11. Lifting and handling of slabs

Permission and or authorisation

  • Operators of hoisting equipment (bridge cranes, truck cranes, pulley tackle, suction cups, etc.) must have special theoretical and practical training.
  • Warehouse operators must be properly trained and experienced. When a person is alone in the warehouse handling slabs, that person must obey respect these guidelines:
  • Operators will have an alert system (“man down system”).
  • The system will warn persons who are in the vicinity in the workplace.
  • Jumbo or granite slabs must not be moved without assistance from another person.
  • In non-habitual operations, the Work Managers must issue a technical operational instruction that takes into account the measures required to control the risk.

General provisions

  • Helmets must be worn by operators handling hoisting equipment and anyone within the radius of action of such equipment (assistance, truck driver, operator handling the telescopic fork during loading/unloading, operators inside containers, etc.).
  • Slabs must always be stored with the slope facing the inside of the rack, and with both safety bars on each side of the rack, fitted with permanent covers and as close as possible to the slab packs.
  • The ground must be firm and flat (including the warehouse and the area where the truck is parked for loading/unloading).
  • The foreman will create aisles in the slab storage area to guarantee safe passage of the staff, with a minimum width of 1m.
  • The floor signs must be respected.
  • Before carrying out any operation, the operator will evaluate the work conditions and consult their supervisors immediately if they have any doubts.
  • Always respect the maximum permitted loads and established loads (slings, clamps, suction cups, etc.).
  • Make a visual inspection to verify the correct state of the slab. Check that the load is balanced and in good condition, with no breakages, veins, faulty inclusions or other defects that could cause the material to break, and that when suspended, no internal slipping can occur. In the event of doubt, ask the foreman for assistance and handle the load with care.
  • Make a visual inspection of the state of the racks and safety bars.
  • Draw up a check-list of the proper state of the hoisting equipment and the hoisting elements (slings, sling protectors, clamps, clamps, hooks, pulleys, chains, suction cups, etc.).
  • Clear the area, and only allow authorised staff to remain there.
  • Mark off the area of passage with tape or chains, to delimit the work area and the radius of action of the forklifts and the sides of the trucks, as applicable.
  • The safety bars must be positioned before manipulating the slabs (whether in warehouses, trucks or containers) and always placed as close as possible to the slab package when removed from the rack, or to the slab package when placed on the rack.
  • The slabs can rest on the safety bars (with a maximum of 5 slabs in the “standard” size and 3 in the “jumbo” size, or granite slabs) only for the short time required for the operation and with an operator making sure that no-one is in the area where the slabs could fall.
  • Ensure that the slings or clamps (and hoisting elements in general) do not become hooked to the package of material before operating the bridge crane.
  • In operations that involve moving loads, never stand below a suspended load or within the danger zone (area where the slabs could fall/overturn). The forklift operator or driver is responsible for enforcing this regulation. The operator must also have perfect visibility at all times of the point where the slabs could fall, in the case of an accident. In trucks with canvas sheets or open top containers, to guarantee this visibility, the load will enter through the door (not the side), and the operator will ensure that no-one is in the danger zone.
  • The driver will remain in a safe place during loading / unloading, and he is advised to stay on the pavement outside the warehouse.
  • After the hoisting equipment operations have been completed, the load will be placed in an area where it is not possible for people to pass below it or it will be left on the ground.
  • In loading/unloading and slinging/unslinging operations, the operator will always stand aside, out of the danger zone, in case the load overturns or falls.
  • Racks will be loaded on both sides, to distribute the weight evenly on both sides. Never load/unload only a part of the rack. During rack loading / unloading operations, the packs will be positioned/removed simultaneously on both sides, to compensate the load and the stability.
  • The planks will not exceed the slab height.
  • To open the slabs, use an ergonomic lever, and avoid over-exerting your body. Do not leave the tool on the slabs to prevent workers from falling and/or being hit or cut. Open the slab with the lever edge facing away from and not toward the worker.
  • To move the transfer cart forward, a person must stand next to the emergency stop to make sure no-one approaches during the operation.
  • When vehicles enter or leave the warehouse, a person must act as a “guide” and coordinate the movements to prevent other persons from being hit.
  • All loading/unloading vehicles will be parked with the handbrake on and chocks placed on the wheels.
  • Hoisting hooks will not be connected to more than one accessory without using the rocker.

Additional and/or special measures in handling Dekton:

  • Warning: the material may be sharp, particularly broken pieces.
  • Carefully check the state of the slabs before handling them. If you detect a fissure, do not touch it and call the foreman. Handle them with special care when using cranes or forklifts.
  • The slabs must be handled and prepared wearing cutresistant half-sleeve gloves and protective glasses.
  • Discarded material must be handled with care.
  • Do not knock the discarded material to reduce its size, as a broken piece could generate flying particles.

