OSHA Conveyor Standards

OSHA Conveyor Standards

1926.555(a) General requirements. 1926.555(a)(1) Means for stopping the
motor or engine shall be provided at the operator's station. Conveyor systems shall be equipped with an audible warning signal to be sounded immediately before starting up the conveyor.

1926.555(a)(1) Means for stopping the
motor or engine shall be provided at the operator's station. Conveyor systems shall be equipped with an audible warning signal to be sounded immediately before starting up the conveyor.

1926.555(a)(2) If the operator's station is at a
remote point, similar provisions for stopping the motor or engine shall be provided at the motor or engine location. 1926.555(a)(3) Emergency stop switches shall be arranged so that the conveyor cannot be started again until the actuating stop switch has been reset to running or "on" position.

1926.555(a)(4) Screw conveyors shall
be guarded to prevent employee contact with turning flights. 1926.555(a)(5) Where a conveyor passes over work areas, aisles, or thoroughfares, suitable guards shall be provided to protect employees required to work below the conveyors.

..1926.555(a)(6)
1926.555(a)(6) All crossovers, aisles, and passageways shall be conspicuously marked by suitable signs, as required by Subpart G of this part. 1926.555(a)(7) Conveyors shall be locked out or otherwise rendered inoperable, and tagged out with a "Do Not Operate" tag during repairs and when operation is hazardous to employees performing maintenance work.

1926.555(a)(8) All conveyors in use
shall meet the applicable requirements for design, construction, inspection, testing, maintenance, and operation, as prescribed in the ANSI B20.1-1957, Safety Code for Conveyors, Cableways, and Related Equipment.
Conveyor Safety Information & Resources
Is Your Conveyor Operation as Safe as it Should Be?

Conveyors are one of the best productivityenhancing tools available to warehouses, industrial facilities, and distribution centers, but conveyor injuries in the U.S. cost employers millions of dollars every year. Thats money you can save and pain you can avoid with the right processes and design. In fact, conveyors are generally safer than other material handling alternatives if they are maintained, designed and properly operated.
Is Your Conveyor Operation as Safe as it Should Be?

The U.S. Department of Labor Bureau of Labor
Statistics reports over fifty workplace fatalities a year where conveyors are the primary source of injury. Workplace injuries account for nearly 25% of all workers compensation claims and up to 35% of all associated costs. Clearly, your company cannot afford to ignore conveyor safety, and must actively find ways to enforce it.
Unsafe Conditions & Environmental Causes

Inadequate guarding, or unguarded conveyors
are a crucial safety breach that can be minimized with good training and employee awareness. We always recommend having adequate conveyor guarding in every situation. It can be expensive, too: Unguarded conveyor belts that exposed workers at a Worcester, Mass., CVS Pharmacy to possible fractures and crushing injuries resulted in $61,575 in fines from OSHA. Clearly, you want to avoid these kinds of fines and the potential injuries that can result by unsafe conditions.

Defective conveyor equipment is
unproductive and dangerous. When conveyors are not running at correct speeds, belt tensions, or in other ways, accidents can result. Your people should be trained to avoid these situations, and to report any malfunctioning conveying equipment as soon as theyre aware of it.

Conveyors that are arranged hazardously can be
a source of accidents. If your conveyor layout is made so that it flows foot traffic into areas where people can come into contact with moving conveyors, training can help them avoid injuries. Many order pickers are in contact with conveying equipment on a frequent basis. Instructing them how to safely utilize the conveyors and how to avoid contact with them is an investment that will pay off.

Another possibility is that overhead or
elevated conveyors may result in conveyed items that fall, possibly causing injuries. To avoid this, we recommend that conveyors be guarded either with railings, safety netting, or other fall protection products that prevent conveyed items from falling onto people who walk beneath.
Conveyor Safety Training is Fundamental

In the CVS case, OSHA inspectors also
discovered that employees were not instructed on how to prevent accidental conveyor startups while clearing product jams and the company lacked written instructions for doing so. Employees also faced tripping hazards from material stored directly in front of the conveyor. These conditions resulted in three alleged serious violations with $6,375 in proposed fines.

