Work Equipment and Machine Guarding

Overview
Moving machine parts have the potential to cause severe workplace injuries, such as
crushed fingers or hands, amputations, burns, or blindness. Amputations, lacerations,
and abrasions are costly and have the potential to increase workers' compensation
premiums. Amputation is one of the most severe and crippling types of injuries in the
occupational workplace, often resulting in permanent disability. Due to this fact,
Occupational Safety and Health Administration (OSHA) has established a set of
standards around machine guarding.

The OSHA regulates machinery, equipment, and mechanical power transmission

apparatus that are commonly used in machine shops, maintenance operations and repair
shops. Requirements for electrical safety, physical safety, and guards pertain to items
such as abrasive wheel machines, belt guards on vacuum pumps, woodworking and
metalworking machinery, lawnmowers, flywheels, shafts, belts, pulleys, and gears.

Purpose
The purpose of machine guarding is to protect the machine operator and other employees
in the work area from hazards created during the machine's normal operation. This would
include hazards of concern such as: ingoing nip points, rotating parts, reciprocating,
transversing, and/or flying chips & sparks.
Any machine part, function, or process that might cause injury must be safeguarded.
When the operation of a machine or accidental contact with it could injure the operator or
others in the vicinity, the hazards must be either controlled or eliminated.

Machine guards are protective devices that cover moving pieces of machinery that may
pose a danger to workers. Moving machine parts present a hazard
to machine operators and flying debris can affect anyone in the vicinity of a machine.
Why is machinery safety important?

Moving machinery can cause injuries in many ways:

 People can be struck and injured by moving parts of machinery or ejected material.
Parts of the body can also be drawn in or trapped between rollers, belts and
pulley drives.
 Sharp edges can cause cuts and severing injuries, sharp-pointed parts can cause
stabbing or puncture the skin, and rough surface parts can cause friction or
abrasion.
 People can be crushed, both between parts moving together or towards a fixed
part of the machine, wall or other object, and two parts moving past one another
can cause shearing.
 Parts of the machine, materials and emissions (such as steam or water) can be
hot or cold enough to cause burns or scalds and electricity can cause electrical
shock and burns.
 Injuries can also occur due to machinery becoming unreliable and developing
faults or when machines are used improperly through inexperience or lack of
training.

Where Mechanical Hazards Occur?

Dangerous moving parts require safeguarding because these three areas of the machine
are most likely to cause injuries:

 The point of operation

That point where work is performed on the material, such as cutting, shaping,
boring, or forming of stock.

 Power transmission apparatus

All components of the mechanical system that transmit energy to the part of the
machine performing the work. These components include flywheels, pulleys,
 belts, connecting rods, couplings, cams, spindles, chains, cranks, and gears.

 Other moving parts

All parts of the machine that move while the machine is working. These may
include reciprocating, rotating, and transverse moving parts, as well as feed
mechanisms and auxiliary parts of the machine.

Safeguarding

Safeguarding of machinery provides detailed guidance for the design, installation, use
and maintenance of machinery. The use of machinery in a workplace exposes workers
using it, and people near it, to various hazards.

The hazards that cannot be eliminated using the inherently safe design approach should
be reduced by means of the application of guards or protective devices
(safeguarding).

Types of Safeguarding
1. Guards
Guards are barriers which prevent access to danger areas.
 Fixed – provides a barrier between a person and the point of opera, power train
or other moving parts. These include fences, gates, and protective covers for
blades, presses and all moving parts.
Safeguarding Action: Provides barrier.
 Interlocked – when opened or removed disengage the machine’s power source.
It cannot be restarted until the guard is replaced.
Safeguarding Action: Shuts off or disengages power, stops the moving parts and
prevents starting of the machine when the guard is open; should require the
machine to be stopped before the worker can reach into the danger area.
 Adjustable – provide a barrier that can be adjusted to many different operations,
such as varying sizes of stock.
Safeguarding Action: Provides a barrier that may be adjusted to facilitate a
variety of production operations.
 Self-adjusting – barriers that move or self-adjust, according to the size or position
of the workplace. The guard returns to its resting position when no material is
passing through.
Safeguarding Action: Provides a barrier that moves according to the size of the
stock entering the danger area.
 2. Devices
When it is impossible to apply guards, Presence-sensing protective devices are used
to reduce risk. There are several types of these devices.
 Optoelectronic protective devices (light curtains, scanning devices like laser
scanners) and
 Pressure-sensitive devices (mats, trip bars, trip wires etc.) are often used).

