Safe Work Procedure No: 003

Belt Conveyor Safety

May 2002

Contents
Introduction ..

I- Hazards .
a) Entrapment in the in-running nip points between rollers and belt ....
b) Crushing beneath gravity tensioning weights .....

3
3
5

II- Key Points ...

III- Prevention of accidents .......

a) Tail Pulley Systems .....
b) Head Pulley stems ...
c) Conveyor Bends ...
d) Gravity Tensioning Units ....
e) Less Severe Nip Points ..
f) Emergency Stop Systems ...
g) Unexpected Start up

8
8
11
14
16
17
19
21

IV- Guard Construction ..

22

V- Reach Distance Criteria

23

Extracts from BS 5304:1988 and BS 7300:1990 are reproduced with the permission of BSI.
Complete copies of the standard can be obtained by post from BSI Sales, Linford Wood,
Milton Keynes. MK14 6LE. Tel: +44 (0) 908 221166. Website: www.bsi-global.com.
Extracts from the BACMI Code of Practice for the Safeguarding of Machinery used in Coated
Stone, Aggregates, Ready Mixed Concrete and Slag Plants are reproduced with the
permission of the Quarry Products Association, 156 Buckingham Palace Road, London,
SW1W 9TR. Tel: +44 (0) 20 7730 8194. Website: www.qpa.org
It should be noted that a number of the images used have been adapted from the original

Belt Conveyor Safety May 2002

2

Introduction
Belt conveyors are used extensively to transport materials and they are capable of
killing people and causing very serious injuries. Injuries are often caused because
guard systems are inadequate or because guard systems have been removed for
cleaning or maintenance. In many cases, poor conveyor design prevents adequate
guard systems from being fitted or requires that the guard system must be removed for
cleaning or maintenance.
This document outlines the principal hazards together with the minimum precautions
that should be taken to prevent injury.

I- Hazards
a) Entrapment in the in-running nip points between rollers and belt

Head Pulley Systems

Note the in-running nip points on the belt upper surface at the first troughing roller and
at the point where the belt wraps onto the pulley.
Similarly, there is a hazardous in-running nip point at the snub roller on the return run
of the belt on the underside of the conveyor.
In general terms, the hazard is increased where a belt makes a significant change of
direction over a pulley and the greater the proportion of pulley circumference wrapped
by the belt, the greater the hazard.

Belt Conveyor Safety May 2002

3

Tail Pulley Systems

Here, the danger points are principally on the underside run of the belt, frequently
made more hazardous by spillage collecting in and around the nip points, resulting
in the need for the area to be cleaned. Cleaning is frequently done without isolation
because materials can be more easily removed by using the conveyor as a
transport medium.
Troughing rollers, particularly on larger and longer belts (with a greater loading)
can generate significant hazards. Again, the first troughing roller frequently
generates the most significant hazard because it initiates a change of direction and
thus applies tension and an increased entrapment risk.
Where troughing rollers are used to support a belt beneath a bin or hopper in the
form of a series of rollers, each roller represents a very significant hazard because
of the combined load applied from the hopper or bin and its contents

Belt Conveyor Safety May 2002

4

b) Crushing beneath gravity tensioning weights

Gravity Tensioning Unit

Here, again, in-running nip points are a very significant hazard because they are
commonly accessible from the conveyor walkway, or in the case of the lower
tensioning roller, from the ground.
Added to this is the crushing hazard from the tensioning weight that will result if the
belt should break

Emergency Stop Requirements

Unexpected start-up
From the conveyor system starting up without warning
From the conveyor being started up whilst it, or areas around it are being
worked on

Belt Conveyor Safety May 2002

5

II- Key Points

The head, tail and tensioning elements of conveyor systems must be guarded at all
times unless isolated and locked out for cleaning or maintenance

Conveyor drive components must be guarded in a full enclosure guard

Gravity tensioning units (GTUs) must be enclosed in a 2.5m high guard with no
gate access

Guard systems must take into account the reach distance criteria

Guard construction must be robust, ensuring that the guard will not be damaged by
normal use

