes to mix concrete, once the mixer is fully charged with all the
materials. Charging is an important step
because it gives the materials an opportunity to pre-blend. The type and
condition of the mixer, speed of rotation,
size of the charge, and nature of the materials all determine the correct
mixing time. The mixing time is not
standard for each batch. For example, a drum mixer with a small diameter
creates a greater velocity than a drum
mixer with a large diameter, therefore, the mixing time would be
decreased. However, if the goal is stiffer
concrete, a longer mixing time is required.

3.0 Transporting Concrete

Transporting the concrete mix is defined as the transferring of concrete from the mixing
plant to the construction site. Keep in mind that not all concrete is mixed on the actual
construction site and could require some significant travel. This is most common for
ready-mixed concretes. The main objective in transporting concrete is to ensure that the
water-cement ratio, slump or consistency, air content, and homogeneity are not
modified from their intended states.

3.1 Important Factors in Choosing Transportation

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There are many elements of transporting that need to be considered in order to ensure
that a mix does not change its state as specified in the contract. The two key goals when
transporting concrete from the mixing plant to the construction site are to prevent
segregation and to not reduce the workability of the mix. This transportation process
must be well thought out and organized efficiently. As a general rule of thumb, thirty to
sixty minutes of transportation are acceptable on small jobs. At a central or portable
ready-mix plant, concrete should be discharged from a truck mixer or agitator truck
within two hours. If non-agitating transporting equipment is used, this time is reduced
to one hour. All delays must be avoided in order prevent honeycombing,

Many factors determine which type of transportation is most suitable. Type and
constituents of the concrete mix, size and type of construction, topography, weather
conditions (i.e. temperature, humidity, wind speed), location of the batch plant, and cost
are all taken into consideration when choosing a mode of transport for your concrete. If
you choose the wrong mode of transportation, your concrete could be segregated, which
would in effect, make it useless. Therefore it is essential that adequate thought be given
to the type of transportation you actually need.

3.2 Categories of Transportation

There are many modes of transportation as shown below:

1. Wheelbarrow or motorized buggy

2. Truck mixer
3. Bucket or steel skip
4. Chute
5. Belt conveyor
6. Concrete pump
7. Pneumatic placer

Sources : https://www.engr.psu.edu/ce/courses/ce584/concrete/library/construction/mixingtransport/
mixingandtransporting.html

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TYPES OF HAULING EQUIPMENT

Their are 6 different types of hauling equipment that use in masonry and Here are 6 Major
Types of Hauling Equipment

1. Cranes

Cranes are used to lift materials and even in demolition. They commonly move building
supplies, drilling supplies, or soil with cables, sheaves and a hoist. Mobile cranes are mounted onto
flat cars, trucks, or other mobile platforms with trusses.
Fixed cranes cannot move and are fixed onto steel towers. Thus, fixed cranes can reach higher,
farther, and can support greater loads.
Cranes are widely being used to lift materials. Therefore, cranes play a major role behind the
construction projects. You will often be able to see how cranes are being used in the skyscraper
construction projects.
However, it is also important to keep in mind that they play a major role behind certain demolition
projects as well. No matter for what purpose you are going to use cranes, we will be able to help
you with getting them transported to the destination that you want.

2. BULLDOZERS

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 Bulldozers are normally used to create pilot roads, loosen hard soils, shift dirt, and work in
terrain that is too tough for normal trucks. Bulldozers come with either a track base or a wheelbase.
Track-based bulldozers are better for sandy or muddy areas because the weight of the bulldozer is
spread across a greater surface area.

3. EXCAVATORS

Excavators are equipment used for digging holes, demolishing buildings, and lifting heavy
loads to name a few. They have an extendable arm with a digging bucket attached to the end and
come in many different sizes.
Excavators provide an excellent assistance to people by digging holes. If there is a need for you to
use excavators, you can contact us.
That’s because we will be able to provide support and assistance to you with getting the excavators
transported to the destination location with ease. We have all the tools and expertise needed to
provide this service to you.
4. LOADERS

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Loaders, like bulldozers, can be wheel-based or track-based. Their primary use is to load loose
materials onto a conveyor belt or into a dump truck. The dump truck or conveyor belt then moves
the materials away.

Loaders are also used to move machinery.

Loaders can either be wheel based or track based. No matter what the base is, we will be able to
deliver the best heavy equipment transportation services and help you with getting them
transported to the destination with ease. Therefore, you will be able to receive a perfect experience
out of getting them transported at the end of the day.

5. TRACTORS

Tractors work at much slower speeds but can be hooked up to do most any job. One can add
buckets, blades, backhoes, or quick hitches to a tractor. They also have the power to push or pull
other construction equipment.
If you have any requirements with the transportation of tractors, we will be able to support with
our professional services. In fact, we know that tractors are widely being used in getting numerous
activities done at the construction sites.
No matter what activity you have to get done with the help of tractors, you should first make sure
that they are transported to the location. We will be able to help you with that. You can contact us
and we will offer our service to you.
6. TRUCKS

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 Trucks are used to haul materials on roads because the hauling cost for trucks is low compared
to other construction equipment. Dump trucks commonly move sands, dirt, soils, and clay.
Articulated dump trucks are available to use in tougher terrain. Hauling trucks are used to move
equipment from one location to another.
Having hauling equipment at the worksite on time is important for the success of any construction
job. Your hauling equipment is necessary for a job well done and it needs to arrive not only on
time but safely.
A trustworthy transportation company can help you ship your hauling equipment so that arrives
where it needs to be and within the desired time frame.

HAULING EQUIPMENT

There is a variety of hauling equipment used for building and construction purposes. Some
of the most common types include bulldozers, cranes, excavators, forklifts, and dump trucks,
among others. Bulldozers are immensely powerful machines that are equipped with a dozer blade

Heavy equipment (also called heavy machinery) is the term used to describe the heavy-duty
machines that are used in the construction, forestry, agriculture and mining industries. These
machines are commonly used to move earth and other large materials, but they are also frequently
used to drill, lift, grade, suction, pave and compact.

The History of Heavy Equipment

A continuous track from 1909.

Because heavy machinery is frequently powered by gasoline, one would assume that construction
machinery is a relatively recent invention. Heavy equipment, however, has been in existence since
at least the first century. Reports show that the ancient Romans used cranes and other types pf
heavy equipment. The first pile driver was thought to have been invented in approximately 1500.
Until the 19th century, however, most heavy machinery used human or animal power. Once the
portable steam-power engine was invented, the combine harvester and tractor were reconfigured to
utilize steam power. Later, heavy equipment used kerosene and ethanolengines, before those
energy sources were eventually replaced with diesel fuel or electric power.
Have you ever wondered why a bulldozer often has tracks instead of wheels? This goes back to
World War I, when tracked tanks became a popular military vehicle.

Types of Hauling Equipment

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 There is a variety of hauling equipment used for building and construction purposes.
Some of the most common types include bulldozers, cranes, excavators, forklifts, and dump trucks,
among others. Bulldozers are immensely powerful machines that are equipped with a dozer blade.

 Auto Loading. Generally speaking we advise auto loading for larger incineration
operations over and above 200kg/hr. ...
 Bin Tippers, Elevators and Container Handling. ...
 Ram Loaders. ...
 Crushers, Shredders and Conveyors. ...
 Liquids and Sludge Feed Systems. ...
 Auto De-Ashing. ...
 Ash Bin. ...
 Wet Bath Ash Conveyor.

Heavy Equipment and Their Uses

There are several distinct types of heavy construction equipment, each with its own set of
uses. As you evaluate the types of projects your company is taking on, you may decide it’s time to
add to your fleet. While some pieces of equipment serve one specific purpose, there are others that
overlap — for example, if you’re looking for heavy equipment that can help you move soil or lift
materials, you have a few different options.