Electromechanical protective devices have a probe or contact bar that descends to a

predetermined distance when the operator initiates the machine cycle. If there is an
obstruction preventing it from descending to its full, predetermined distance, the control
circuit does not start the machine.

Pullback protective devices use cables attached to the operator’s hands, wrists and/or
arms. They primarily are used on machines with striking-action hazards. When the
slide/ram is up, the operator is allowed access to the points of operation. When the
slide/ram descends, a mechanical link automatically assures that the operator’s hands
move away from the points of operation.

Restraint protective devices allow the operator’s hands to travel only in a

predetermined safe area.

3. Safety Controls
Safety trip controls, such as pressure-sensitive body bars, safety tripods and safety
tripwire cables, can quickly deactivate a machine.

Two-hand controls require both hands and constant pressure on the controls for the
machine to operate.

4. Gates
Gates are movable barriers that protect the operator at the point of operation before the
machine cycle starts.

5. Location/Distance
Though not actual guards, location and distance can keep employees safe. You can place
a machine in an infrequently traveled area or where it’s dangerous moving parts are not
accessible. A thorough hazard analysis of each machine and particular situation is
essential before using this safeguarding technique.

Protective devices that do not create actual physical barriers perform their protective
functions by means of generating a signal that stops a dangerous motion of a given
machine element after having detected that a part of the operator’s body is too close to
the danger zone.
The following are some examples of machines requiring point of operation guarding:

 Guillotine cutters
 Shears
 Alligator shears
 Power presses
 Milling machines
 Power saws
 Jointers
 Portable power tools
 Forming rolls and calendars

Requirements for Guards

Guards must meet these minimum general requirements:
 Prevent contact
The guard must prevent hands, arms, and any other part of a operator's body
from making contact with dangerous moving parts.

 Secure
Operators should not be able to easily remove or tamper with the guard. Guards
and safety devices should be made of durable material that will withstand the
conditions of normal use. They must be firmly secured to the machine.

 Protect from falling objects

The guard should ensure that no objects can fall into moving parts.

 Create no new hazards

A guard cannot create a hazard such as a shear point, a jagged edge, or an
unfinished surface that could cause a laceration.

 Create no interference
Any guard that prevents the operator from performing the job quickly and
comfortably might soon be overridden or disregarded.

 Allow safe lubrication

If possible, operators should be able to lubricate the machine without removing
the guards.

Simple Rules to Maximize Worker Safety

1. Always be sure that moving mechanisms are clear of people and objects.
2. Be sure that workers are not wearing any jewelry or loose clothing that could get
snagged in the machines.
3. Keep an eye on overheard moving parts, like pulleys, for potential hazards.
4. Check that guards are in place at all points where you could contact moving parts
before turning the machine ON.
5. Be aware of how to turn power on and off if you should have to do so quickly.
6. Read the manufacturer’s instructions on how to operate the machine safely and
correctly.
7. Feed material into the machine with push sticks, not your hands.
8. Take it easy. Rushing through a job is one of the major causes of accidents.
9. Make sure maintenance is performed when required. If you think your equipment might
have missed its scheduled maintenance let your supervisor know.
10. Use lockout/tagout procedures when a machine needs repair or maintenance. Turn
the machine and the power to the machine off and tag it so that no one tries to use it.