Personnel who will use a guard system should be consulted on the form that the
guard should take

Each conveyor power supply and any related pneumatic or hydraulic systems must
be fitted with an isolation system capable of being locked out (Visible Cut-off
Switch)

On conveyors longer than 200m, isolation and lockout systems shall be installed at
each end of the conveyor

Local procedures dealing with the isolation and lockout of conveyor systems and
related equipment must be written and rigidly adhered to

Personnel must be fully trained in the isolation and lockout procedures and related
cleaning and maintenance procedures before being permitted to carry out the
activity alone

Each conveyor system must have an audible start-up warning system supported by
a visual system where necessary

Each conveyor system must be fitted with a hard wired emergency pullcord stop
system configured with dual circuit redundancy so that the system will fail to
minimum danger (fail safe mode). Each switch must have a manual reset facility

Each emergency pullcord must be no greater than 50m in length

Where more than one pullcord is used in a conveyor length, they should be
configured to ensure that the pullcord is accessible for the entire conveyor,
overlapping pullcords where necessary

Emergency pullcord systems must preferably have a taut/slack operation switch at

each end. A switch at one end and a spring at the other is an acceptable
compromise

Belt Conveyor Safety May 2002

6

Emergency pullcord systems must cover the full length of each conveyor where a
walkway is present. Where there is a walkway on each side of a conveyor, an
emergency pullcord must be fitted on each side

The pullcord in an emergency pullcord should be mounted 10cm to 20cm above

the level of the conveyor belt, configured to ensure that small spillage from the belt
will not trip the system

Emergency stop systems must never be used to isolate a conveyor system whilst it
is being worked on

Belt Conveyor Safety May 2002

7

III- Prevention of Accidents

Accidents caused by conveyors are best avoided by preventing access to the
hazardous parts of the conveyor system. Suggestions on some ways to achieve this
are outlined below:
a) Tail Pulley Systems

Infill Guard: This type of guard can be used where there is no hazard from belt
fastener entanglement. It can also be used to guard head pulley systems. The guard
has the advantage that it does not obstruct access to the belt itself, often making
cleaning activities easier without compromising safety.
Key Criteria:
The guard must fit closely to the pulley and to each belt run. (Maximum gap
should be less than 6mm)
The length of the guard should be no less than 600mm from the in-running nip
point
The width of the guard should be no greater or less than the pulley width
The upper guard surface should be shaped to maintain the belt troughing profile
onto the pulley
If required, the guard can be linked to the pulley shaft on each side, so that the
guard maintains its position in relation to the pulley when the belt is adjusted.
(See diagram below)
The rear face (Elevation X in the diagram above) should provide a complete seal
across the rear of the guard system no access into the pulley space must be
possible
Guard removal only after power isolation and lockout, with non-reverse ratchet
engaged where necessary.
Belt Conveyor Safety May 2002
8

a) Tail Pulley Systems

An example of how an infill guard can be tied to the pulley shaft, ensuring that when
the belt is tracked or adjusted, the guard maintains its relationship with both belt and
pulley without further need for adjustment

Belt Conveyor Safety May 2002

9

a) Tail Pulley Systems

Enclosure Guard: Here, a dragout conveyor system is shown beneath a feed bin
having idler rollers supporting the top run of the belt beneath the bin and its licker
strip system. In this case, a single guard has been used to enclose the tail pulley
hazard and the idler rollers
Key Criteria:
The guard must enclose the tail pulley and all idler rollers, ensuring that access
cannot be gained from above or from the front
The guard must be high enough to prevent access into the idler rollers from the
top or a guard cover must be fitted over the top, fitting closely to the bin sides
The guard must extend beneath the conveyor to prevent access into the
dangerous in-running nip point. Mesh size for the underside section should be
large enough to ensure that the mesh does not blind as a result of spillage whilst
preventing access. The guard must extend for at least 1m beyond the pulley
centre
Provide the means to clean the area beneath the tail pulley and belt without
removing the guard to do so (ie: leave space for cleaning).
Provide the means to adjust and track the belt without removing the guard
(Ensure tracking stud adjusters are outside guard)
Provide the means to lubricate the pulley bearings without removing the guard
(Extend lubricators to outside of guard)
Guard removal only after power isolation and lockout, with non-reverse ratchet
engaged where necessary.
Note: In this diagram, the dragout conveyor head pulley guard cannot be seen. It is important that
the head pulley is also fully protected against access. (See head pulley guard section)

