MACHINE GAURDING

B.R. Sharma
Microtek Engineers and Consultants
Gurgaon 9810321025

1
Machinery is a major hazard at work..

8 out of 10 workplace fatalities and 1 in 4

workplace injuries involve mechanical
equipment.

2
Why Machines are dangerous?
Machines are designed to change the shape
and form of the material which human body
cannot do
Machines have tremendous force and likely to
cause injury

During man and machine interfaces possibility

of accidents arises
Nearly one third of reportable accidents in
factories are due to machines

3
ARE YOUR CONTROLS ADEQUATE?

Hazard

Something with the potential to cause harm

A RISK ASSESSMENT IS YOUR

BEST INVESTMENT
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spot the hazards

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spot the hazards

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MACHINE GUARDING
Creates
A barrier to prevent limb / clothing to come in contact
with the dangerous parts of the machinery
Can be obtained by
Keeping dangerous part of the machinery inaccessible
when in motion
• Machinery Guard - Any barrier or device constructed to
prevent a person or his clothing coming into contact
with dangerous parts of machinery. The term guard is
not intended to specify a particular type of safeguard,
but implies a prohibition of access to dangerous part;
thus for all practical purposes enclosure, fencing and
guarding may be taken to have the same meaning. (IS
9474)
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 Machine Guarding is required because of :
Legal Requirement
Factories Act
Sec- 21 - Fencing of machinery
Sec-22 - Working on or near machine in motion.
Sec-23 - Employment of young persons on dangerous
m/c.
Sec-24 - Striking gear & devices for cutting power.
Sec- 25 - Self acting m/c
Sec-26 - Casing of new m/c.
Sec- 30 - Revolving m/c
Sec- 35- Protection of eyes.
Factory Rules.
Social Requirement
IS 9474 1980 8
Dangerous moving parts in these three basic
areas need safeguarding:
• 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 which 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 which
move while the machine is working. These can
include reciprocating, rotating, and transverse moving
parts, as well as feed mechanisms and auxiliary parts
of the machine.
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Motion in machines
 Rotating motion
Rotating motion can be dangerous; even smooth, slowly rotating shafts can
grip hair and clothing, and through minor contact force the hand and arm
into a dangerous position. Injuries due to contact with rotating parts can be
severe. Collars, couplings, cams, clutches, flywheels, shaft ends, spindles,
meshing gears, and horizontal or vertical shafting are some examples of
common rotating mechanisms which may be hazardous. The danger
increases when projections such as set screws, bolts, nicks, abrasions, and
projecting keys or set screws are exposed on rotating parts.
 In – Running nips
n-running nip point hazards are caused by the rotating parts on
machinery. There are three main types of in-running nips. Parts
can rotate in opposite directions while their axes are parallel to
each other. These parts may be in contact (producing a nip point)
or in close proximity. In the latter case, stock fed between two rolls
produces a nip point. As seen here, this danger is common on
machines with intermeshing gears, rolling mills, and calendars.
Nip Points between rotating and
tangentially moving parts
Nip points are also created between rotating and
tangentially moving parts. Some examples would be: the
point of contact between a power transmission belt and its
pulley, a chain and a sprocket, and a rack and pinion.
 Transverse motion
Transverse motion (movement in a straight, continuous line)
creates a hazard because a worker may be struck or caught in a
pinch or shear point by the moving part.
 Reciprocating motions
Reciprocating motions may be hazardous because,
during the back-and-forth or up-and-down motion, a
worker may be struck by or caught between a moving
and a stationary part.
 Cutting action
Cutting action may involve rotating, reciprocating, or transverse
motion. The danger of cutting action exists at the point of
operation where finger, arm and body injuries can occur and
where flying chips or scrap material can strike the head,
particularly in the area of the eyes or face. Such hazards are
present at the point of operation in cutting wood, metal, and other
materials. Examples of mechanisms involving cutting hazards
include band saws, circular saws, boring and drilling machines,
turning machines (lathes), or milling machines.
 Punching action results when power is
applied to a slide (ram)
Punching action results when power is applied to a slide (ram) for the
purpose of blanking, drawing, or stamping metal or other materials. The
danger of this type of action occurs at the point of operation where stock
is inserted, held, and withdrawn by hand. Typical machines used for
punching operations are power presses and iron workers.
 Bending action
Bending action results when power is applied to a slide in order
to draw or stamp metal or other materials. A hazard occurs at
the point of operation where stock is inserted, held, and
withdrawn. Equipment that uses bending action includes power
presses, press brakes, and tubing benders.
 Shearing action
Shearing action involves applying power to a slide or knife in order
to trim or shear metal or other materials. A hazard occurs at the
point of operation where stock is actually inserted, held, and
withdrawn. Examples of machines used for shearing operations
are mechanically, hydraulically, or pneumatically powered shears.
 What hazards exist?
• Crushed by or drawn into equipment
• Struck by moving parts
• Struck by failed components or particles
 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
 Rotating Parts
• Can grip hair or clothing
• Can force the body into a dangerous position
• Projecting pieces increase risk
 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
 Guarding Methods
• Location / distance
• Guards
– Fixed
– Interlocked
– Adjustable
– Self-adjusting
 Guarding Methods
• Devices
– Presence sensing
– Pullback
– Restraint
– Safety controls (tripwire cable, two-hand
control, etc.)
– Gates
 Guarding Methods
• Feeding & ejection methods
– Automatic and/or semi-automatic feed and
ejection
• Robots
• Miscellaneous aids
– Awareness barriers
– Protective shields
– Hand-feeding tools
 Fixed Guard