Safe Work Practices

Besides machine guarding, there are other safe work practices that can be followed to
help prevent injuries associated with moving machinery, i.e. amputation type injuries.

 Avoid loose clothing or jewelry and tie up loose hair to prevent it from becoming
entangled in the moving parts.
 Use push sticks and tampers for pushing stock or food into the point of
operation. NEVER reach your hand toward the point of operation.
 Allow time for machine to stop moving once turned off. Some blades will take up
to 15 seconds to spin down when powered down.
 Ensure the machine is unplugged or locked out and tagged out before removing
guards for cleaning or maintenance.
 Use the proper blades at the proper operating speeds as specified by the
manufacturer of the equipment.
 Maintain blades and bits in good condition and replace when damaged.

Personal Protective Equipment (PPE)

Overview

Personal protective equipment, commonly referred to as "PPE", is equipment worn to

minimize exposure to hazards that cause serious workplace injuries and illnesses. These
injuries and illnesses may result from contact with chemical, radiological, physical,
electrical, mechanical, or other workplace hazards. The main protective equipment
includes respirators, eye protection, hearing protection and protective clothing . Personal
protective equipment may include items such as gloves, safety glasses and shoes,
earplugs or muffs, hard hats, respirators, or coveralls, vests and full body suits.
All personal protective equipment should be safely designed and constructed and should
be maintained in a clean and reliable fashion. It should fit comfortably, encouraging
worker use. If the personal protective equipment does not fit properly, it can make the
difference between being safely covered or dangerously exposed. When engineering,
work practice, and administrative controls are not feasible or do not provide sufficient
protection, employers must provide personal protective equipment to their workers and
ensure its proper use. Employers are also required to train each worker required to use
personal protective equipment to know:

 When it is necessary?
 What kind is necessary?
 How to properly put it on, adjust, wear and take it off?
 The limitations of the equipment
 Proper care, maintenance, useful life, and disposal of the equipment

If PPE is to be used, a PPE program should be implemented. This program should

address the hazards present; the selection, maintenance, and use of PPE; the training of
employees; and monitoring of the program to ensure its ongoing effectiveness.
Head Protection

Protective hats for head protection against impact blows must be able to withstand
penetration and absorb the shock of a blow. In some cases, hats should also protect
against electric shock.

Each type and class of head protector is intended to provide protection against specific
hazardous conditions. The wearer should be able to identify the type of helmet.

For industrial purposes, three classes are recognized:

 Class A - general service, limited voltage protection;
  Class B - utility service, high-voltage protection; and
 Class C - special service, no voltage protection.
Hats and caps under Class A are intended for protection against impact hazards. They
are used in mining, construction, shipbuilding, tunneling, lumbering, and manufacturing.
Class B utility service hats and caps protect the wearer's head from impact and
penetration by falling or flying objects and from high-voltage shock and burn. They are
used extensively by electrical workers.
The safety hat or cap in Class C is designed specifically for lightweight comfort an impact
protection. This class is usually manufactured from aluminum and offers no dielectric
protection. Class C helmets are used in certain construction and manufacturing
occupations, oil fields, refineries, and chemical plants where there is no danger from
electrical hazards or corrosion. They also are used on occasions where there is a
possibility of bumping the head against a fixed object.

Eye and Face Protection

Eyes are always at risk of exposure to different hazards that may include contact with
dust, metal particles, debris, glass particles, gas, chemicals, blood borne pathogens and
thermal hazards. Suitable eye protectors must be provided where there is a potential for
injury to the eyes or face. Exposure to these hazards may lead to the development of
adverse illness that affect eyesight which can include eyeball lacerations, affectations to
the cornea such as corneal abrasions, conjunctivitis, and burns. Eye protection is vital
to provide an appropriate response and assure health and safety of emergency response
and recovery workers using safety glasses or protective goggles.

Eye related injuries at work can have different origins that may include contact with
chemical substances, penetration with external objects, among others.