Any facility that utilizes conveyors should work
to train everyone involved in safe operations. This should include frequent updates and refresher classes. Training and process are probably the single most important aspect of conveyor safety. Everyone involved in a conveyor-using facility can be responsible for safety. Preventing unsafe acts should be part of your culture.

Operating conveyors without training or
authority should be avoided. People who dont understand how the system might react shouldnt be at the controls, even if the degree of complexity is simple on the surface. Always be sure to train everyone who works in a conveyor area about how to operate the equipment and where the controls are. Everyone should know where stop switches are, how to use them, and when to use them.

Conveyors should never be operated in an unsafe
manner. This includes people standing or riding on the conveyor, overloading it, or reaching into or under the conveyor when its in motion. At times, people will deactivate safety devices to expedite work or to quicken the pace. You should understand what devices are installed on a conveyor to make it safer, and be sure yours are always operational and in place. Your employees should report any inoperative devices or other hazards as a matter of process, as quickly as possible. Employees should never knowingly use unsafe equipment.

Unsafe loading of conveyors is another factor.
When people understand where conveyors are to be loaded, and how to interact with the equipment, the chances of injuries are reduced significantly. Loading a conveyor over guards or railing, for instance, increases the chance the employee bending incorrectly or unsafely, or that he will load near a drive or motor and have a better chance of catching clothing in the rollers.

Workstations that include lift tables or other ergonomic
devices help to ensure employees load in the right position, as the devices make loading easier and faster, as well as safer. Obviously, many of the same principles apply when loading and lifting with conveyors as when lifting and loading elsewhere. Employees who are familiar with correct lifting techniques are less likely to be injured due to conveyors, especially when moderate to heavy items are being loaded and unloaded. Unsafe position and posture are critical to conveyor safety.

In general, workers should never interact
with in-motion conveyors. Conveyor lines can be designed to move totes to a spur or workstation to be scanned, to be orderpicked, etc.
Get Employees Involved!

Establishing safety committees and inspection
committees is one way to involve your people in issues involving their own safety. It helps both you and them to understand what issues may exist in the facility, and where people could be injured. Safety committees can frequently and comprehensively advise, evaluate, and investigate your material handling processes. The key for management is to get involved and ensure the committees meet, that they stay onfocus, and that standards are set.
What are the Typical Conveyor Hazard Points?

According to FFVA Mutual Insurance Company, the top hazard points for conveyors are: Power transmissions Nip points Shear points Pinch points Spill points Areas under counterweights Transfer counterweights Transfer mechanisms Passage areas under conveyor Under special circumstances
How Do You Address these Specific Areas of Concern?

Guards - Guards constitute one of the
more common types of safety devices used for the protection of conveyors. Guards are coverings or barricades provided for safety purposes, such as gears, chains, or nip point guards.
Area of Concern: Guards

Operation and Maintenance of
Guards - It is the owners responsibility to see that his conveyor/conveyor system is never operated unless the guarding provided is in place. Also, that all guards be maintained in a safe condition and warning signs be kept in legible condition.
Area of Concern: Power Transmission

Power Transmission - The need for power
transmission equipment is common to all types of powered conveyors involving items such as drives, gears, shafts, couplings, etc. Conveyor equipment must be carefully examined by the owners to assure that guarding is provided for all exposed power transmission equipment to protect their operators and others in the work area from accidental contact. Typical items to be observed include:
Area of Concern: Drive Guards, Coupling Guards

Drive Guards for chain, v-belt, and gearing must be both practical and durable. Guards can be constructed of expanded metal, perforated or solid sheet metal, sire mesh, plastic, or other materials securely fastened to the conveyor framework. Coupling Guards must be provided around all direct connections between motors and gearboxes when couplings are used to connect shafts.
Area of Concern: Line Shaft Guards, End Shaft Guards

