Machine Guarding

Group V

2006 TEEX

What hazards exist?

Crushed by or drawn into equipment
Struck by moving parts
Struck by failed components or particles

2006 TEEX

Fatalities
Many fatalities have resulted from
employees getting caught in
rotating shafts such as well boring
drills & lathes.

2006 TEEX

 This man lost his

finger when a
machine in a
foundry cut it off.
There was no guard
in place, as required
by law, to keep his
finger out of a point
of contact.
4

2006 TEEX

Key parts of machines

1. Point of operation: where work is
performed on the material, such as cutting,
shaping, boring, or forming of stock.
2. Power Transmission Device: transmits
energy to the part of the machine performing
the work

Includes flywheels, pulleys, belts, connecting

rods, couplings, cams, spindles, chains, cranks,
and gears.
2006 TEEX

Key parts of machines

3. Operation Controls: Control
mechanisms
4. Other moving parts: can include
reciprocating, rotating, and transverse
moving parts, feed mechanisms, and
auxiliary parts of the machine

2006 TEEX

Hazards to be Guarded
Things to guard include

In-running nip points

Rotating equipment
Flying chips or sparks
Belts or gears
Parts that impact or shear

2006 TEEX

Requirements for Safeguards

Prevent contact - prevent workers body or clothing
from contacting hazardous moving parts
Secure - firmly secured to machine and not easily
removed
Protect from falling objects - ensure that no objects
can fall into moving parts
Create no new hazards - must not have shear points,
jagged edges or unfinished surfaces
Create no interference - must not prevent worker from
performing the job quickly and comfortably
Allow safe lubrication - if possible, be able to lubricate
the machine without removing the safeguards
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2006 TEEX

Rotating Parts
Can grip hair or clothing
Can force the body into a dangerous
position
Projecting pieces increase risk

2006 TEEX

In-Running Nip Points

Between 2 rotating parts
Between rotating and tangential parts
Between rotating and fixed parts which
shear, crush, or abrade

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2006 TEEX

Reciprocating Parts
Risk of being struck between stationary
and moving part

11

2006 TEEX

Transverse motion
Continuous straight line motion
Worker struck or caught in pinch or
shear point

12

2006 TEEX

Cutting action
Direct injury from cutting action
Flying chips or sparks
Saws, drills, lathes, mills

13

2006 TEEX

Punching action
Ram stamps materials
Danger at point of operation

14

2006 TEEX

Shearing action
Powered blade that shears materials
Hazard at point of operation

15

2006 TEEX

Bending action
Power applied to a slide to stamp/shape
materials
Hazard at point of operation

16

2006 TEEX

Guarding Principles
Prevent contact between hazardous moving
parts and body or clothing
Secure guard: not easily removed
Protect from objects falling into machinery
No new hazards: sharp/rough edges
No interference with job/comfort/speed
Allow safe lubrication: without removing
guards if possible
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2006 TEEX

Guarding Methods
Location / distance
Guards

18

Fixed
Interlocked
Adjustable
Self-adjusting

2006 TEEX

Guarding Methods
Devices
Presence sensing
Pullback
Restraint
Safety controls (tripwire cable, two-hand
control, etc.)
Gates

19

2006 TEEX

Guarding Methods
Feeding & ejection methods
Automatic and/or semi-automatic feed and
ejection

Robots
Miscellaneous aids
Awareness barriers
Protective shields
Hand-feeding tools
20

2006 TEEX

Fixed Guard
Barrier is a
permanent part of
machine
Preferable over other
types

21

2006 TEEX

Interlocked Guard
Stops motion when guard is opened or
removed
Interlocked
guard on
revolving drum

22

2006 TEEX

Adjustable Guard
Barrier may
be adjusted
for variable
operations
What are the
drawbacks?

23

Bandsaw blade
adjustable guard

2006 TEEX

Self-Adjusting Guard
Adjusts according to size/position of
material
Circular table saw
self-adjusting guard

24

2006 TEEX

Pullback Device
Cables attached to
operators hands or
wrists
Removes hands
from point of
operation during
danger period
What are the
drawbacks?
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2006 TEEX

Restraint Device
Cables attached to
fixed point and
wrists or hands
Adjustable to let
hands travel in
predetermined area
May be
accompanied by
hand-feeding tools
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2006 TEEX

Safety Tripwire Cable

Device located
around the
perimeter of or
near the danger
area
Operator must be
able to reach the
cable to stop the
machine
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2006 TEEX

Two-Hand Control
Requires constant
pressure on both
pads to activate
the machine
Hands on controls
at safe distance
while machine is
in dangerous
cycle
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2006 TEEX

Gate
Must close fully to protect user before
cycle will start

Gate Open
29

Gate Closed
2006 TEEX

Safeguarding by
Location/Distance
Location of hazardous parts that is
inaccessible or not a hazard during
normal operation
Must maintain safe distance
Training, warning, communication
necessary

30

2006 TEEX

Protective Shields
Protection from flying particles or
splashing fluids
Do not protect
completely from
machine hazards

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2006 TEEX

Machinery and Machine Guarding

Guards
Guards shall be designed, constructed and used that they will:
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.