• Barrier is a permanent part

of machine
• Preferable over other types
 Interlocked Guard

• Stops motion when guard is opened or removed

Interlocked
guard on
revolving drum
 Adjustable Guard
• Barrier may be
adjusted for
variable
operations
– What are the
drawbacks? Bandsaw blade
adjustable guard
 Self-Adjusting Guard

• Adjusts according to size/position of material

Circular table saw

self-adjusting guard
Pullback Device
• Cables attached to
operator’s hands or
wrists
• Removes hands from
point of operation
during danger period
– What are the
drawbacks?
 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
 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
 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
 Gate
• Must close fully to protect user before cycle will
start

Gate Open Gate Closed

 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

 Protective Shields

• Protection from flying particles or splashing

fluids
• Do not protect
completely from
machine hazards
Grinding Operation General requirements

• Abrasive wheels must

be guarded, with
exceptions

• Guard design
dependent on type of
work and type of
wheel
 Exposure adjustment

• For type where operator

stands in front of
opening: Adjustable for
decreasing wheel size

• Adjustable tongue guard

must never be more than
¼ inch from wheel
 Exposure adjustment

• For type where operator

stands in front of
opening: Adjustable for
decreasing wheel size

• Adjustable tongue guard

must never be more than
¼ inch from wheel
Ring Test
 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

 Transmission Apparatus

(a) General requirements

(b) Prime-mover guards

(1) Flywheels

(2) Cranks and connecting rods

(3) Tail rods or extension piston rods

(c) Shafting

(d) Pulleys
(e) Belt, rope, and chain drives

(f) Gears, sprockets, and chains

(g) Guarding friction drives

(h) Keys, setscrews, and other projections

(i) Collars and couplings

(j) Bearings and facilities for oiling

(k) Guarding of clutches, cutoff couplings, and

clutch pulleys
(l) Belt shifters, clutches, shippers, poles, perches,
and fasteners

(m) Standard guards-general requirements

(o) Approved materials

(p) Care of equipment

• Prevent contact:
– The safeguard must prevent hands, arms, or any part of a worker's body
or clothing from making contact with dangerous moving parts. A good
safeguarding system eliminates the possibility of the operator or other
workers placing parts of their bodies near hazardous moving parts.

• Secure:
– Workers should not be able to easily remove or tamper with the
safeguard, because a safeguard that can easily be made ineffective is no
safeguard at all. 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 safeguard should ensure that no objects can fall into moving parts.
A small tool which is dropped into a cycling machine could easily
become a projectile that could strike and injure someone.

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• Create no new hazards:
– A safeguard defeats its own purpose if it creates a hazard of its own
such as a shear point, a jagged edge, or an unfinished surface which
can cause a laceration. The edges of guards, for instance, should be
rolled or bolted in such a way that they eliminate sharp edges.

• Create no interference:
– Any safeguard which impedes a worker from performing the job
quickly and comfortably might soon be overridden or disregarded.
Proper safeguarding can actually enhance efficiency since it can
relieve the worker's apprehensions about injury.

• Allow safe lubrication:

– If possible, one should be able to lubricate the machine without
removing the safeguards. Locating oil reservoirs outside the guard,
with a line leading to the lubrication point, will reduce the need for
the operator or maintenance worker to enter the hazardous area.