Belt Conveyor Safety May 2002

10

b) Head Pulley Systems

Box Guard: A simple box guard around the head pulley. Note that the first
troughing roller does not change the belt direction and does not therefore represent
a significant risk. Note also the drive system guard.
Key Criteria:
Fixed securely in place using bolts or other fixings requiring a tool to remove the
fixing
Preferably a full enclosure guard (as shown)
The outfeed from the conveyor must obviously remain open but should limit
access to hazardous parts by extending the guard downward to increase access
distance. (But see Head Pulley and Snub roller guard)
Ensure that the reach distance criteria (see guard construction section), are met,
to prevent access to hazardous parts
Provide the means to lubricate the pulley bearings without removing the guard
(Extend lubricators to outside of guard)
Guard removal only after power isolation and lockout, with non-reverse ratchet
engaged where necessary.
Drive Guard:
Full local enclosure guard to front, sides and rear of drive system
Fixed securely in place using bolts or other fixings requiring a tool to remove the
fixing
Facility built in for belt tension adjustment without compromising guard integrity

Belt Conveyor Safety May 2002

11

b) Head Pulley Systems

Enclosure Guard: This type of guard is often used for horizontal conveyor systems
mounted close to the ground. If gaps are not left around the base of the guard,
cleaning cannot be done without removing the guard system
Key Criteria:
Fixed securely in place using bolts or other fixings requiring a tool to remove the
fixing
Preferably a full enclosure guard (as shown)
If the conveyor is feeding a bin or a second conveyor, the outfeed from the
conveyor must remain open to maintain feed but should limit access to hazardous
parts by extending the guard downward to increase access distance. (But see
Head Pulley and Snub roller guard)
Distance from in-running nip point to rear edge of guard must be no less than 1
metre, ensuring that the reach distance criteria (see guard construction section),
are met, to prevent access to hazardous parts.
Provide the means to lubricate the pulley bearings without removing the guard
(Extend lubricators to outside of guard)
Guard removal only after power isolation and lockout, with non-reverse ratchet
engaged where necessary.

Belt Conveyor Safety May 2002

12

b) Head Pulley Systems

Enclosure and Chute Guard: Here the head pulley guard has been incorporated with
a feed chute that also encloses the snub roller.
Key Criteria:
Fixed securely in place using bolts or other fixings requiring a tool to remove the
fixing
Preferably a full enclosure guard (as shown)
Distance from snub roller in-running nip point to rear edge of guard must be no less
than 1 metre (recognising reach distance criteria)
Provide the means to lubricate the pulley bearings without removing the guard
(Extend lubricators to outside of guard)
Guard removal only after power isolation and lockout, with non-reverse ratchet
engaged where necessary.

Belt Conveyor Safety May 2002

13

c) Conveyor Bends

Where a conveyor bends progressively (as in diagram 1 above), each pulley that the
belt passes over will have a hazardous in-running nip. Where the bend is safe by
position (ie 5m from the ground, with no walkway provision), guards are not strictly
necessary (although they are recommended). Where a walkway or other access is
adjacent, guards are certainly needed and should be configured as shown in 1 above.
Detail guard elements can be seen in Diagram 2 below.
This gap to be determined
by the material being
handled

32mm clearance for

spillage removal
2

Belt Conveyor Safety May 2002

14

c) Conveyor Bends
Key Criteria:
At the conveyor entry point into the guard, a 1m enclosure of the first in-running
roller nip must be provided
At the conveyor exit point from the guard, a 300mm enclosure of the last in-running
roller nip must be provided
A gap of 32mm may be left along the base of the guard to permit spillage removal
The height of the guard above the belt edge must be determined by the nature of the
materials being transported on the belt but should be kept as low as possible
If a belt cover is used to help prevent wind-whip, it may be appropriate to
incorporate the guards into the cover
Fixed securely in place using bolts or other fixings requiring a tool to remove the
fixing
Provide the means to lubricate the pulley bearings without removing the guard
(Extend lubricators to outside of guard)
Guard removal only after power isolation and lockout, with non-reverse ratchet
engaged where necessary.