 ASPHALT PAVERS

If you need a piece of equipment to lay asphalt on roads, bridges, parking lots or another
surface, the type of heavy construction equipment you’re looking for is an asphalt paver. This type
of equipment is often accompanied by a dump truck full of the asphalt and a roller. The dump
truck feeds the asphalt into the paver, which distributes it onto the surface. While it does provide a
small amount of compaction, it needs to be followed by a roller to ensure the asphalt is in place.

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  BACKHOE LOADERS

Backhoe loaders are versatile types of heavy construction equipment because they are a
combination of three types of machinery: a tractor, loader and backhoe. The primary function of
this tool is the backhoe, which can be used to dig hard materials, often compact earth. It can also
be used to lift heavy loads and put them in a particular place.

You can use the loader to move dirt and supplies. The fact that it’s a tractor gives you the ability to
move effortlessly over rough terrain. They can rotate 200 degrees and make an excellent fit for
light-to-medium duty jobs. Think of backhoe loaders as tractors with attachments that make them a
versatile addition to any fleet.

 COLD PLANERS

Cold planers are also known as milling machines. This type of construction equipment is
used to remove asphalt and concrete from a surface. Inside these machines, a big drum rotates and
grinds the surface accompanied by cutters that will cut the pavement. Loose pavement is
automatically pushed to the center of the rotating drum and fed onto a conveyor belt that’s attached

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to the machine. During this milling process, water is usually applied to the drum to minimize dust
and heat.

 COMPACT TRACK AND MULTI-TERRAIN LOADERS

If you need to move dirt or supplies from point A to point B on site, this piece of equipment is
a powerful addition to your fleet. These machines are built to maximize work with a minimal
footprint. Our compact track and multi-terrain loaders are equipped with a rubber track
undercarriage, which is ideal for navigating through a variety of terrains and conditions. Not all
heavy equipment types come with this level of versatility, traction and stability.

6. COMPACTORS

There are several types of compactors, but they all are used to reduce the size of a material.
The type of machine you need depends on the type of material you need to compact. If you are
working with waste, a landfill compactor is the best fit. On the other hand, you’ll want a soil
compactor if you’re working with soil. Tandem vibratory rollers are used to compact fresh asphalt,
and pneumatic rollers are used with a variety of materials.

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7. DOZERS

A dozer is recognized by a large metal blade in the front, which is used to push massive
quantities of soil or other material. If you need to move large quantities a short distance, pushing
the load with a dozer is a great way to do it. If you need to move material more than just a short
distance, the combination of a backhoe loader and an articulated dump truck will be a better fit.
There are two different types of dozers: track dozers and wheel dozers. Both provide the
same function, but the way they navigate is different. Track dozers spread the weight of this large
piece of machinery out evenly over the larger tracks you’ll find in place of the wheels, decreasing
the amount of pressure on the ground overall and making it less likely to sink into soft ground.
In place of tracks, wheel dozers have large tires and can move up to three times faster than
a track dozer. The type of dozer you need depends on the priorities for the various jobs you
complete.

7. EXCAVATORS

Think of excavators as a relative of backhoe loaders, with a few key differences — they
can rotate a full 360 degrees, are often larger than backhoe loaders and are used for medium-to-
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heavy duty jobs. There are mini excavators, which can be used for light-to-medium duty jobs.
Think of them as a compact version that can perform similar tasks to digging, lifting, landscaping
and demolishing — just on a smaller scale, within a smaller footprint.
You’ll find the same bucket attachment you can use for digging trenches and moving heavy
materials, and you can choose between track excavators and wheel excavators. On tracks, you’ll be
able to navigate a variety of terrains and conditions without worrying about leaving the deep
impressions you can get with wheels. But with wheels, you’ll be able to move a lot faster.

9. FELLER BUNCHERS

If you’re working with trees instead of soil, you may be in the market for a feller buncher. A
“feller” is another name for a lumberjack, and you could say this machine replaces the function of
several lumberjacks. It works like a weedwhacker for trees, except instead of leaving bits of trees
everywhere, it gathers or bunches the trees as it works.

10. FORWARDERS

Once your feller buncher has taken care of gathering, cutting and stacking the trees, you can
quickly load and remove the cut trees from the area with the help of a forwarder. If you also have a
loader and a back that resembles an open basket, this type of equipment can help you get a big job
done quickly.

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11. HARVESTERS

If you reviewed the description of a feller-buncher but weren’t sure it did everything you
need it to, chances are a harvester will be a good fit for you. In addition to bunching and cutting
trees, a harvester strips the limbs from the tree, combining the jobs of a feller-buncher, delimber
and slasher. Think of this as taking your logging to the next level.

12. KNUCKLEBOOM LOADERS

When the trees have been cut down, stripped and cut to their desired size, they need to be
loaded onto a truck and transported to their ultimate destination. Loading a logging truck takes a
unique piece of equipment known as a knuckleboom loader, a swing machine with a boom
specifically designed for picking up and loading logs. They move surprisingly quick for a large
piece of heavy construction equipment.

13. LOADERS

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 There are two different types of loaders: track loaders and wheel loaders. If there were such
a thing as an extra-large skid steer loader, it would be a track loader. This type of construction
equipment does everything a skid steer loader can, such as lifting, pushing and moving, but on a
larger scale and with a larger capacity. Their tracks give them the ability to distribute their weight
evenly among the surface they’re traveling on, making them less likely to sink into soft ground.
Wheel loaders can tackle the same jobs but have wheels. This makes them comparable to a
backhoe loader, just without the backhoe. The wheels give them the ability to lift, push and move
at a faster pace than a track loader, but they also make them susceptible to leaving their mark on a
job site, as the weight of the machine is not spread out over tracks, but over the four wheels.

14. MOTOR GRADERS

A motor grader has a blade, as many other pieces of construction equipment do, but the
difference is its location between the front and rear axles. The most common function of a motor
grader is to level ground, usually in anticipation of adding more layers to prepare a new roadway.
However, that’s not the only purpose they serve. They can also be used to move a relatively small
amount of soil from one location to another, eliminate a layer of soil from a surface or to remove
snow.

15. OFF-HIGHWAY TRUCKS

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 When a truck is designed specifically for off-highway use on a construction site, mine or
quarry, it’s sure to give you more flexibility in moving large quantities. With big tires and a huge
bed for materials, this is one type of construction equipment that comes in handy for a variety of
construction projects.

16. SKID STEER LOADERS

One of the most important things to remember when it comes to skid steer loaders is that
size matters. These machines are recognized for being some of the most versatile on the market.
However, a small skid steer, which is ideal for interior demolition projects, won’t be able to tackle
the excavating projects a larger skid steer can.
In addition to size, part of what makes these machines so versatile is the diversity of
attachments available for them — everything from lifting to pushing.
17. SKIDDERS

When you’re working on construction projects that involve the clearing of wooded land,
skidders are used to pull trees that have been cut down out of the woods and into the landing area,
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where they are usually delimbed and cut to size. There are two types of skidders: cable and
grapple. Cable skidders are the classic models, which require pulling the trees with a cable. A
grapple resembles a claw, grabbing the trees and pulling them that way.

18. TELEHANDLERS

There are several types of heavy construction equipment that can help you lift materials,
and telehandlers are one of them. With a telescopic boom that enables them to reach forward and
upward, along with the different types of attachments you can get — such as pallet forks, buckets
and lifting jibs — you’ve got a machine that can help you move almost anything. In some cases,
telehandlers can even be a cost-effective alternative to cranes.

19. WHEEL TRACTOR-SCRAPERS

Another option for earthmoving is a wheel tractor-scraper. This piece of equipment is long
and has two axles with a complex assortment of features. It combines the ability to begin to grade a
surface with a scraper, but instead of solely pushing the dirt, it collects it. The scraper has a sharp
edge that digs into the ground, making it loose.
The scraper is angled and has a conveyor belt so that as the soil loosens, it moves from the
edge into the hopper, or bowl, which is kind of like an enclosed truck bed. That bowl collects the
soil until it’s full, and then can be transported to another area on site to be dumped. The hopper
moves hydraulically, making it possible to dump the soil you’ve collected.

