WIXLIB

Concrete and Masonry Construction29 CFR Part 1926, Subpart Q 1926.702 – Requirements for equipment andtoolsConsult these standards directly to ensure fullcompliance with the provisions as this publicationis not a substitute for the standards. States withOSHA-approved plans have at least equivalentstandards. For detailed information about machineguarding and lockout/tagout, see the followingresources: Machine Guarding Safety and Health TopicsPage ml) Machine Guarding eTool ndex.html) OSHA Publication 3067, Concepts and Techniquesof Machine Safeguarding (http://www.osha.gov/Publications/Mach Safeguarding/toc.html) OSHA Directive STD 01-05-019 [STD 1-7.3],Control of Hazardous Energy (Lockout/Tagout)—Inspection Procedures and Interpretive Guidance Control of Hazardous Energy (Lockout/Tagout)Safety and Health Topics Page ndex.html) OSHA’s Lockout Tagout Interactive TrainingProgram tm) OSHA Publication 3120, Control of HazardousEnergy (Lockout/Tagout)OSHA standards, directives, publications,and other resources are available online atwww.osha.gov.National Consensus StandardsOSHA recognizes the valuable contributions ofnational consensus standards and these voluntarystandards may be used as guidance and recognitionof industry accepted practices. For example, theAmerican National Standards Institute (ANSI) publishes numerous voluntary national consensus standards on the safe care and use of specific machinery.These consensus standards provide you with usefulguidance on how to protect your em-ployees frommachine amputation hazards and the controlmethods described may assist you in complyingwith OSHA performance-based standards.Furthermore, OSHA encourages employers toabide by the more current industry consensus standards since those standards are more likely to beabreast of the state of the art than an applicableOSHA standard may be. However, when a consensus standard addresses safety considerations, OSHAmay determine that the safety practices describedby that consensus standard are less protective thanthe requirement(s) set forth by the pertinent OSHAregulations. OSHA enforcement policy regardingthe use of consensus standards is that a violationof an OSHA standard may be deemed de minimisin nature if the employer complies with a consensus standard (that is not incorporated by reference)rather than the OSHA standard in effect and if theemployer’s action clearly provides equal or greateremployee protection. (Such de minimis violationsrequire no corrective action and result in no penalty.)For example, the OSHA point-of-operationguarding provisions, contained in paragraph1910.212(a)(3), require the guarding device to bein conformance with any appropriate standardsthereof, or in the absence of applicable specificstandards, shall be so designed and constructed asto prevent the operator from having any part of hisbody in the danger zone during the operating cycle.The terms applicable standards or appropriate standards, as used in the context of 29 CFR 1910.212,are references to those private consensus standards that were adopted (source standards) orincorporated by reference in the OSHA standards.In some instances, a specific national consensusstandard (that is not incorporated by reference or asource standard), such as an ANSI standard for aparticular machine, may be used for guidance purposes to assist employers in preventing an operator from having any body part in the machine danger zone during the operating cycle. Also, OSHAmay, in appropriate cases, use these consensusstandards as evidence that machine hazards are recognized and that there are feasible means of correcting the hazard. On the other hand, some national consensus standards may sanction practices thatprovide less employee protection than that providedby compliance with the relevant OSHA provisions.In these cases, compliance with the specific consensus standard provision would not constitute compliance with the relevant OSHA requirement.Under the Fair Labor Standards Act (FLSA), theSecretary of Labor has designated certain nonfarm jobs as particularly hazardous for employees younger than 18. Generally, these employees are prohibited from operating: Band saws Circular saws Guillotineshears Punching and shearing machines Meatpacking or meat-processing machines Certain power-driven machines: Paper productsmachines, Woodworking machines, Metalforming machines, and Meat slicers.6Occupational Safety andHealth Administration

Recognizing AmputationHazardsTo prevent employee amputations, you and youremployees must first be able to recognize the contributing factors, such as the hazardous energy associated with your machinery and the specific employeeactivities performed with the mechanical operation.Understanding the mechanical components ofmachinery, the hazardous mechanical motion thatoccurs at or near these components and specificemployee activities performed in conjunction withmachinery operation will help employees avoid injury.Reciprocating Motion (Figure 2) is back-and-forthor up-and-down motion that may strike or entrapan employee between a moving part and a fixedobject.Figure 2 Reciprocating MotionTableBed (stationary)Hazardous Mechanical ComponentsThree types of mechanical components presentamputation hazards:Point of Operation is the area of the machinewhere the machine performs work – i.e., mechanical actions that occur at the point of operation,such as cutting, shaping, boring, and forming.Transversing Motion (Figure 3) is motion in astraight, continuous line that may strike or catchan employee in a pinch or shear point created bythe moving part and a fixed object.Figure 3 Transversing MotionPower-Transmission Apparatus is all componentsof the mechanical system that transmit energy,such as flywheels, pulleys, belts, chains, couplings,connecting rods, spindles, cams, and gears.Other Moving Parts are the parts of the machinethat move while the machine is operating, suchas reciprocating, rotating, and transverse moving parts as well as lead mechanisms and auxiliary parts of the machine.Hazardous Mechanical MotionsA wide variety of mechanical motion is potentiallyhazardous. Here are the basic types of hazardousmechanical motions:Rotating Motion (Figure 1) is circular motion suchas action generated by rotating collars, couplings,cams, clutches, flywheels, shaft ends, and spindles that may grip clothing or otherwise force abody part into a dangerous location. Even smoothsurfaced rotating machine parts can be hazardous.Projections such as screws or burrs on the rotating part increase the hazard potential.Cutting Action (Figure 4) is the action that cutsmaterial and the associated machine motion maybe rotating, reciprocating, or transverse.Figure 4 Cutting ActionFigure 1 Rotating ROMA M P U TAT I O N S7