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 TYPE OF GUARDS
• Fixed Guards: This type of guard should be provided in
every practicable case as the preferred method of attaining
secure fencing.
• The guard should by nature of its design and construction,
prohibit access to the dangerous parts of machinery and
should remain in position after installation.
• Opening for the work to be fed through the guard into the
machine should be sufficient only for the size of the work-
piece; it should not allow a person to gain access to the
dangerous parts. The effectiveness of any fixed guard
should always be judged by a test to see that finger tips
cannot reach beyond a safe limit.

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 TYPE OF GUARDS
Interlocking Guard - A barrier to prevent access to the
dangerous parts except when those parts are at rest and
prevents the machinery from being operated until the barrier is
in enclosed position.
Automatic Guard - A device which operates to remove any
part of a person exposed to danger to a position of safety and
functions independently of the operator.
Trip Guard - A barrier or device arranged so that approach
beyond a safe limit causes machinery to stop before a person
can come in contact with the dangerous parts.

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 Fixed Guards - Provides a barrier
Advantages
– Can be constructed to suit many specific
applications
– In-plant construction is often possible
– Can provide maximum protection
– Usually requires minimum maintenance
– Can be suitable to high production, repetitive
operations
Limitations
– May interfere with visibility
– Can be limited to specific operations
– Machine adjustment and repair often require its
removal, thereby necessitating other means of
protection for maintenance personnel
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Fixed point of operation guard

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 Interlocked
Safeguarding Action
– Shuts off or disengages power and
prevents starting of machine when
guard is open; should require the
machine to be stopped before the
worker can reach into the danger
area
Advantages
– Can provide maximum protection
– Allows access to machine for
removing jams without time-
consuming removal of fixed guards
Limitations
– Requires careful adjustment and
maintenance
– May be easy to disengage
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 Adjustable
Safeguarding Action
– Provides a barrier which may be
adjusted to facilitate a variety of
production operations
Advantages
– Can be constructed to suit many
specific applications
– Can be adjusted to admit varying
sizes of stock
Limitations
– Hand may enter danger area -
protection may not be complete at
all times
– May require frequent maintenance
and/or adjustment
– The guard may be made ineffective
by the operator
– May interfere with visibility

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 Self-Adjusting
Safeguarding Action
– Provides a barrier which moves
according to the size of the stock
entering danger area
Advantages
– Off-the-shelf guards are often
commercially available
Limitations
– Does not always provide
maximum protection
– May interfere with visibility
– May require frequent maintenance
and adjustment

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 Safety Devices

• Stop the machine if a hand or any part of the

body is inadvertently placed in the danger area;
• Restrain or withdraw the operator's hands from
the danger area during operation;
• Require the operator to use both hands on
machine controls, thus keeping both hands and
body out of danger; or
• Provide a barrier which is synchronized with the
operating cycle of the machine in order to prevent
entry to the danger area during the hazardous
part of the cycle.

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 Photoelectric
Safeguarding Action
– Machine will not start cycling when
the light field is interrupted
– When the light field is broken by any
part of the operator's body during the
cycling process, immediate machine
braking is activated
Advantages
– Can allow freer movement for
operator; simplicity of use; no
adjustments required
Limitations
– Does not protect against mechanical
failure
– May require frequent alignment and
calibration
– Excessive vibration may cause lamp
filament damage and premature
burnout
– Limited to machines that can be
stopped

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 Pullbacks
Safeguarding Action
– As the machine begins to cycle, the
operator's hands are pulled out of the
danger area
Advantages
– Eliminates the need for auxiliary
barriers or other interference at the
danger area
Limitations
– Limits movement of operator
– May obstruct work-space around
operator
– Adjustments must be made for
specific operations and for each
individual
– Requires frequent inspections and
regular maintenance
– Requires close supervision of the
operator's use of the equipment

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Restraint (holdback)

Safeguarding Action
– Prevents the operator from
reaching into the danger area
Advantages
– Little risk of mechanical failure
Limitations
– Limits movements of operator
– May obstruct work-space
– Adjustments must be made for
specific operations and each
individual
– Requires close supervision of
the operator's use of the
equipment

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 Safety-trip controls

Safeguarding Action
– Stops machine tripped
Advantages
– Simplicity of controls
Limitations
– Other guards are also required for
operator protection--usually fixed
barrier guards
– Requires frequent maintenance
– May not be adaptable to stock
variation

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Safety Trip Controls (cont’d)
• When pressed by hand, the safety tripod deactivates the
machine.
• Because it has to be actuated by the operator during an
emergency situation, its proper position is also critical.