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Hauling Tools, Lifting and its Uses
These are the most commonly used Lifting and Hauling Tools with tips on using them safely and effectively.

Rockbar (Pry Bar)

For trail work a rockbar 4-foot in length and weighing 16 to 18 pounds with a beveled end is best.
This is an essential tool for prying and levering large, heavy objects such as boulders, logs, and
beams. The secret of using a rockbar is leverage. Slip the beveled end under a heavy object, and
then apply basic physics to raise the object and ease it toward its destination. As with all hand
tools, rockbars require wise use. Work as a team, making sure everyone understands each step of a
rock move before it begins. A rockbar can also be used as a drop hammer to break rock or open a
crack.
Safety tip: Keep toes and fingers clear of places where they could be pinched.

Timber Carrier (Log Carrier)

Timber carriers are used for transporting heavy timbers and logs. They look like giant ice
tons with 5-foot-long wooden handles. These handles allow room for two people on each side of
the carrier. One carrier can be used to drag the log, and a heavy log can be carried using two or
more in order to avoid dragging the log through a fragile area. Timber carriers can be used to move
bridge stringers and are helpful in shelter construction.

Safety tip: A firm tap on the back of the hooks will set the hooks into the log before carrying in
order to avoid slippage.

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Peavey and Cant Hook (Cant Dog/Log Dog)

The peavey (named after its inventor Joseph Peavey) and cant hook (a cant is a square-edged
timber or a squared log) are used for rolling and positioning logs and timbers. This includes rolling
the log or timber to move it to another site or to rotate it in place. The main difference between
these two tools is the shape of the their ends. The Peavy has a straight spike at the end whereas
cant hook has a blunt tip. The spike allows more control over the handling of the logs, but may
cause more damage to the surface of the log. Peaveys are quicker to reposition when rolling a log
or timber some distance while trying to maintain momentum. Cant hooks provide for more precise
rotating. When arranged as opposing pairs, either tool can serve as a timber carrier if a true carrier
is not available.
Safety tip: Exercise caution not to roll timber or logs onto your or someone else’s toes.

Griphoist (Cable Winch)

Griphoist is the brand name for a compact, lightweight-rigging tool (cable winch) that can be used
to move rock or timber. The machine consists of a metal body with a cable running through it. By
cranking the lever, a set of cams clench the cable and pulls it a few inches, moving heavy objects
with ease. Its biggest advantage is that is a continuous cable puller. In other words, a cable of any
length can be used. This allows for long pulls without having to re-anchor, which is particularly
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helpful when pulling from across a stream or ravine. Nylon slings (which weight less and do less
damage than chains) should be used to anchor the winch to a tree and to harness rock or logs. The
winch cable should be kept freely suspended (rather than dragging it through dirt or rock) to avoid
fraying and deterioration of the cable. Only crews trained in the art of rigging should use the
Griphoist.
Safety tip: Always stand clear of stressed lines and out of the load’s path of movement.Come Along
(Comealong/Come-a-long/Come-along/Power Pull/Power Puller/Winch Puller/Ratchet Winch)

The come along is a simple ratchet-and-pawl cable winch used for pulling, lifting, or
stretching. The better models can move substantial loads—large rocks, logs, and stumps—without
breaking but are limited by the length of cable that can be wound around the spool (usually about
25 feet). Because of this limitation, hauling material a considerable distance requires frequent
reanchoring of the winch.

Safety tip: Stay out from under the load.

Rigging (Block and Tackle)

Rigging refers to a system of cables, pulleys, and winches used to suspend and move heavy
loads. Rigging systems are most appropriate when there is a considerable amount of work to do at
one site, such as when constructing a bridge, retaining wall, steps, or a shelter.
Safety tip: The setup and use of a rigging system requires sophisticated training or experience and
should not be attempted without this knowledge. Severe accidents can occur if this system is used
improperly.

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Wheelbarrow

A wheelbarrow can be used to haul materials and tools to a work site as well as moving
rock and dirt. Most wheelbarrows have a metal box and frame, wood or aluminum handles, and
solid rubber or pneumatic tires. Pneumatic-tired wheelbarrows are recommended because you can
adjust the tire inflation to roll easily on uneven terrain. Lift a loaded wheelbarrow with your legs,
not with your back. Another option is to use a two-wheeled cart. They have better balance and can
often carry heavier loads; however, they require wider space to maneuver.
Safety tip: Do not overload a wheelbarrow. Several light loads will be easier and safer to manage
than one large one. Stay behind handles, not between them.

Personal Protective Equipment (PPE)

What is Personal Protective Equipment?

Personal protective equipment is any equipment or clothing used

or worn to protect a worker against health and safety risks.
Hazards include physical, environmental, chemical, and bio-
hazard risks.

What Does PPE Protect You From?

PPE can protect the lungs, eyes, head, feet, skin, or body –
depending on what you wear. It protects you from work-related
dangers, including:

 Contaminated air.
 Skin infections.
 Cuts and punctures.
 Impacts.
 Chemical burns.
 Electric shocks.

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  Extreme temperatures.
 Projectiles that could harm eyes.
 Entanglement in machinery.

Where occupational hazards like these exist, the employer must

perform a risk assessment and determine how to reduce or
eliminate risks. They will first try means such as control measures
and safe working systems to eliminate or reduce the risk.

However, if these do not reduce the risk sufficiently, personal

protective equipment will be issued as a last resort to protect
workers from dangerous work activities. In some situations it will
always be necessary to wear PPE, e.g. hard hats and hi-vis on
construction sites.

Who Is Responsible for PPE?

Employers should provide suitable PPE for work. Under section 9

of the Personal Protective Equipment at Work Regulations 1992,
employees do not have to pay for necessary PPE – employers
must cover the cost. They must also train employees in how to
use it. Equipment should be readily available or there should be
clear instructions on where to find PPE.

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Employees must maintain their PPE and report faults to their
supervisor or manager immediately. Even a small crack or tear
can be enough to compromise you safety.

PPE Selection

You should choose PPE with careful consideration.

1. Pick PPE that is appropriate for the specific hazard(s) to

which users are exposed. For example, if an employee
works in wet conditions, safety boots must be waterproof.
2. If you need multiple articles of PPE, make sure they are
compatible. For example, if workers need hard hats and need
noise reduction equipment you need to make sure they can
be used together.
3. Make sure the PPE is suitable for its user. PPE must fit
workers correctly, so be sure to choose suitably-sized high
visibility jackets for smaller and bigger individuals.

There will be various other factors worth considering – depending

on your workplace, of course. If in doubt, ask your supplier for
advice on the different types of PPE available.

What is the important of Personal Protective Equipment in Masonry Construction ?

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Importance of PPE in Construction
The construction industry reports the highest number of fatal injury accidents every
year. Even after thorough risk assessments and the implementation of adequate controls into a
work environment, workers could still be subject to health and safety risks from hazards, which is
why PPE is so important.
Personal Protective Equipment (PPE) includes all equipment (even those used to protect
against adverse weather conditions) used to protect employees from health and safety risks they
might encounter at work, including injuries to the lungs, head, eyes, ears and skin.
Where required, wearing task-appropriate, well-fitted PPE can be the difference between life and
death in the event of an accident.

Types of Personal Protective Equipment

When selecting PPE, it is important to ensure that:
The products chosen are CE marked to ensure they comply with the Personal Protective
Equipment Regulations 2002.

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The equipment is tailored; the correct size, fit and weight of the PPE must be chosen for every
user, so it is safe and easy for them to make use of.
If multiple items of PPE must be worn simultaneously, all the equipment can be utilised
effectively together. For example, do not use safety glasses that disturb the seal of a respirator.
Workers are properly trained and instructed on how to use their PPE. Ensure they are aware of the
PPE’s limitations, why it is needed and when they should use it.

Head Protection

Head protection is required on almost all construction sites.