33

provide positive protection;

prevent all access to the danger zone during operations;
not interfere unnecessarily or inconvenience operation or production;
operate automatically or with minimum effort;
be suitable for the job and the machine;
not obstruct or interfere with machine oiling, inspection, adjustment
and repair;
withstand long use with minimum maintenance;
resist normal wear and stock;
be durable, fire and erosion resistant;
not constitute a hazard by themselves; and
give protection against operational contingencies and not merely
against normally expected hazards.

2006 TEEX

 Standard guards or enclosures shall be made of

materials suitable for the purpose for which they are
designed and constructed.
All machinery guards shall be securely fastened to the
machine or to the floor, wall or ceiling and shall be kept
in place whenever the machine is in operation.

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2006 TEEX

Framework
The following are minimum standards for the construction of machinery
guards:

Small Guards
Minimum dimensions of materials of the framework of
metal guards 75 cm (30 in.) or less in height and
width, a surface area not exceeding 1 sq. meter (11
sq. ft.) shall be 1 cm. (3/8 in.) for solid rod, 20 mm x
10 mm x 3 mm (3/4" by 3/8" by 1/8") for angle iron.

35

Other construction may be substituted for guards of

the same areas if such
will provide equal strength.

2006 TEEX

Braced Guards
minimum dimensions of materials of the framework of guards
more than 75 cm. (30 in.) in height and with a surface area
exceeding 1 sq. meter (11 sq. ft.) shall be 25 mm. x 25 mm. x 3
mm. (1 x 1 x 1/8") for angle iron or 20 mm. (3/4 in.) diameter
for metal pipe.
such guards should be rigidly braced every 90 cm. (3 ft.) or
fractional part of their height to some fixed part of machinery or
other structure.

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2006 TEEX

Braced Guards
minimum dimensions of materials of the framework of guards
more than 75 cm. (30 in.) in height and with a surface area
exceeding 1 sq. meter (11 sq. ft.) shall be 25 mm. x 25 mm. x 3
mm. (1 x 1 x 1/8") for angle iron or 20 mm. (3/4 in.) diameter
for metal pipe.
such guards should be rigidly braced every 90 cm. (3 ft.) or
fractional part of their height to some fixed part of machinery or
other structure.

37

2006 TEEX

 Joints
All framework joints shall be of equivalent
strength to the materials of the frame.

38

2006 TEEX

 Horizontal Overhead Belt Guards:

a.
b.
c.
d.
e.

39

25 x 25 x 5 mm. (1 by 1 by 3/16 in.) for belts up to 25 cm.

(10 in.) in width;
38 x 38 x 6 mm. (1 1/2 by 1 1/2 by 1/4 in) for belts over
25 up to 35 cm (10 to 14 in.) in width;
50 x 50 x 8 mm. (2 by 2 by 5 /16 in.) for belts over 35 up
to 60 cm. (14 to 24 in.) in width; and
80 x 80 x 10 mm. (3 by 3 by 3/8 in.) for belts over 60 cm.
(24 in.) in width;
Horizontal overhead belt more than 2100 mm. above a
floor, platform or other working level shall be guarded for
their entire length if located over passageways of
working places.
2006 TEEX

 Guards support, if of flat iron, should be of the following

dimensions:
a. 38 x 6 mm. (1 1/2 by 1/4 in.) for belts up to 25 cm. (10 in.)
in width;
b. 50 x 8 mm. (2 by 5/16 in.) for belts over 25 up to 35 cm.
(10 to 14 in.) in width;
c. 50 x 10 mm. (2 by 3/8 in.) for belts over 35 up to 60 cm.
(14 to 24 in.) in width., and
d. 65 x 10 mm. (2 1/2 by 3/8 in.) for belts over 60 cm. (24
in.) in width.

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2006 TEEX

 All guards should be provided with an adequate number

of supports and attachments to ensure sufficient rigidity
and resistance.

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2006 TEEX

General Requirements

Machine guarding
1. One or more types of guarding to
protect from hazards.

Barrier guards
Two-hand tripping devices
Electronic safety devices
Etc.

2. Affixed to machine where possible

43

Guard must not cause its own hazard

2006 TEEX

Machine guarding
3.

Point of operation guarding:

ii.

Guarded if exposes employee to injury

iii.
iv.

44

According to standards or
Keep any part of body out of danger zone

Hand tools to permit material handling

in addition to guards, not instead
Examples of machines requiring guards
on point of operation
2006 TEEX

Machine guarding
4. Revolving barrels, drums, containers
guarded by interlocked enclosure
(cannot turn without guard in place)
5. Exposure to fan blades: guard
openings 1/2 inch

45

2006 TEEX

Anchoring fixed machinery

Machines designed for fixed location
must be anchored to prevent moving
This pedestal grinder is
designed for anchoring,
but is not anchored

46

2006 TEEX

Abrasive Wheel Machinery

General requirements
Abrasive wheels
must be guarded,
with exceptions
Guard design
dependent on type
of work and type of
wheel

48

2006 TEEX

General requirements
Work rests:
Rigid, clamped in place securely
Adjusted to within 1/8 inch of wheel
Never adjusted while in motion
Work rest is closely
adjusted