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Safety tripwire cables
Are located around the perimeter of or near the danger area.
The operator must be able to reach the cable with either hand
to stop the machine.

Calender equipped with this type of control.

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 Two-Hand Controls
Safeguarding Action
– Concurrent use of both hands is
required, preventing the operator
form entering the danger area
Advantages
– Operator’s hands are at a
predetermined location
– Operator’s hands are free to pick
up a new part after first half of
cycle is completed
Limitations
– Requires a partial cycle machine
with a brake
– Some two-hand controls can be
rendered unsafe by holding with
arm or blocking, thereby permitting
one-hand operation Protects only
the operator
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Not two hand controls

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Two-Hand Trip
• Requires concurrent application of both of the operator's control buttons
to activate the machine cycle, after which the hands are free.
• Trips must be placed far enough from the point of operation to make it
impossible for the operator to move his or her hands from the trip
buttons or handles into the point of operation before the first half of the
cycle is completed.

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 Gate
• Movable barrier which protects the operator at the point of
operation before the machine cycle can be started.

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 Guard Ergonomics
Reach Measurements - design and position guards to
restrict access to danger points as follows:
Reach Minimum Distance Assumed
– Arm reach 850mm - under arm to fingertip
– Elbow reach 550mm - inside elbow to finger tip
– Wrist reach 230mm - wrist to tip of middle finger
– Vertical reach 2500mm - floor to danger point
– Finger reach 130mm

* distances include an allowance

for clearance from danger points

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Use of Mesh for Guards

67
 Guard Placement

Size of mesh or Minimum distance

other opening between guard and
in guard danger point

• less than 9mm - 15mm

• 9 to 25mm - 120mm
• 25 to 40 mm - 200mm
• greater than 40mm - 1000mm

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 Robots

Robot
Press

Stock
Conveyor

Fixed
Barrier

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Miscellaneous

Awareness Barrier

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Shields

71
Machine guarding
• One or more methods of machine guarding shall be provided to protect
the operator and other employees in the machine area from hazards
such as those created by point of operation, ingoing nip points,
rotating parts, flying chips and sparks

72
Guards shall be affixed to the machine where
possible and secured elsewhere if for any reason
attachment to the machine is not possible.

•The guard shall be such that it does not offer an accident

hazard in itself.
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The point of operation of machines whose operation
exposes an employee to injury, shall be guarded.

74
Fan Blades
• When the periphery of the blades of a fan is less
than 7 feet above the floor or working level, the
blades must be guarded with a guard having
openings no larger than ½ inch.

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76
77
Anchoring Fixed Machinery
– Machines designed for a fixed location must be
securely anchored to prevent walking or moving

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Unguarded Dough Mixer
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Hazards:
• Contact with
rotating parts
Guarding Method:
• Interlocks
What happened?
• Employee by-passed
interlock
Result - Death

Ingredient Mixer

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 Injection Molding Machine

Guarded
Not Guarded

Guarding Method:
• Interlocked barrier gate

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 Injection Molding Machine
(Plastic molding)

1 - Electrical Interlock
2 - Hydraulic Interlock

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 175 Ton Injection Molding Machine

Mechanical Blocking Mechanism

Interlocked
Safety Gate

Die Halves Stationary Platen

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 Injection Molding Machine

3 - Mechanical Blocking Mechanism

Prevents the dies from closing
84
 Standards:
• Machine guarding
• Point of operation
Hazards:
• Contact with pinch points
• Struck by hot metals
• Caught in two die halves
Guarding Method:
• Barrier guard

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Swing arm in motion

86
Addison Tube Bender

Safety mat
and
foot pedal control

87
Photo electric sensing
across face and barrier
across the ends of the
press

Press

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Forming Mill

In-running nip point

Point of Operation

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 Forming Mill

Shows the process of metal forming – Metal is being pulled

through dies and formed as it progresses.
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 Back of a shear – Material Take-off Conveyor

Standards: Guarding Method:

• Machine guarding • Barrier guard
Hazards: • Isolation
• Contact between the belt and the
pulley nip (drum)

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 Conveyor Nip

Nip Point

92
 Scissor lift table

Standards:
• Machine guarding Guarding Method:
Hazards: • Telescoping barrier guard
• Contact between the scissors arms • Isolation

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 REEL
Paper mill Pope

94
Primary arm guard

95
 Lathe
Standards:
• Rotating parts
Hazards:
• Contact with rotating
parts
Guarding Method:
• Barrier guard

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Abrasive wheel machinery

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98
Guard Design
• The safety guard shall cover the spindle
end, nut, and flange projections.