It is important for construction work to be organised to minimise
all risks to workers, however, it is likely that hazards will still
remain and everyone will be required to wear safety helmets at all
times while on site.

To comply with the Personal Protective Equipment

Regulations 1992, employers must provide all employees with, and
ensure they wear, suitable head protection.

Employees should be provided with a safety helmet or hard

hat for use at work; bump caps only protect from non-moving
hazards and are not adequate protection for construction
workers.

The only exception to the ‘hard hat rule’ is for Sikhs who
wear turbans. They are exempt from the legal responsibility of
wearing a hard hat on site, however, it is important to stress the
risks they are taking by not wearing head protection.

Acceptable head protection should:

 Be in good condition. Do not wear damaged PPE. If it’s

damaged, it must be thrown away and replaced by the
employer.
 Be a good fit for each individual and be worn properly.
 Not prevent someone from wearing hearing protection when
required.
 Only be purchased from a reputable supplier.

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Ear Protection

Ear protection is needed to protect workers from noise hazards. Both the exposure duration
and the sound level workers are submitted to can contribute to ear damage. Even if workers are
only subjected for a short duration, very high-level sounds can still pose a hazard to the ears.
Therefore, it is necessary for all workers to be provided with the correct type of hearing protection
for the type of work they are undertaking.
The options available for ear protection are earplugs, earmuffs and semi-insert/canal caps.
Ear PPE must provide a suitable level of protection for the work being undertaken and must not
compromise safety or communication. All workers must also be clear on how to wear their PPE
correctly, to ensure maximum protection.
Foot and Leg Protection

Construction workers are always be expected to wear protective footwear while on site.
The bones in the foot are easily damaged, with an injury to muscle or tendons potentially
prohibiting normal foot movement for several months. Therefore, it is highly important to take
precautions that minimise the risk of a foot injury. The ideal foot PPE encompasses steel toecaps,
to protect from dropped objects, and steel midsole protection, to protect against puncture or
penetration wounds from stepping on sharp objects.
The employer must provide a basic standard of footwear (or a suitable kit for individuals who
cannot wear basic footwear for medical reasons) free of charge, on the condition that employees
look after their equipment appropriately and make it last for a reasonable length of time.

What About Rigger Boots?

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Rigger boots have seen a surge in popularity over recent years, likely because they are a cross
between lace up boots and wellingtons and are simple to put on. But, due to their loose fit, rigger
boots leave workers more susceptible to sprained or twisted ankles as workers are unable to stop
their foot from twisting when walking on uneven ground. For this reason, some contractors refuse
to allow rigger boots on site. This is a justifiable argument against rigger boots and workers are
expected to understand the reasoning and comply with the contractor’s ruling.

However, when working with asbestos or cement, rigger boots might be the preferred type of foot
protection. This is because boots without lace holes provide a greater deal of protection in this case
as cement and asbestos are prevented from entering the PPE.

Can Workers Wear Shorts?

Whether workers are allowed to wear shorts on a construction site depends on the site’s
policy. Clothing worn on construction sites must protect against hazards. Wearing shorts could
leave the lower leg vulnerable to various injuries that could become infected, as well as weather
conditions and trade specific hazards (such as overexposure to UV light when working with arc
welders).

If the site policy states that workers must not wear shorts to work, then everyone is expected to
adhere to the ruling.

Eye and Face Protection

It is important to wear eye and face protection when at risk of

hazards involving chemical or metal splashes, dust, projectiles,
gas, vapours and radiation.

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The types of eye protection available are:

 Saftey spectacles.
 Goggles.
 Face screens.
 Faceshields.
 Visors.

When selecting eye and face protection, it is important to ensure

that it is task-suitable and that the correct fit is selected for each
worker. If not, workers will still be vulnerable to risks.

Lung Protection

Lung protection is commonly required when working on a

construction site as workers often encounter hazards such as
dust, gases and vapours. When selecting lung PPE, it is important
to ensure that the chosen piece of equipment fits the intended
user properly. If incorrectly fitting respiratory PPE is selected, an
adequate seal might not be formed, leaving workers susceptible to
workplace hazards.

Examples of lung protection include:

 Filtering facepieces.
 Respirators.
 Power-assisted respirators.
 Self-contained breathing apparatus.
 Fresh-air hose.

It is important to ensure that the right type of respirator filter is

used for the specified hazard, as each filter is only suitable for a
small range of substances. Additionally, filters only have a limited
lifespan. Therefore, if exposed to high levels of harmful fumes,
confined spaces or atmospheres with a shortage of oxygen,
workers must only use breathing apparatus, never use filtering
cartridges.

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Identifying Fake PPE
Fake PPE can kill. Safety helmets are currently the most common
version of faked PPE on the market, with some fakes being weak
enough that they can be snapped using only your bare hands. Fake
safety helmets would definitely not provide a high standard of
protection if a hazard was encountered. It is important for
everyone’s safety to know how to detect fake PPE.

Some key hints that PPE might be a fake are:

1. The PPE is not a uniform colour throughout.

2. The markings on the PPE are not clear or legible, and the
product is not durable.
3. The user information leaflet provided is a photocopy, rather
than an original.
4. The information leaflet contains spelling errors and does not
list the manufacturer’s contact details.

Helmets are not the only item of PPE that can be faked, and if
workers have any concerns about the PPE they have been
provided with, they should raise the issue with their employer. If
workers are not content with the assurances that their employer

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provides, and still believe there are issues with the legitimacy of
the PPE provided, they should contact their regional office.

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 Self – Check 1.2-1

Test Your Knowledge of the Importance of PPE

Wearing personal protective equipment (PPE) while at work is of

great importance. It ensures that, should any accidents occur, the
damage imposed on the wearer is significantly reduced or
prevented altogether. Personal protective equipment is defined as
equipment, including those that protect from adverse weather
conditions, that is intended to be worn or held by a person at work
and protects them against one or more risks to their health and
safety. Think you know all about PPE? Take our quick PPE quiz
and test your knowledge!

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 Answer Key 1.2-1

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 Information Sheet 1.2.3

Handling Materials and Storage

Brief Introduction
The purpose of this document is to provide procedures to assist the safe handling
of materials (manual handling and mechanical handling).

Scope This document describes the requirements for the following –

Responsibilities in materials handling. The requirements for specialist personnel.

Lifting equipment requirements, ranging from a fork lift truck to a heavy lift mobile crane
to a simple eyebolt. The requirements for the safety of materials in transit and in store.
This document does not override any other company regulations, international or local
regulations. Regulations relating to lifting equipment.

Definition

Banks man: The person who is responsible for giving directions to a crane operator
Anti-two-blocking device - a device that, when activated, disengages all crane functions
whose movement can cause two-blocking.
Competent person - one who is capable of identifying existing and predictable
deficiencies in mobile cranes and boom trucks.
Emergency operations - operations that include fire, power line contact, loss of stability,
or control malfunction.

Health-care professional - any licensed/registered/certified health-care provider

working within his or her license/registration/certification and providing medical

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services to employees. This includes physicians, physician assistants, nurse practitioners,
and registered nurses.

Mobile crane - a crane that is self-propelled. This includes crawler cranes, wheel-mounted
cranes, and any variations thereof. Overhead cranes, gantry cranes, side boom tractors,
trolley boom cranes, and cranes with a rated capacity of one ton or less are
specifically excluded.

Periodic inspection - detailed safety and maintenance inspection performed by a qualified

person to verify compliance with the provisions of local/country standards.
Qualified person - one who, by possession of a recognized degree, certificate, or
professional standing, or certified government body or who by extensive knowledge,
training, and experience, has successfully demonstrated the ability to solve or resolve
problems relating to mobile cranes and boom trucks.

Two-blocking - the condition in which the lower load block or hook assembly
comes in contact with the upper load block or boom point sheave assembly. (Condition
under which the load block or load suspended from the hook becomes jammed
against the crane structure preventing further winding up of the hoist drum).