Additional and/or special measures when using clamps:

  • If the material is fragile (resin-coated marble, for instance), do not use lifting clamps.
  • Use wooden (or plastic) chocks to open slabs and do not rest them the safety bars.
  • Slabs dressed on one side will be grasped with their dressed sides facing each other. Grasping operations with clamps will cover the whole surface.
  • When handling slabs with forklifts fitted with telescopic forks and crocodile clamps, the truck must only move after it received the signal from the worker hooking the slabs, who must always be facing it to control the movement and remain outside the danger area where slabs could fall and hit him.
  • Before starting the lifting operation, the user must check that the load is balanced and in good condition, with no breakages, veins, hairline cracks, faulty inclusions or other defects that could cause the material to break, and that when suspended, no internal slipping can occur.
  • The PS clamp (red) must be used to press a single piece or load (one slab).
  • The Iremar/Insemac clamp can lift two pieces only if they are joined on a fixed unit. The clamp can pick up 2 slabs with a maximum of 3 cm. (See illustration below).

Additional and/or special measures when using suction cups:

  • Use the largest possible gripping surface.
  • The valves must all be open when the cup is placed on the slab.
  • Close the valves only when necessary, in order to use the largest possible gripping surface.
  • Lift the slab only when the manometer indicates the vacuum.
  • Perform a small test, without lifting it brusquely.
  • When the cup is in place, all the valves must be open.
  • Do not leave suction cups resting on the rubbers, as they could become deformed and lose their elasticity.

Additional and/or special measures when using slings:

  • The type of load to be lifted must be known, considering the manner of use and nature of the load.
  • Do not overload the slings (See Load Table).
  • Take care to guarantee personal safety during the lifting operation. People in the danger zone must be warned that the operation is to take place, and if necessary, the zone must be evacuated immediately. (Hands and other body parts must be kept outside the sling, to prevent injury) (ISO 12480-1 standard for planning and directing lifting operations, and implementing safe work systems).
  • They must never be knotted or twisted.
  • A test lift must be performed. The load must be lifted slightly, checking that it is safe and in the appropriate position.
  • The load must be lowered in a controlled manner, in the same way as when it was lifted. Make sure that the sling is not caught when the load is lowered. The load must not be supported by the sling, as this could cause damage, and the sling must not be dragged beneath the load when the
    load is deposited on it.
  • Nylon slings may only be used with the upper and lower clamps and protectors.
  • The slings must be inspected visually at least once a year by a competent person. Records of these inspections will be kept. Damaged slings must be discarded from service, and never repaired by staff.

Loading/unloading of containers:

This operation will be carried out as described in the container loading/unloading video (available in the folder Lucas_nt/Planificación_ Preventiva accessible to the chain of command).

  • In operations involving the tensioning of both chains in open top containers, the operator will perform this operation on the ground, and if necessary, use a rope to pass the chain to the other side of the truck. He will use a ladder with a safety rail to tension the chains. It is forbidden to climb onto the slab packs.

Loading/ unloading of trucks:

  • The racks will be secured to the truck and safety bars will be used.
  • To climb into/out of the truck use the approved stepladders, which must be in good condition.
  • When loading trucks and containers, until the package is placed on the rack, operators will stand on the other side of the rack (opposite side to the one being loaded).
  • If possible, do not handle the slabs inside the truck, and in all cases, safety bars must be available. Always balance the loads when loading/unloading to prevent the truck from tilting and the slabs from overturning.
  • In loading, use planks to separate the slabs, to perform the unloading in complete safety.
  • All truck loads must be tensioned with 2 chains, even for journeys with short distances. In addition, the rack must be secured or fastened with slings to the vehicle frame. Non-slip material will be placed between the rack and the frame.

Loading/unloading of containers:

  • The racks will be secured to the truck and safety bars will be used.
  • To climb into/out of the truck use the approved stepladders, which must be in good condition.
  • When loading trucks and containers, until the package is placed on the rack, operators will stand on the other side of the rack (opposite side to the one being loaded).
  • If possible, do not handle the slabs inside the truck, and in all cases, safety bars must be available. Always balance the loads when loading/unloading to prevent the truck from tilting and the slabs from overturning.
  • In loading, use planks to separate the slabs, to perform the unloading in complete safety.
  • All truck loads must be tensioned with 2 chains, even for journeys with short distances. In addition, the rack must be secured or fastened with slings to the vehicle frame. Non-slip material will be placed between the rack and the frame.

Maintenance:

  • The maintenance programme will include the racks and hoisting equipment (bridge crane, truck crane, pulleys, suction cups, etc.) with their additional elements (slings, clamps – for slabs of paper, crocodile forks, hooks, beams, etc.) and, work areas (corridors, signs, etc.), etc. The programme will consider the following aspects, among others:
  • Daily visual inspections by users.
  • Monthly documented inspections by the maintenance managers.
  • Inspections of all the hoisting equipment and their additional elements by specialised external firms. The frequency will depend on what is set out in the legislation and the supplier’s manual and on the frequency of use and experience in maintenance.
  • State of welding on racks.
  • Painting of pedestrian and forklift passage areas.
  • Painting of storage areas.