Line Shaft Guards Line shaft drives are still utilized on some types of conveyors to distribute power to the conveying mechanisms. Care should be taken in their location to prevent fingers, aprons, strings, or hair entering the line shaft guard. End Shaft Guards The protruding ends of rotating shafts or keyed shafts are particularly dangerous. Plastic end caps can be used to enclose ends to prevent items from becoming caught in shafts.
Area of Concern: Nip Points

Nip Points - Nip Point by definition is
that point at which an element of the conveyor machinery moving in a line or rotating meets another element which is either rotating or moving in a line in such a manner that it is possible to nip, pinch, squeeze, or entrap objects coming in contact with one of the two elements.
Area of Concern: Guards Special Circumstances

Guarding Under Special Circumstances - All
exposed, moving parts of a conveyor which present a hazard to employees at their workstation should be mechanically or electrically guarded or guarded by position or location. Ease of access or approach to conveying equipment is essential to assure proper and continuous usage. To assure an accessible and safe conveyor operation requires understanding between the design/manufacturer and safety training by the owner.
Area of Concern: Electrical Controls

Providing a safe working place involving
conveyors also requires consideration of electrical controls. Companies that use
powered conveyors should make reference to these sections of the Safety Standards regarding conveyor guarding using electrical controls and stop switches for safety.
More on Conveyor Safety

According to FFVA Mutual, the majority of conveyor
accidents are a direct result of an original design or implementation error. Conveyor safety is generally considered as a part of general safety. The practices described in this article may not give sufficient attention to the nuances required to provide a safe conveyor system. The responsibility for the planning, design and implementation of a conveyor system is often fragmented, lacking central responsibility. Attention to these details at the very beginning of the conveyor purchasing process can result in enhanced safety in your facility.
Conveyor Safety Resources

Conveyor Safety Poster This printable poster can be posted in break
rooms and conveyor area to reinforce training. Conveyor Safety Manual (PDF document): Click to read, right-click to download to your drive. Printable conveyor safety standards from Hytrol Conveyors, Inc. American Society of Safety Engineers Conveyor Safety Manual. Features case studies also illustrate that the nuances and special details required for the planning, design and implementation of a safe conveyor system are often overlooked in considering conveyor safety as part of a general safety program. Conveyor Safety Tips from The U.S. Department of Labor. Some tips on belt conveyor safety. Concepts and Techniques of Machine Guarding.
Keeping Conveyor Operators Safe with Emergency Stops

How we design conveyor systems to
protect your employees and your business Visible signs, such as this one from Emedco are an excellent safety idea

Emergency stops and other safety designs cost more,
but they make your people and your business safer. Conveyor systems that are accessible to operators must be equipped with emergency stops. (please note that we design our systems with these precautions - individual conveyors do not fall under the scope of this article). Guarded by location The only conveyors that dont require them are systems that are mounted more than eight feet above the working surface, since those are guarded by their elevationcalled guarded by location.

When any conveyor system isn't accessible to operators,
it is guarded by location. The conveyor isnt accessible to warehouse workers, and can only be accessed by maintenance personnel who can lock out or tag out the conveyor before performing maintenance. All Emergency Stop circuits should fail in the event of a power loss to the Emergency Stop Circuit. In the event that an Emergency Stop is activated, the conveyor system must be inspected for unsafe or box jam conditions by the operators. Once it is verified that the condition has been resolved the system may be restarted. Safety by design

Our controls systems are design so that in order to
restart the system, two things have to happen. First, the emergency stop pull cord or push button at the conveyor is reset, and then the start button at the panel is activated. Once the system is restarted the warning horn on the system must be sounded prior to conveyors starting again. All conveyor systems should be equipped with an audible warning horn. In order to provide a safe work environment for our customers and their employees any powered machinery provided will adheres to these minimum requirements for safety stops and operations. Safety Standards
Policies by Occupation Safety & Health Administration