SWL - Safe working load SLI – Safe load indicator, it is a system which cut-off all the
unsafe crane operations if overloaded and anti two blocking comply.

Safe access route to the place for the crane set up shall be checked with SS or SFE. Ensure
that ground can carry the load of the crane. If soil is soaked with water the loading
capability is significantly reduced. Check for underground cables and pipes as well as
vicinity to any above ground obstructions like fire hydrants, firewater valves and pits.
Ensure that trailer bringing the load also has a safe access, not blocked by the intended set
up of the crane.

Load: Weight of load can be from equipment data sheet, marking on packing, marking on
pipe spool, calculation (add 15% allowance for inaccuracies) or weighing. Guessing the
weight of the load is not allowed. Crane user shall maintain record of how the weight was
derived until the lift is successfully completed.

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Length x Width x Height (LxWxH): Is required for bigger equipment for deciding lifting
radius and lifting height. For bigger surface, say above 25 m2, also wind loads need to be
considered. For small pipe spools, valves etc. this data is not required.

Lift Radius: Maximum horizontal distance between the point at which the centre of crane
rotation meets the ground and the vertical centreline passing through the load lifting
attachment.

Lift Height: The height above the setting of the crane that the load must be lifted to. To
derive at the boom height the length of hook, slings and load must be added as well as
some free space above any equipment the load will be slew over.

Eccentric Load: Load centre of gravity does not correspond to the geometrical centre, e.g.
an unevenly loaded container. In case of eccentric load for heavy loads, say above 2 T,
centre of gravity should be calculated and lifting points defined accordingly. For light loads
the most practical is to determine the centre of gravity by trial and error without lifting the
load completely off the ground.

Ground for crane set up safe: Can the ground support the point load from outriggers or
crawlers? Ground loading capability must be established. Underground cables and pipes
exposed to the load of the crane shall be identified and if required protected by spreading
the load by e.g. applying spreaders under the outriggers. Experiences at site and elsewhere
have shown that paved areas are not necessarily having the loading capability as per
design.

Safe workload at lift radius will be derived from the selected Crane Load Chart for the
calculated lift radius and boom length. Adjustment shall be done in relation to valid load
test and only 90% of the load test value shall be considered as safe workload. Weight.

Weight of hook block, slings and attachments shall be derived from crane load chart and
tables for slings.

Total weight is the sum of the weight of the load and weight of hook block, slings and
attachment.
Capacity loading will be calculated by dividing the total weight with the safe workload at
lift radius. It shall not exceed 85%. For capacity loading above 85% a lifting plan is
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required. No capacity loading above 100% shall be allowed, equal to 90% of load test. If
Safe Load.

Indicator is not installed the capacity loading shall not exceed 60%; if above a lifting plan
is required. For lifting personnel the capacity loading must be below 50%.

Attachment description: List type of slings; belts, wire ropes, chains, shackles etc. to be
used to attach the load, if required make a simple sketch under lift description.

Standard lift: If load to be lifted weighs less than 15 ton, it is a standard lift. The crane
user is required to complete “Mobile Crane Planning & Risk Assessment Checklist”.

Standard lift in non-hazardous area: If the lift is carried out without any risk to damage
lines or equipment containing hydrogen, hydrocarbon, H2S, corrosive or toxic chemicals,
steam, instrument air and nitrogen it is in a non-hazardous area. If it is carried out in a
hazardous area a risk assessment for the risks related to possible damage of these system
must be done together with SS or SFE before the lift will be permitted. The lower section
of the “Mobile Crane Planning & Risk Assessment Checklist” shall be used; “Risk
Assessment for Crane Operation in Running Plants” Dunnage: Packing material usually
made of wood.

RESPONSIBILITIES

Station Head The station head is responsible for ensuring that:

A competent authorised person is appointed to control the inventory of lifting
equipment and arrangements Its periodic examination in accordance with relevant
standards and procedures. All supervisors involved in materials handling understand the
requirements of this standard. A system of review and control is established to ensure that
the implementation of this standard is assessed on a regular basis as appropriate to the
requirements of the operation.

Competent Authorised Person (CAP)

The Competent Authorised Person (CAP) is competent by virtue of training, experience

and qualification and is appointed to examine lifting equipment on behalf of the Station
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Head. He is not only competent to inspect for damage, deterioration or other defects, but is
also capable of assessing and advising what effect such defects will have on the strength
and function of the lifting equipment. CAP qualifications must be assessed and verified.

The CAP must supervise the examination and maintenance of all loose lifting equipment
within his area of responsibility every six months and must ensure timely inspection and
test of other items of lifting equipment requiring inspection and testing by third party.

The CAP must maintain a register and keep a copy of certificates for each piece of lifting
equipment under his control.

This information must include:  Date received  Serial number  Description  Safe
working load

 Date last inspected / certified  Colour code  Date destroyed This record is to include
permanently attached slings on equipment under his responsibility, and will be available
for inspection by Safety Advisors.

Supervisors
Supervisors are responsible for ensuring that persons under their supervision who
are involved in, or are within the area, where materials handling operations are being
conducted:
Are trained in the techniques required for the safe execution of their work. Only use
equipment which has been inspected and certified in accordance with requirements. Do
not try to manually handle an article which is beyond their physical capability to manage.
Are aware of the hazards associated with, and on the perimeter of, their work area.
Understand and comply with the requirements of this standard.

PERSONNEL
All company staff and contractors receive basic instruction in manual lifting and
handling techniques during their induction. This basic instruction must be emphasised at
safety meetings with supplementary material such as training packs, posters and booklets.
The correct technique for manual lifting is shown in section 16.
Specialists

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 Materials handling involves a number of specialist activities which are carried out
by people either as their full-time occupation or as an additional part of their job. These
activity related tasks include:
 Riggers and Slingers  Banks men  Pedestal crane operators  Mobile and Crawler
crane operators  Fork lift truck operators  Self-load (truck mounted loading arm) truck
drivers
All personnel shall be selected, trained, appointed and managed in compliance with local
legislation.

INSPECTION AND CERTIFICATION

All materials handling equipment (e.g. fork lift trucks, cranes and lifting
accessories) used must be inspected, tested and certified in accordance with the Tata Power
Cos checklist for the above Equipments.

HAND TRUCKS
Hand trucks are for moving loads over short distances (typically less than 100m),
and shall be specially designed for lifting and moving packages or pallets e.g. hand pallet
trucks. In the latter case, the facility to jack up the truck shall be incorporated. Hand pallet
trucks are suitable for loads up to 1500kg.

General Requirements

Hand pallet trucks must be clearly marked with their SWL and have an in-date
certificate of inspection / test from a third party competent person as per Factories Act &
Rules. Hand trucks must not be used on sloping steel surfaces such as ramps and
particularly not on long inclines (maximum recommended gradient 1:15). If there is no
alternative, consideration should be given to using trucks fitted with brakes. Hand trucks
must not be used on uneven or soft surfaces. Such surfaces, e.g. cracked concrete, distorted
tarmac, sand and grassy areas, increase both the physical effort required and the risk of
toppling. Special care must be taken when using hand trucks in split level areas, e.g.
loading bays, especially where no guard rails are fitted. Hand trucks must have all their
wheels in contact with the working surface at all times during their use. Users of hand
trucks must report any mechanical defects to the appropriate supervisor.

FORTLIFT TRUCKS

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 Fork lift trucks used in plant premise shall include industrial and rough terrain types.

Operations
Only fork lift truck operators who have been properly trained and certified (valid
license from RTO) shall operate a fork lift truck.
Before using a fork lift truck, operators must check the truck and associated
equipment to ensure they are in safe and proper condition. Operators must ensure audible
and visual warning equipment is working correctly by carrying before using the fork lift.

Parking
When unattended, fork lift trucks must be left with the fork arms tilted forward and
lowered to rest on the ground. The engine must be switched off, the key removed and the
handbrake applied.

Ignition keys must be kept in a safe place and only issued to authorised operators for the
duration of the duty period or task. When not in use, fork lift trucks must be parked in
secure areas.