Belt Conveyor Safety May 2002

15

d) Gravity Tensioning Units

Here a Gravity Tensioning Unit (GTU) is shown with guards to prevent access to inrunning nip points from the conveyor walkway and the ground, together with other
necessary safety systems to prevent crushing injuries.
Key Criteria:
Access into all in-running nip points must be prevented, using guards if the
hazards are accessible from the conveyor walkway
The GTU weight must be prevented from swinging by installing a vertical guide
system
Stops must be installed to prevent the GTU weight from hitting the ground. The
stops should be set at a minimum height from the ground of 200mm
Scotching systems or locking pins must be provided to prevent the weight from
falling should someone be required to work beneath the GTU
The lower guard must be 2.5m high from the ground and may be combined with
the upper guard system if appropriate
A gap of 150mm should be kept on each guard face between the ground and the
guard underside to facilitate cleaning with a scraper
Guards must be securely fixed with fasteners requiring a tool to remove them
Gates must not be used. If there is no alternative, any gates installed must be
interlocked to the conveyor Emergency Stop system
Reach distance criteria must be met for each guarded hazard

Belt Conveyor Safety May 2002

16

e) Less Severe Nip Points

This type of guard is not suitable for use on head or tail pulleys but can be used to
good effect on idler rollers and often where rollers or pulleys are used to change belt
direction.
Here, a length of metal the same width
as the pulley and at least 75mm long is
shaped to fit closely to the pulley.
The guard can be tack welded to the
conveyor structure at either side
Gaps must be less than 6mm
If the conveyor is a transmission
conveyor, the belt wear strip can be
extended fully into the head pulley
nip to fulfil the same function
Here, the guard is fabricated from mild
steel sheet so that the sides and rear of
the guard shield access into the hazard.
The guard can be tack welded to the
conveyor structure on either side
The top surface of the guard must be
at least 75mm long
Gaps must be less than 6mm
Here, the guard is fabricated from a
length of angle iron with a length of mild
steel sheet pre-shaped to fit the roller
profile then welded into the angle iron
Tack weld guard to conveyor
structure
Gaps must be less than 6mm
Angle pitch to suit roller diameter

Belt Conveyor Safety May 2002

17

e) Less Severe Nip Points

Direction of
belt

Max 6
mm

This is a more conventional guard type

involving enclosure of the roller within a mesh
basket. It can be used on a reversing belt
conveyor
Mesh pitch must be small enough to
prevent access into nip (or distance from
hazard set accordingly) but large enough
to prevent blinding
Belt to guard gap must be less than 6mm
Fix (with bolts) to conveyor structure at
each side

Belt Conveyor Safety May 2002

18

f) Emergency Stop Systems

These two diagrams (above) show two typical configurations of emergency pullcord
for a conveyor system. The upper diagram is the preferred configuration, having a
taut/slack wire switch at both ends of the pullcord. An emergency pullcord system
must never be configured with a switch at one end of the pullcord with the other end
fixed to a stanchion or wall since pulling against the fixed end will not operate the
stop system..
Key Criteria:
Each conveyor system must have an emergency pullcord system fitted to it
wherever access is possible to the conveyor
Emergency pullcord systems must not be used instead of guarding systems, they
should be fitted as complementary systems
The pullcord system must be configured as part of the Emergency Stop (E-Stop)
system
The E-Stop system must be hard wired and should not operate under software or
PLC control
The E-Stop system must operate through dual circuit redundancy relay systems
having a cross monitoring system to indicate failure of either of the channels. This
will ensure failure to minimum danger (Fail-Safe mode)

Belt Conveyor Safety May 2002

19

f) Emergency Stop Systems

The E-Stop system should always be a separate stop system to that used for a
Production Stop (P-Stop) system
Note:

P-Stop systems normally bring the plant to a phased controlled stop

whereas E-Stop systems must initiate an immediate crash stop.