The following are excerpts of Policies by
Occupations Safety and Health Administration, American Society of Mechanical Engineers and the National Fire Protection Association regarding powered transmission and conveyor. OSHA 1926.555 (a)

(1) Means for stopping the motor or engine shall be provided at the operators station. Conveyor systems shall be equipped with an audible warning signal to be sounded immediately before starting up the conveyor. (2) If the operators station is at a remote point, similar provisions for stopping the motor or engine shall be provided at the motor or engine location. (3) Emergency stop switches shall be arranged so that the conveyor cannot be started again until the actuating stop switch has been reset to running or on position.

ASME B20.1-2003 Section 5.11.2 (a) Control stations should be so arranged and located that the operation of the equipment is visible from them, and shall be clearly marked or labeled to indicate the function controlled. (b) A conveyor that would cause injury when started shall not be started until personnel in the area are alerted by a signal or by a designated person that the conveyor is about to start.

(1) When a conveyor that would cause injury when started is automatically controlled or must be controlled from a remote location, an audible device shall be provided that can be clearly heard at all points along the conveyor where personnel may be present. The warning device shall be actuated by the controller device starting the conveyor and shall continue for a required period of time before the conveyor starts. A flashing light or similar visual warning may be used in conjunction with or in place of the audible device if more effective in particular circumstances.

(c) Remotely and automatically controlled conveyors, and conveyors where operator stations are not manned or are beyond voice and visual contact from drive areas, loading areas, transfer points, and other potentially hazardous locations on the conveyor path not guarded by location, position, or guards shall be furnished with emergency stop buttons, pull cords, limit switches, or similar emergency stop devices.

(1) All such emergency stop devices shall be easily identifiable in the immediate vicinity of such locations unless guarded by location, position, or guards. Where the design, function, and operation of such conveyor clearly is not hazardous to personnel, an emergency stop device is not required. (2) The emergency stop device shall act directly on the control of the conveyor concerned and shall not depend on the stopping of any other equipment. The emergency stop devices shall be installed so that they cannot be overridden from other locations.

(d) Inactive and unused actuators,
controllers, and wiring should be removed from control stations and panel boards, together with obsolete diagrams, indicators, control labels, and other material that might serve to confuse the operator.

ASME B20.1-2003
Section 5.11.3 Safety Devices All safety devices, including wiring of electrical safety devices, shall be arranged to operate such that a power failure or failure of the device itself will no result in a hazardous condition. ASME B20.1-2003

Section 5.11.4 Conveyor controls shall be so arranged
that, in case of emergency stop, manual reset or start at the location where the emergency stop was initiated shall be required for the conveyors and associated equipment to resume operation.

Before restarting a conveyor that has been stopped
because of an emergency, an inspection of the conveyor shall be made and the cause of the stoppage determined. The starting device shall be locked or tagged out before any attempt is made to remove the cause of the stoppage, unless operation is necessary to determine the cause or to safely remove the stoppage. Refer to ANSI Z244.1-1982, American National Standard for Personnel Protection Lockout/Tagout of energy Sources Minimum Safety Requirements. ASME B20.1-2003 Section 5.12

(b) Where safety is dependent upon
stopping devices or starting devices or both, they shall be kept free of obstructions that could endanger personnel.

NFPA 79 Section 9.2.5.4.1.1 In addition to the requirements for stop, the emergency
top shall have the following requirements: (1) It shall override all other functions and operations in all modes. (2) Power to the machine actuators, which causes a hazardous condition(s), shall be removed as quickly as possible without creating other hazards (e.g. by the provision of mechanical means of stopping requiring no external power, by reverse current braking for a Category 1 stop). (3) Reset of an emergency stop circuit shall not initiate a restart.

OSHA Conveyor Standards

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