Operating Areas :
Care must be taken at all times during fork lift truck operations to avoid
pedestrians, other vehicles and hazards within their area of operations. Fork lift truck
operators must only drive in areas where they are authorised to do so. Fork lift trucks must
only be used in areas where there is enough room for safe operation. Particular care must
be taken to ensure that fork lift trucks used in aisles have enough room to circulate and
manoeuvre either loaded or empty.

Sharp bends and overhead obstructions must be avoided as far as possible. Special
care must be taken to avoid hazards such as loading bays, excavations, columns, pipe work,
racks and other plant. Industrial fork lift trucks must only be driven on suitable surfaces;
road humps and rough or soft surfaces are to be avoided. Fork lift trucks must not be
operated on excessive gradients. (In general, fork lift trucks should be driven forwards up a
slope, backwards down a slope and in line with the incline. It shall be necessary to raise the
forks slightly at the bottom of a slope to avoid grounding.) Fork lift trucks must not be
operated across gradients.

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 Stability of Fork Lift Trucks
Loads and Handling
Fork lift trucks must only be used to lift loads within their certified capacity. Loads
must be correctly placed and secured on the forks to avoid tipping forwards or sideways.
Wherever possible, fork lift trucks must be driven with the forks in the lowered position
and with the mast slightly tilted back. The forks should be so adjusted that the fork heels
should never touch the ground. Movement with loads in excessively raised positions must
be avoided to minimise the danger of toppling, especially on uneven surfaces and while
cornering. Fork lift trucks must only be used for loads which can be carried safely on the
forks or attachments fitted. Non-standard, un-packaged and excessively wide loads must be
avoided wherever possible. In particular, long tubes must be carried using appropriate
attachments.

Attachments
Fork lift trucks must only be used with attachments which have been specifically
designed, constructed and certified for it and the intended load, and attachments must only
be used as prescribed. Attachments must be produced by a recognised specialist
manufacturer and must be certified in accordance with IS standards. Care must be taken to
ensure that where attachments are used, any consequential de-rating of lifting capacity is
not exceeded.
General Operations
Operators must not carry passengers anywhere on the fork lift truck. Operators
must not allow pedestrians to walk underneath the load. A load must not be picked up if
someone is standing close to it. Fork lift trucks must only be driven in a direction where
visibility is not blocked. Stacking and un-stacking on inclines must never be attempted.
Rapid acceleration, hard braking and sharp cornering which increase the risk of load
tipping must be avoided. Operators must exercise caution and drive slowly on slopes,
uneven and damaged surfaces. Particular care must be taken when operating in proximity
to pedestrians and other vehicles. Operators must obey site traffic regulations or, in their
absence, must keep to the left.
Operators must be aware of hazards in and at the perimeter of their areas of operation.

Rough Terrain

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 The operation of rough terrain fork lift trucks involves special hazards which require
additional care and consideration: Care must be taken at all times to ensure that traction is
retained. Loss of traction due to the nature of the terrain or weight transfer taking load off
the driving wheels is to be avoided. Care must be taken and speeds minimised to reduce
the risk of load toppling caused by the imbalance induced when operating on rough terrain.
Operators must ensure that the parking brake is capable of holding the fork lift truck
stationary on an incline. (Some rough terrain vehicles are capable of climbing inclines
steeper than those on which the parking brake will hold the vehicle.) Checks for overhead
obstructions must be made before lifting and transporting loads. Special care must be
taken near power lines and other materials handling vehicles such as mobile cranes.
Driving rough terrain fork lift trucks on public roads must be kept to a minimum. When
public road travel is necessary, fork arms must be removed, folded or protected in some
way so that they do not present a hazard to other road users. Where this is not possible,
forks must be painted or otherwise made highly visible. Rough terrain fork lift truck
operators must wear seatbelts while operating their vehicles.

CRANES

Cranes used in the plant include wheeled and tracked mobile units with fixed or
telescopic booms, self loading truck, loading arm type units fitted to trucks and diesel
hydraulic excavators when they are fitted with lifting attachments.
Please refer Mobile Crane Safety Procedure No. P-008 available in Sangam / click
attached PDF file.

SIGNALS

Prior to any lifting operation being made a banksman is to be appointed and identified to
the crane operator. This applies without exception in cases where: The load exceeds 50%
of the rated capacity of the crane in the configuration used for the lift. The lifting is of
heavy or large loads. Any portion of the load or load lift route is obscured from the crane
operator’s direct line of sight. Lifting operations are to or from a boat or offshore platform.

In cases where the lift is small, routine, less than 50% of the rated capacity of the lifting
appliance, within visual contact of the crane operator at all times and has the authority of
the work site supervisor, this requirement may be waived. Banksmen are to wear a
luminous orange or green waistcoat, must always be in a position to have a good view of
the whole operation, and are to establish clear visual or radio.

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communication with the crane operator prior to the commencement of any lift. If two banks
men are required, the crane operator must be aware of the division of responsibilities
between the two. Only one banksman must give signals to the crane operator at a time.
The banksman is the only person permitted to pass instructions to the crane operator, and
the crane operator is not permitted to follow instructions from persons other than the
banksman. The banksman must direct lifting operations and signal to the crane operator
using standard hand signals

A crane must not be operated unless: The banksman has a clear view of the load, lifting
assembly and crane operator to give signals. The banksman has checked that Riggers and
all other personnel are clear of the vicinity of the load. The crane operator has a clear view
of the banksman to receive signals. Banksmen, Riggers and other personnel involved in
crane operations must wear safety helmets and other relevant personal protective
equipment. The crane operator is exempt from this requirement while he is in the crane
cab, operating the crane. Crane activities must cease in the event of any emergency or
potentially dangerous situation and the crane operator must immediately obey all
emergency stop signals.

GENERAL PRECAUTIONS

1. Cranes must not be left unattended whilst suspending a load. When not in use and
left unattended, crane cabs and control compartments must be kept closed with controls or
power-packs locked off and the vehicle parked without obstructing normal access. 2.
Cranes must not be used for any purpose other than for lifting in a vertical plane. 3. Crane
booms must not be used to apply sideways force to an object, for example during
demolition, tree felling or pushing materials and boxes. 4. Cranes must not be used as
winches to drag materials or equipment. 5. Cranes must not be used if they are not fully
rigged or are in a defective condition, e.g. if outriggers do not fully extend, there are
hydraulic fluid leaks or controls and safety equipment are defective. 6. Lifting operations
must be conducted cautiously without hoisting, lowering or slewing at excessive speed. 7.
Load swinging and snatch loading must be avoided. 8. On completion of crane operations,
the crane boom and hook must be properly secured before the crane operator leaves the
crane. The crane boom must be left on any fitted rest, with the hoist rope slackened, or
pointing downwind with the boom angle lower than 45 . 9. Any defect or damage to the
crane or its structure affecting the safety of the crane or personnel must be reported to the
Asset Holder. The crane must be taken out of service immediately the defect or damage is
detected and not used until it has been rectified, and re-certified if necessary, or clearance
to use the crane has been given in writing by the CAP.
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LIFTING ACCESSORIES
Any piece of equipment used to attach a free or contained load to a crane hook, or
hoist a load by hand, or put load restraining ropes under tension is classed as a lifting
accessory Lifting accessories are listed and defined. For many of these items (e.g. swivels,
elevators, trolleys, runway beams, etc), there are no specific definitions for their use and
operation.

All lifting accessories must be: Stored in a suitable, secure location under cover and
dedicated to the purpose. The location must be under the direct control of the CAP. Colour
coded in accordance with the HSE Standard and Colour Codes. Lifting accessories which
are incorrectly colour coded must be stored in a separate clearly marked area. Checked
before they are used to confirm their correct rating for the work to be done. Visually
examined for defects and damage prior to use. Equipment in unacceptable condition must
be tagged and set aside for repair or disposal in the same place as incorrectly colour coded
accessories. Used only within their certified safe working load ratings. Loaded
progressively without shock loading. Removed from service for inspection, testing and re-
certification if it is suspected they have been subjected to loads in excess of their rated
capacities, including the effect of shock loading by snatch lifting.