Hearing Protection
Occupational hearing loss is a common work-related illness. Not just in everyday work
activities but also in emergency settings where hazardous noise levels and ototoxic
chemicals can affect emergency response and recovery workers hearing. To reduce
workplace noise such as hierarchy controls are available including elimination or
substitution, engineering and administrative control and use of personal protective
equipment such as earplugs or earmuffs.
Protective Clothing

Protective clothing is designed to protect users from unintended dermal exposures that
could lead to the development of an adverse health hazard. Depending on the hazard
different types of protective clothing must be developed to create a barrier that protects
workers from occupational hazards that could affect them through dermal contact. There
are different considerations that must be taken into account when selecting the
appropriate protective clothing including the hazard, the material, design, durability
comfort and functionality. Some examples of protective clothing include coveralls or fluid
resistant garments.

Respiratory Protection
Respirators are one of the most important pieces of personal protective equipment for
workers when other control systems are not feasible to protect the health and safety of
workers. Respirators cover as minimum the nose and mouth of users and remove
contaminants from the air by filtering airborne particles or chemical agents from air. This
type of respirator is called an air purifying respirator. Other type of respirator known as air
supplying respirator supplies clean air from another source to the user, this last type
includes self-contained breathing apparatus that include their own air supply and airline
respirators that use compressed air from a remote source.
Arm and Hand Protection

Burns, cuts, electrical shock, amputation and absorption of chemicals are examples of
hazards associated with arm and hand injuries. A wide assortment of gloves, hand pads,
sleeves, and wristlets for protection from these hazards is available.

The devices should be selected to fit the specific task. Rubber is considered one of the
best materials for insulating gloves and sleeves and must conform to ANSI standards.
Other glove and clothing materials such as latex, nitrile, butyl rubber, neoprene, etc. are
available. Each material is thoroughly tested and rated against specific chemical
compounds.

PPE for Construction

Required personnel protection equipment (PPE) must be worn at all times when on
construction or renovation sites. At a minimum, each employee is required to wear a hard
hat and safety glasses. High visibility safety vests with reflective striping are required
when employees are exposed to vehicular traffic. In the absences of vehicular traffic, high
visibility shirts should be worn at all times. All workers must wear shirts with sleeves, long
work pants, and sturdy work shoes or boots when working on a construction or renovation
site. Sleeveless or tank top shirts, short pants, sweatpants, sneakers, sandals, and high-
heeled or open-toed shoes are not permitted High visibility safety vests with reflective
striping are required when employees are exposed to vehicular traffic. In the absences of
vehicular traffic, high visibility shirts should be worn at all times. All workers must wear
shirts with sleeves, long work pants, and sturdy work shoes or boots when working on a
construction or renovation site.

Sleeveless or tank top shirts, short pants, sweatpants, sneakers, sandals, and high-
heeled or open-toed shoes are not permitted.
PPE for Manufacturing/Industrial Workers

Industrial workplaces can often be a dangerous place, and PPE is an effective and proven
way to improve the safety of a facility. Depending on your industry, it can be tempting to
skip out on some of the items usually associated with personal protective equipment
(PPE). Some workers may find it uncomfortable or inconvenient to wear certain PPE
items. It is indeed cheaper for management not to have to provide all of the possible PPE
equipment.
PPE for Electric Utility/Power Plant Workers
Depending on the job task to be performed, PPE for the electric power industry generally
includes safety glasses, face shields, hard hats, safety shoes, insulating (rubber) gloves
with leather protectors, insulating sleeves, and flame-resistant (FR) clothing. Additional
PPE, such as fall protection equipment, respirators, chemical-resistant or cut-resistant
gloves, and chaps, may be required, depending on the results of the hazard assessment
PPE for Arc Flash
Protective equipment for arc flash, as shown in Figure 3 consists of:
 Flame resistant protective clothing
 Arc Flash protection hood
 Hard hat
 Safety glasses
 Gloves