49

2006 TEEX

Exposure adjustment
For type where operator
stands in front of
opening: Adjustable for
decreasing wheel size
Adjustable tongue
guard must never be
more than inch from
wheel

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2006 TEEX

Mounting
Inspect for damage and ring test
immediately before mounting
Tap with light nonmetallic implement
(screwdriver, wooden mallet)
If sound is dead, cracked ring may not be
used

Check spindle speed against maximum

for wheel
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2006 TEEX

Ring Test

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2006 TEEX

Machine Guarding

Hazards on Oil and Gas Sites

Parts Requiring Guarding

Drive belts and shafts mud pumps
and tank area
Pony rods
Rotating parts
Shale shaker
Agitator shafts & couplings
Moving generator parts
(explore)
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2006 TEEX

Mud Pumps

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2006 TEEX

Shale Shaker

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2006 TEEX

Generators

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2006 TEEX

Parts Requiring Guarding

58

Air compressors
Crown sheaves
Kelly bushing or controls
Rotary chain drive
Air hoist line
Drawworks
Bench grinder wheels
2006 TEEX

Crown Sheaves

59

2006 TEEX

Kelly and Bushing

Alternative Abatement:
STD 1-12.28 CH-1

60

2006 TEEX

Drawworks

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2006 TEEX

Parts Requiring Guarding

Belts, drive chains, gears and drives on
power and hand tools
Traveling blocks
Sheaves
Cathead?

62

2006 TEEX

Drilling Line

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2006 TEEX

Traveling Block

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2006 TEEX

Hoisting Line

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2006 TEEX

Machine Guarding

Safety Responsibilities

Safety Responsibilities
Management:
Ensure all machinery is properly guarded

Supervisors:
Train employees on specific guard rules in their areas
Ensure machine guards remain in place and are
functional
Immediately correct machine guard deficiencies

Employees:
Do not remove guards unless machine is locked and
tagged
Report machine guard problems to supervisors
immediately
Do not operate equipment unless guards are in place
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2006 TEEX

Training
Operators/affected employees should receive
training on:
Hazards associated with particular machines
How the safeguards provide protection and the
hazards for which they are intended
How and why to use the safeguards
How and when safeguards can be removed and
by whom
What to do if a safeguard is damaged, missing, or
unable to provide adequate protection
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2006 TEEX

Hand and Portable Power Tools

Construction vs. General

Industry
Construction, alteration, or repair?
Applicable standard depends on type of
operations:
1910 Subpart P: Hand and Portable
Powered Tools and Other Hand-Held
Equipment
1926 Subpart I: Tools Hand and Power

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2006 TEEX

General
Employer is responsible for safe
condition of tools and equipment
Including equipment furnished by
employee

Compressed air must not be used for

cleaning unless:
Reduced to <30 p.s.i.
Only with effective chip guarding and PPE
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2006 TEEX

Portable powered tools

Portable circular saws >2 in. guarded

Switches and controls:

72

Automatic return to covering position

constant pressure control for circular and
chain saws
other controls for other tools as
appropriate

2006 TEEX

Portable powered tools

Portable belt sanding machine guarding
Nip points
Unused run of sanding belt

Cracked saws: remove from service

Grounding: Meet Subpart S

73

2006 TEEX

Pneumatic powered tools and

hose
Tool retainer to prevent ejection
Airhose designed for applied pressure
and service

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2006 TEEX

Guarding of portable powered

tools
c. Portable abrasive wheels:

Must be guarded
Ring test and inspection

d. Explosive actuated fastening tools

e. Power lawnmowers

75

Guarding
Controls and shutoff device
Labeling, manuals
Design
2006 TEEX

Other portable tools and

equipment
a. Jacks

Loading and marking

Operation and maintenance

b. Abrasive blast cleaning nozzles:

operating valve and support

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2006 TEEX

General requirements
Maintained in safe condition whether
furnished by employer or employee
Shall be guarded when designed to
accommodate guards
Moving parts that create hazards shall
be guarded by one or more methods
Fan openings; anchoring machinery
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2006 TEEX

General requirements
Abrasive wheel guards
PPE if necessary for objects, particles,
gases
Allowable switches by tool type

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2006 TEEX

Hand tools
Use of unsafe hand tools not
permitted
Wrenches shall not be used when
jaws are sprung to the point of
slippage
Including adjustable, pipe, end &
socket wrenches

Impact tools shall be kept free of

mushroomed heads
Such as drift pins, wedges & chisels

Wooden handles shall be kept

Free of splinters or cracks
Tight in the tool
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2006 TEEX

Power-operated hand tools

Electric power-operated tools
Double-insulated or grounded
Never hold by the cord

Pneumatic power-operated tools

80

Secure tools, attachments, and muzzle

Compressed air use restrictions
Never hold by the hose
Reduce pressure in case of hose failure
2006 TEEX

Power-operated hand tools

Fuel operated tools
Stop while refueling or servicing
Watch concentrations in enclosed spaces

Hydraulic power tools

Fire-resistant fluids
Safe operating pressures

Powder-actuated tools
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2006 TEEX