Chains
The chains used in chain slings, chain block hoists and to secure loads must not be:
Hammered to reshape distorted links. Joined together using bolts and nuts. Shortened by
twisting or knotting. Subjected to load if the chain is kinked or twisted and the links
cannot move freely.

Fibre Slings

Also known as webbing and flat belt slings, fibre slings are made of synthetic
material and may have a round or flat cross section. Their use must be restricted to lifting
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items such as coated pipe and turbine rotors which could be damaged by lifting with
conventional chain or wire rope slings. Fibre slings must be protected from sharp edges, by
sacking or similar padding, and from chemical damage.

Lifts using fibre slings must always be vertical to avoid: Overloading the edge of a
flat sling. The risk of tearing the sling. The risk of cutting a sling by lateral movement of
the sling over sharp edges.

Wire Rope and Wire Rope Slings

Wire ropes must be not be used when: More than five of the wires can be seen to be
broken in any five diameter length, or three or more closely-grouped wires are broken.

Permanent distortion such as bulging, crush damage, stranding and core protrusion
is visible. During materials handling operations involving wire rope slinging, ensure that:
 The correct sling or combination of slings for the load to be lifted is selected.  Slings
are not dragged along the ground or deck.  Slings are kept well away from operations
involving welding and flame cutting.  Riggers and slingers wear protective leather gloves
and that hands are clear of slings before lifting commences. Wire rope should be passed
from hand to hand and not allowed to slide through the hands.  Allowance is made for a
reduction in the rated capacity of multi-leg slings due to the angle between the legs of the
assembly. Always consult a Sling Chart and Safe Working Load Tables.  Slings are not
bent round sharp corners of a load.  A sling is only connected to a shackle by passing the
shackle pin through one eye of the sling. When a reeving sling is used, the bight is not
forced down onto the load. The included angle formed by the sling must not exceed 120 .
Tag lines are attached to long, heavy and awkward loads. All personnel stand clear before
the operation commences. Spinning loads without tag lines or which cannot be stopped
from spinning with tag lines must be carefully lowered to the ground or deck to kill the
spin. Loads are supported so that slings can be removed from underneath without
damaging them.

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 Sling Angles

For min/max of sling angles, refer to IS Standard Specification Wire Rope

Slings and Sling Legs for Gener Do’s and Don’ts al Lifting Purposes WLL f or synthetic

Do’s and Don’ts

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 Wire Rope Clips

Wire rope slings and semi-permanent terminations of wire ropes are frequently
made using wire rope clips. These provide a quick and easy way to terminate wire ropes and when
properly applied including the insertion of a thimble in the eye of the sling, and the application of
sufficient torque to the securing nuts, provide up to 80% of the strength of the original rope.
U-Bolt clips must have the U-Bolt section on the short end of the rope, and the saddle on
the longer end of the rope. The incorrect installation of one clip can reduce efficiency of the
connection by 60%.
When making up a sling or termination, always ensure that:
Never use fewer than the number of clips recommended in Table 4 New clips are used;
used clips do not have the full holding ability A thimble is inserted in the eye of the sling; this
prevents the rope from wearing and deforming The clips are fitted in accordance with the
manufacturer’s instructions All threads and nut bearing surfaces are greased, unless
manufacturer’s instructions state otherwise Full recommended torque settings are achieved, e.g.
49Nm for 16mm diameter rope A record is kept of measured torque values when terminations are
first made and during each subsequent periodic check Periodic checks of torque settings are
carried out as specified below: - as soon as the service load is hung on the rope - after 24 hours in
service - after 7 days in service - after 1 month in service - at 6 monthly intervals from the date of
installation Correct use of Wire rope slings

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 Shackles

Ensure that: Shackles are matched to the grade of sling in use. The correct shackle pin is
used. Never replace a pin with a bolt and nut. Threaded shackle pins are secured in place with
seizing wire prior to use. Pre-slung loads, e.g. containers and bottle racks, with slings permanently
attached are only fitted with “nut and cotter pin” shackles. The use of screwed pin shackles on pre
slung loads is forbidden.

Plate Clamps
Wherever possible, plates must be lifted using shackles inserted in holes near the edge of
the plate. If there are no holes in the plate, a plate clamp must be used and only one plate at a time
must be lifted. Packing must not be inserted between the jaws of the clamp and the plate.

Eyebolts

Eyebolts must be screwed down to the shoulder or until the threaded section reaches the
end. Shoulder type eye bolts are preferred. Care must be taken to avoid mismatching of dissimilar
threads. Ensure that eyebolts and lifting lugs supplied by equipment manufacturers are for the
whole of the load and not just for a particular part of the assembly, e.g. the top cover of a
horizontally split compressor. Eyebolts must only be used in combination with hooks when a
shackle which comfortably accommodates the hook is fitted between the hook and the eyebolt.

Slings must never be passed through eye bolts; use shackles with the eye of the sling
attached to the shackle.

Hooks
Care must be taken during materials handling operations to ensure that: The safety latches
on crane and sling hooks are in good working order and that the latches close properly. Hooks are
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only used in conjunction with other lifting accessories such as rings and slings which fit properly
and are secure on the hook. Personnel are kept clear of the swing path of a hook. Personnel do not
place themselves underneath a hooked load.

Chain Blocks
For operations involving the use of chain blocks or chain hoists, users must ensure that;
The correct rating of chain hoist is used for the load to be lifted. Only one man operates the hoist
and he is able to operate it with ease (otherwise a larger capacity hoist should be used). Loads do
not remain suspended for any length of time without securing the pull chain to prevent the load
dropping. The load chain is not run out to the point where the load is entirely dependent on the
bolt holding the dead end of the chain. The load chain is not used to encircle the load (a sling must
be used). A load is not lifted or tilted with the tip of the chain block hook.

Load Binders

These devices, also known as chain tensioners, are used to tighten the chains used to
secure loads on trucks, trailers, etc. There are two types of load binder, one operating on the
eccentric lever principle and called a lever-type, the other operating on the principle of a
bottle screw and called a ratchet-type.

When using load binders, operators must ensure the following:

Use a binder only while standing on the ground; do not stand on the load being secured.
Position a lever-type binder so that the handle is being pulled down to tension the chain. Do not
extend lever-type binder handles; if additional leverage is required, use a ratchet type binder. After
tensioning the chain, check that the lever handle is touching the chain and secured in that position
either with the free end of the chain or with soft wire. Take great care when releasing a lever-type
binder after a journey; there may be stored energy in the chain which could cause the binder handle
to whip. When releasing a lever-type binder by hand, use an open hand palm upwards under the
handle; never grip the handle and always stand clear of the path of the moving handle. Levers
which cannot be releas LOAD SECURITIES

Inadequately secured loads present a hazard because they shall shift or fall and cause injury
or damage. Whatever the mode of transportation, e.g. truck, van, helicopter or ship, personnel who
load materials must ensure that loads are properly secured. The persons in charge of the mode of
transportation, e.g driver, pilot or Master, must satisfy themselves that the load is secure before
leaving.

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 During the loading of materials and goods onto any mode of transportation, the following
must apply:

Where items have to be stacked; the heaviest ones must be placed at the bottom. Ensure a
friction contact between the load and its platform; avoid metal-to-metal contact, slippery surfaces
and loose dunnage or packing material. Pack loads tightly before the load securing equipment is
applied so that they do not vibrate free during transit. Keep the load centre of gravity as low as
possible and near the centreline. Distribute loads evenly over the load platform. Protect items that
could be damaged by rain with covers. Load securing devices, e.g. load binders, must be used as
designed and be in good condition. Loads must be secured such that the failure of one leg of the
securing system must not result in failure of the others. Ensure that load securing material such as
rope, chains and webbing straps do not pass over sharp edges which could cut or weaken them.
Rope used for securing loads must be steel wire greater than 8mm diameter, polypropylene,
polyester, sisal or manila. Nylon rope must not be used. ed by hand are to be prised open by using
a steel bar under the handle, with the operator standing clear to avoid injury from whip action.