99
safety guard

100
On offhand grinding Work rests.
machines, work rests shall be
used to support the work.
They shall be of rigid
construction and designed to
be adjustable to compensate
for wheel wear. Work rests
shall be kept adjusted closely
to the wheel with a maximum
opening of one-eighth inch to
prevent the work from being
jammed between the wheel
and the rest, which may cause
wheel breakage. The work rest
shall be securely clamped
after each adjustment. The
adjustment shall not be made
with the wheel in motion.
Work rest 1/8”

101
Tongue Guard • Exposure adjustment
– one-fourth inch.

102
 Mounting - Wheel Speed

• (1) Inspection.
– The spindle speed of the
machine shall be checked
before mounting of the wheel
to be certain that it does not
exceed the maximum
operating speed marked on
the wheel

103
Mounting - Ring Test
• (1) Inspection.
– Wheels should be tapped
gently with a light
nonmetallic implement,
such as the handle of a
screwdriver for light
wheels, or a wooden
mallet for heavier wheels.
If they sound cracked
(dead), they shall not be
used. This is known as
the "Ring Test".

“Ring test”
104
FLOOR STAND GRINDERS

• Self Closing Guard

– floor stand grinders for use with a 24”
diameter wheels or larger where personnel are
required to be in the plane of rotation of the
wheel shall be equipped with guards which
close automatically in case of wheel breakage.
Other guard designs which provide equivalent
protection to the personnel in the plane of
rotation of the wheel may be used.

105
106
Guard down

107
108
Surface grinder with top guard
109
Mechanical Power-Transmission
Apparatus

110
 Guarding horizontal shafting.
• (i) All exposed parts of
horizontal shafting
shall be protected by
a stationary casing
enclosing shafting
completely or by a
trough enclosing
sides and top or sides
and bottom of
shafting as location
requires.

Shafting must be guarded

111
112
 Projecting shaft ends
• (i) Projecting shaft
ends shall present a
smooth edge and
end and shall not
project more than
one-half the
diameter of the
shaft unless
guarded by
nonrotating caps or
safety sleeves.
• (ii) Unused keyways
shall be filled up or Shafting shall not extend more
covered. than 1/2 the diameter of the
shaft unless guarded
113
Pulley Guarding
• (1) Pulleys, shall be
guarded in accordance
with the standards

114
115
Gears, sprockets, and chains

116
 Gears
• (1) Gears shall be guarded in
accordance with one of the
following methods:
– (i) By a complete enclosure;
or
– (ii) By a standard guard
– (iii) By a band guard
covering the face of gear
and having flanges
extended inward beyond
the root of the teeth on the
exposed side or sides.

117
 Sprockets and chains.
• All sprocket wheels and chains shall be enclosed unless
they are more than Where the drive extends over other
machine or working areas, protection against falling shall
be provided..

118
Safety Responsibilities

Machine Guarding
 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
 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
Hand and Portable Power
Tools
Construction vs. General Industry
• Construction, alteration, or repair?

• Applicable standard depends on type of

operations:

– Hand and Portable Powered Tools and Other

Hand-Held Equipment

– Tools – Hand and Power

 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

 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
 Power-operated hand tools
• Electric power-operated tools

– Double-insulated or grounded

– Never hold by the cord

• Pneumatic power-operated tools

– Secure tools, attachments, and muzzle

– Compressed air use restrictions

– Never hold by the hose

– Reduce pressure in case of hose failure

 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
 Portable powered tools
• Portable circular saws >2 in. guarded

– Automatic return to covering position

• Switches and controls:

– constant pressure control for circular and

chain saws

– other controls for other tools as appropriate

 Portable powered tools

• Portable belt sanding machine guarding

– Nip points

– Unused run of sanding belt

• Cracked saws: remove from service

• Grounding: Meet Subpart S

 Pneumatic powered tools and hose

• Tool retainer to prevent ejection

• Air hose designed for applied pressure and

service
 Guarding of portable powered tools
c. Portable abrasive wheels:

– Must be guarded

– Ring test and inspection

d. Power lawnmowers

– Guarding

– Controls and shutoff device

– Labeling, manuals

– Design
 Other portable tools and equipment

a. Jacks

– Loading and marking

– Operation and maintenance

b. Abrasive blast cleaning nozzles: operating

valve and support
 General requirements
• Abrasive wheel guards

• PPE if necessary for objects, particles, gases

• Allowable switches by tool type