The pullcord switches must be capable of operating on both a taut and a slack
wire initiation
The maximum length of pullcord between switches (or between switch and spring)
must not exceed 50m. Where there is friction in the system or where smaller
switches are used, it may be necessary to use shorter pullcord lengths
The pullcord must stop the conveyor when pulled from any direction
The pullcord system must cover the whole length of the conveyor, including head
and tail pulleys, using additional pullcord switches if necessary, to ensure that
friction is not excessive
Where more than one pullcord/switch system is used on a conveyor, the switches
and fixing must ensure that there are no gaps in the pullcord system. If necessary,
overlaps should be deliberately created to ensure the pullcord is accessible for the
full conveyor length
Where possible, the pullcord must be 100mm to 200mm above the level of the
conveyor belt (to ensure that a person dragged by the conveyor will automatically
operate the E-Stop). (Note: the pullcord must be positioned to ensure that minor spillage
from the conveyor will not operate the E-Stop normally 100mm to 200mm above the
conveyor will ensure that this is the case)
The E-Stop or P-Stop systems must never be used to isolate and maintain
isolation whilst a conveyor is being cleaned or maintained. Visible cut-off switches
shall normally be used (See Unexpected Start-up section).
Resetting an E-Stop or P-Stop system must not permit a plant restart. The
conveyor restart must be initiated from the main control centre following a manual
reset at the switch which has tripped out
Specific local procedures must be developed and used for:
o Isolation, Lockout and maintenance of conveyors
o The removal of spillage and the cleaning of conveyors
o Routine testing of pullcords and other E-Stop systems (weekly minimum)
Personnel likely to work near to or with conveyors must be fully trained to
recognise the hazards and in the use of the necessary precautions and
procedures before they are permitted to start work

Belt Conveyor Safety May 2002

20

g) Unexpected Start-up
Even when guards are in position, a conveyor can be hazardous if it should
start unexpectedly or without warning whilst personnel are working on or near
to it, perhaps working in a bin being fed by the conveyor. Simple precautions
can be taken which will completely prevent such accidents.
When guards have been removed, the risks from unexpected start-up are
magnified and it becomes doubly important that the precautions outlined are
followed.
Key Criteria:
Each conveyor motor drive system must have an isolator capable of being
locked off with control over restart being given to each person working on
the conveyor individually, such that the conveyor cannot be restarted until all
locking systems have been removed from the isolator.
The isolator and lockout facility must be close to each conveyors motor
(Visible Cut-off Switch)
The electrical power supply isolation method must be through all three
phases of electrical power only. Control power isolation is not acceptable
Where it is necessary, hydraulic and pneumatic power must also be capable
of isolation and lockout using similar methods to those outlined above
Where more than one conveyor system are linked, it may be necessary to
arrange gang isolation and lockout
The release or reset of E-Stop, P-Stop or pullcord systems must not cause a
conveyor to restart. In all cases, conveyor restart must be initiated from the
system control position, following a manual reset at the switch which has
tripped
Each conveyor system must be fitted with a start-up warning system which
should be audible unless plant conditions (usually noise levels) require a
visual system. The warning system should cover every part of the conveyor
system(s) and should operate for a minimum of 5 seconds before the
conveyor start process is initiated
Specific local written procedures must be written covering the removal of
guards for cleaning or maintenance from a conveyor, requiring that the
conveyor drive is isolated and locked out before work begins. Local
procedures must also be developed for specific cleaning and maintenance
activities
Personnel must be trained in the procedures and must be equipped with a
personal multi-hasp and padlock before they are permitted to remove
conveyor guard systems or to work near unguarded systems
Rules and procedures must be strictly implemented and enforced by
managers and supervisors