Pipes of the same OD must be loaded together as much as possible. If pipes of different
diameters are loaded together, dunnage must be used to separate the different sizes.

MATERIAL STACKING AND UNSTACKING

Stacking Stacking materials maximises space utilisation and facilitates materials control.
When planning materials stacking, the following points must be considered:

The permissible floor loading and the design load-handling capability of storage racks and
bins. The site layout with adequate walkways and aisles. Materials routing in and out. Method of
stacking to be used. Available or required materials handling facilities and equipment. Area
lighting with avoidance of shadow areas. Pallet design and load bearing capacity.

Factors governing the size of stacks are volume and area available, and size, bulk, weight,
type, rigidity and fragility of materials to be stacked. Note that loaded pallets must not normally be
stacked more than three high.

Stability of stacks must be determined by:

A safe ratio of height to base area. Sound interlocking of the materials, either naturally or
artificially. How much of the aggregate weight is borne by the components in the lowest tier of the
rack. Good placement of every component in a stack, with no overhangs. Heavy items of
equipment stored in custom-built crates or containers must not be stacked on top of the other (only
the bases of these containers are designed to bear the load of the contents). Stacks must be
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positioned at least 0.5m from walls or bulkheads and must not allow footing for persons to gain
access to unguarded machinery. Racks must be inspected periodically by the CAP to determine its
condition and confirm its continuing capability to support the loads for which it was constructed.

Stacking Stacking materials maximises space utilisation and facilitates materials control.
When planning materials stacking, the following points must be considered:

The permissible floor loading and the design load-handling capability of storage racks and
bins. The site layout with adequate walkways and aisles. Materials routing in and out. Method of
stacking to be used. Available or required materials handling facilities and equipment. Area
lighting with avoidance of shadow areas. Pallet design and load bearing capacity.

Factors governing the size of stacks are volume and area available, and size, bulk, weight,
type, rigidity and fragility of materials to be stacked. Note that loaded pallets must not normally be
stacked more than three high.

Stability of stacks must be determined by:

A safe ratio of height to base area. Sound interlocking of the materials, either naturally or
artificially. How much of the aggregate weight is borne by the components in the lowest tier of the
rack. Good placement of every component in a stack, with no overhangs. Heavy items of
equipment stored in custom-built crates or containers must not be stacked on top of the other (only
the bases of these containers are designed to bear the load of the contents). Stacks must be
positioned at least 0.5m from walls or bulkheads and must not allow footing for persons to gain
access to unguarded machinery. Racks must be inspected periodically by the CAP to determine its
condition and confirm its continuing capability to support the loads for which it was constructed.

PALLETS
Only purpose-built pallets in good condition and without loose or broken boards and blocks
must be used for transporting loads. Damaged pallets must be taken out of service and returned for
repair or disposal. Loads must be secured on pallets with tension strapping, plastic shrink-wrap,
cargo netting or, alternatively, using a box pallet. Pallets must be secured on the load platform.
Webbing straps and binders, ropes or chains shall be used providing the pallets and their loads are
strong enough. The use of cargo netting is adequate for light loads. If chains are used, their tension
must be such that the load on the pallet is not distorted and the load fastenings slackened. If pallets
are to be loaded into a constrained area, e.g. in a container or on a truck with side boards, then
netting, ropes or chains shall not be required if movement can be prevented by using chocks.
Where pallets are stacked, each layer must be separately restrained from movement in any
direction. Lashings must not be attached to, or pass under, the strapping used to secure the load on

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the pallet and each pallet in the top layer of a stack must be cross-lashed. Empty pallets must also
be secured during transportation.

TENSION STRAPPING

Frequent use is made of tensioned steel wire, steel banding and plastic strapping to secure
individual packages and boxes or to secure loads on pallets. The strapping is normally applied with
a hand operated tool and removed with side-cutters. During application and removal of tension
strapping, personnel must:
Ensure that strapping tools are in good condition and properly maintained. Use strapping
tools in accordance with manufacturers’ instructions. Wear hand protection and avoid trapping
fingers under the strapping. Beware of strapping “whiplash” when its tension is released for
removal. Coil up removed strapping and place it in a suitable waste bin or skip.

CONTAINERS
The containers referred to here meet the ISO 1496 specifications for freight containers of
the totally enclosed general purpose type for transportation by road, rail or sea. Before loading a
freight container with cargo, an internal and external inspection must be carried out to ensure that:
The container has a valid CSC plate showing tare weight, SWL payload, maximum gross weight
and ID number. The lifting bridle is within the specified inspection period and colour coded to this
effect. There is no obvious damage such as distortion of floor/sides/roof, bent lifting eyes or
cracked welds. Any floor planking is in good condition with no broken or missing planks and no
protruding nails. The doors operate properly, can be easily opened/closed and secured, and sealing
strips are intact. The interior is clean, dry and free from vermin. Any labels or markings relating
to previous cargoes are removed or painted over. Containers must be loaded in accordance with a
load plan drawn up to ensure that:  Cargo to be loaded does not exceed the SWL of the container.

Cargo can be stowed securely with loose items bagged or crated to prevent transit damage.
 Problems are not created for those who will unload the container at its destination.  Heavy
items are stowed as low in the container as possible.  Lightweight items are packed on top of
heavy ones.  The centre of gravity of the loaded container is below the midpoint of its height. 
The centre of gravity of the loaded container is near the midpoint of its length and width.  The
load is evenly distributed over the floor area.  No more than 60% of the weight of cargo is at one
end, in less than half the length of the container.

If a container is not fully packed across its width, cargo must be secured to lashing points inside
the container to prevent load shift during transit. Liquid in barrels, e.g. lubrication oil must be
transported with screwed caps for filling/emptying of contents uppermost. Where there is the
possibility of leakage of liquid cargo, precautions must be taken to minimise the possibility and
provide a means to absorb any leakage. Truck mounted containers must be secured using twist-
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locks. When a container is received at its destination, it must be checked for any warning signs,
e.g. Dangerous Goods, Radioactive Materials, etc., before the doors are opened. Container doors
must always be opened carefully in case cargo has shifted during transit and is liable to fall out of
the open doors.

Back injuries are one of the most common types of industrial accident and although they may
occur at a specific time, they are usually the result of many years of incorrect manual lifting. Back
injuries can be prevented by proper lifting and the correct manual lifting technique is described
below.

Keep the chin in and do not let the head drop forwards or backwards. Take up a crouching or
squatting position by bending the knees while keeping the back straight; this does not necessarily
mean vertical. The important thing is not to bend the back. Take a firm grip of the object to be
lifted, using the palm of the hands and the roots of the fingers. Wherever possible, grip diagonally
opposite corners of the load, one of them underneath. Keep the arms as close to the body as
possible allowing the body, rather than the shoulders, arms or wrists, to take the weight.
Straighten the legs and use the thigh muscles to achieve the lift. When lifting from the ground, take
up the squatting position and allow the legs to do all the work. Lift in stages, i.e. from floor to knee
and from knee to carrying position. When lifting and in the carrying position, the leading foot must
be pointing in the direction of travel. Avoid standing with a heavy load; if you must stop, set it
down by reversing the lifting procedure described in the previous step. Do not carry a load which
obstructs your view and always ensure that your line of travel is clear of obstructions.

Never attempt to change your grip while actually carrying a load. If a change is necessary, set the
load down on a firm support, change your grip and lift the load up again. If the object to be
handled is too heavy or awkward, get help. The lifting method for two or more people is the same
as for one person. If mechanical lifting devices are available, use them.

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 SELF CHECK 1.2.3

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 ANSWER TASK SHEET 1.2.3

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 Date Developed: Document No.
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