Martin Engineering: Challenging Conveyor Safety Myths

24 Oct 2023 CW Team

Martin Engineering, a global leader in conveyor safety, challenges the traditional notion of "Guarding by Location" in conveyor equipment. Despite decades of safe design and comprehensive training, the industry has witnessed lapses in workplace safety due to this practice, sometimes resulting in injuries and fatalities. This article questions the assumption that machinery placed beyond a worker's reach doesn't require a guard and highlights the potential risks associated with this approach.

Risks of Guarding by Location: Conveyors and machinery near workers or walkways are typically fitted with safety guards, but "Guarding by Location" assumes that hazards positioned out of a worker's immediate reach do not require such protection. This assumption can lead to serious hazards, such as unguarded return rollers over walkways that can pose a significant risk.

Worker Risks: Regulations often define a general safe height for components based on the average height of workers. Taller employees, however, may be at risk when reaching into components placed above a certain height. Working above machinery considered "guarded by location" exposes workers to a higher risk of injury if they slip or fall to a lower level.

Unaccounted Factors: Most regulations do not consider the potential accumulation of spillage beneath conveyors or in walkways, which can alter the distance between the working surface and a hazard. In some cases, material is deliberately collected or bins are filled to gain access for service or inspection, leading to hazardous activities when tools extend a worker's reach while the belt is running.

Hazards From Above: Guarding by location can create exceptions to the general requirements for hazard guarding. Hazards such as nip points between the belt and return rollers, drive components, pulley shafts, couplings, drive belts, gears, and chains are often found around elevated conveyors. These hazards, including falling components, can be overlooked if considered guarded by location.

Guarding Best Practices: To address the issues associated with guarding by location, installing guards and baskets to protect workers from lateral and overhead hazards while ensuring safe access is a logical solution. All nip points, shear points, and moving or rotating components should be guarded, regardless of location or access.

Standardisation for Safety: While there is no global standard for guard mesh sizes and mounting distances, standardizing these aspects would improve safety. It would allow maintenance workers to build guards with a shortlist of materials and eliminate the need for gauges to measure distances. Standardisation encourages routine inspections without the need to remove guards.

Ending the Myth: Guarding by location, despite its widespread acceptance, presents challenges in overhead conveyor applications. It's time to acknowledge that, when it comes to conveyors, the concept of "guarding by location" is a myth that should be abandoned in favour of more comprehensive safety measures.

Martin Engineering, a global leader in conveyor safety, challenges the traditional notion of Guarding by Location in conveyor equipment. Despite decades of safe design and comprehensive training, the industry has witnessed lapses in workplace safety due to this practice, sometimes resulting in injuries and fatalities. This article questions the assumption that machinery placed beyond a worker's reach doesn't require a guard and highlights the potential risks associated with this approach. Risks of Guarding by Location: Conveyors and machinery near workers or walkways are typically fitted with safety guards, but Guarding by Location assumes that hazards positioned out of a worker's immediate reach do not require such protection. This assumption can lead to serious hazards, such as unguarded return rollers over walkways that can pose a significant risk. Worker Risks: Regulations often define a general safe height for components based on the average height of workers. Taller employees, however, may be at risk when reaching into components placed above a certain height. Working above machinery considered guarded by location exposes workers to a higher risk of injury if they slip or fall to a lower level. Unaccounted Factors: Most regulations do not consider the potential accumulation of spillage beneath conveyors or in walkways, which can alter the distance between the working surface and a hazard. In some cases, material is deliberately collected or bins are filled to gain access for service or inspection, leading to hazardous activities when tools extend a worker's reach while the belt is running. Hazards From Above: Guarding by location can create exceptions to the general requirements for hazard guarding. Hazards such as nip points between the belt and return rollers, drive components, pulley shafts, couplings, drive belts, gears, and chains are often found around elevated conveyors. These hazards, including falling components, can be overlooked if considered guarded by location. Guarding Best Practices: To address the issues associated with guarding by location, installing guards and baskets to protect workers from lateral and overhead hazards while ensuring safe access is a logical solution. All nip points, shear points, and moving or rotating components should be guarded, regardless of location or access. Standardisation for Safety: While there is no global standard for guard mesh sizes and mounting distances, standardizing these aspects would improve safety. It would allow maintenance workers to build guards with a shortlist of materials and eliminate the need for gauges to measure distances. Standardisation encourages routine inspections without the need to remove guards. Ending the Myth: Guarding by location, despite its widespread acceptance, presents challenges in overhead conveyor applications. It's time to acknowledge that, when it comes to conveyors, the concept of guarding by location is a myth that should be abandoned in favour of more comprehensive safety measures.