Belt Conveyor Safety May 2002

21

IV- Guard Construction

If conveyor guard systems are to be effective, it is crucial that they are designed to
take into account expected usage (and abuse), so that they are strongly constructed
and prevent access to the hazard, without limiting access or normal and acceptable
work practices. They should also look good as this will encourage personnel to care
for them properly.
Materials:
Most conveyor guard systems will be fabricated from steel mesh welded onto a mild
steel angle frame. Where larger guards are needed, support stanchions will also be
required.
Stanchions:
Support stanchions can be fabricated from 75mm rolled steel box section or
channel.
Where stanchions are required to rest on the ground, feet should be
fabricated from 4mm mild steel sheet which will permit the stanchion to be
bolted into the concrete or steel base.
Frames:
In most cases, 35mm x 35mm x 4mm angle iron forms the basis for a solid
frame.

25mm x 25mm x 4mm angle can be used for smaller guard systems

The frames can be welded at the corners to make panels which can be
joined together or to stanchions by welding or bolting.

Mesh:
The most suitable mesh is weldmesh, available in standard mesh sizes from
steel stockists. Expanded mesh may also be used but is less effective

When deciding which mesh to use, it is important that the Reach Distance
Criteria are taken into account to ensure that the mesh prevents access

The mesh can be supplemented by mild steel sheet to improve strength or to

limit access locally to hazardous components inside the guard

Fixings:
Standard hexagon bolt fixings with shake proof nuts are preferable.

Where possible, fixing bolts should be made captive by tack welding them to
stanchions etc so that they cannot be lost

A minimum threaded stud diameter of 10mm is suggested. If possible, they

should be of a rustproof variety

Butterfly nuts, wing nuts or other easily removed fixing must never be used

Hook attachment can be used for positioning or supporting guards but must
always be complemented by bolt fixing requiring a spanner to tighten

Belt Conveyor Safety May 2002

22

Paint:
A water based gloss paint should be used to finish guard systems
Finish coats should be applied over non-lead containing primer and
undercoat.
Guard frames should be painted Signal Red
Mesh sections should be painted matt black (improving visibility of
components inside the guard)

V- Reach Distance Criteria

A minimum standard for conveyor guard systems is to ensure that the guard
will prevent access into any in-running nip point by forcing a reach distance
of 1 metre (1m). This standard can be seen in many of the diagrams earlier in
this guidance.
When fabricating guarding systems, consideration must be given to the potential for
the hazard to be accessed by reaching into an open point of the guard. (Conveyor
local box guarding systems will always provide the opportunity for such access, unless
an infill guard is also used). The following give a crude set of criteria defining the
safety distance from the hazard. Guards should be fabricated taking these minimum
distances into account.
(Example: If it is possible for the arm to be inserted into the guarded area up to the
elbow then the safety distance (the distance from the guard extremity to the hazard)
should be set at a minimum of 510mm (20 inches)):

Body Part

Safety Distance

Hand. From root of finger to fingertip

>125mm (5 inches)

Hand. From wrist to fingertip

>250mm (10 inches)

Arm. From elbow to fingertip

>510mm (20 inches)

Arm. From arm-pit to fingertip

>1000mm (39.5 inches)

Similarly, when constructing a guard from mesh (normally, weldmesh is the most
suitable), the mesh size should be determined to ensure that access to the hazard is
not possible. Mesh sizes suggested are as follows:

(Example: If a hazard is accessible 8cm (3 inches) inside a guarding surface then the
minimum mesh size used should be 12mm or ).

Belt Conveyor Safety May 2002

23

Safety Distance from Danger point

12.5 mm (0.5 inch)

Minimum Aperture Size

5 mm (0.2 inch)

>80mm (3 inches)

12.5 mm (0.5 inch)

>120mm (5 inches)

20 mm (0.75 inch)

> 200mm (8 inches)

25 mm (1 inch)

> 850 mm (1 Yard)

150 mm (6 inches)

It is essential that great care is used when applying the above safety distance criteria.
The physical opportunity to reach the danger point must always be checked before the
guard system is approved.

Belt Conveyor Safety May 2002

24