Punching Action (Figure 5) begins when powercauses the machine to hit a slide (ram) to stampor blank metal or other material. The hazardoccurs at the point of operation where theemployee typically inserts, holds, or withdrawsthe stock by hand.Bending Action (Figure 7) is power applied to aslide to draw or stamp metal or other materials ina bending motion. The hazard occurs at the pointof operation where the employee typically inserts,holds, or withdraws the stock by hand.Figure 7 Bending ActionFigure 5 Punching ActionPunchStockDieShearing Action (Figure 6) involves applyingpower to a slide or knife in order to trim or shearmetal or other materials. The hazard occurs at thepoint of operation where the employee typicallyinserts, holds, or withdraws the stock by hand.Figure 6 Shearing ActionIn-Running Nip Points (Figure 8), also known as“pinch points,” develop when two parts movetogether and at least one moves in rotary or circular motion. In-running nip points occur whenevermachine parts move toward each other or whenone part moves past a stationary object. Typicalnip points include gears, rollers, belt drives, andpulleys.Figure 8 In-Running Nip PointsNip PointNip PointBladeStockNipPointNip PointNipPointTypical Nip Point8Occupational Safety andHealth Administration

Hazardous ActivitiesEmployees operating and caring for machineryperform various activities that present potentialamputation hazards.Machine set-up/threading/preparation,*Machine inspection,*Normal production operations,Clearing jams,*Machine adjustments,*Cleaning of machine,*Lubricating of machine parts,* andScheduled and unscheduled maintenance.*Controlling AmputationHazardsSafeguarding is essential for protecting employeesfrom needless and preventable injury. A good ruleto remember is:Any machine part, function, or process that maycause injury must be safeguarded.* These activities are servicing and/or maintenance activities.Hazard AnalysisYou can help prevent workplace amputations bylooking at your workplace operations and identifying the hazards associated with the use and care ofthe machine. A hazard analysis is a technique thatfocuses on the relationship between the employee,the task, the tools, and the environment. Whenevaluating work activities for potential amputationhazards, you need to consider the entire machineoperation production process, the machine modesof operation, individual activities associated withthe operation, servicing and maintenance of themachine, and the potential for injury to employees.The results from the analysis may then be usedas a basis to design machine safeguarding and anoverall energy control (lockout/tagout) program.This is likely to result in fewer employee amputations; safer, more effective work methods; reducedworkers’ compensation costs; and increased employee productivity and morale.In this booklet, the term primary safeguardingmethods refers to machine guarding techniquesthat are intended to prevent or greatly reduce thechance that an employee will have an amputationinjury. Refer to the OSHA general industry (e.g.,Subpart O) and construction (e.g., Subparts I andN) standards for specific guarding requirements.Many of these standards address preventive methods (such as using barrier guards or two-hand tripping devices) as primary control measures; whileother OSHA standards allow guarding techniques(such as a self-adjustable table saw guard) thatreduce the likelihood of injury. Other less protectivesafeguarding methods (such as safe work methods)that do not satisfactorily protect employees fromthe machine hazard areas are considered secondary control methods.Machine safeguarding must be supplementedby an effective energy control (lockout/tagout)program that ensures that employees are protectedfrom hazardous energy sources during machineservicing and maintenance work activities.Lockout/tagout plays an essential role in the prevention and control of workplace amputations. Interms of controlling amputation hazards, employees are protected from hazardous machine workactivities either by: 1) effective machine safeguarding, or 2) lockout/tagout where safeguards are rendered ineffective or do not protect employees fromhazardous energy during servicing and maintenance operations.Additionally, there are some servicing activities,such as lubricating, cleaning, releasing jams andmaking machine adjustments that are minor innature and are performed during normal production operations. It is not necessary to lockout/tagout a machine if the activity is routine, repetitiveand integral to the production operation providedthat you use an alternative control method thataffords effective protection from the machine’shazardous energy sources.Safeguarding MachineryThe employer is responsible for safeguardingmachines and should consider this need when purchasing machinery. Almost all new machinery isSAFEGUARDINGEQUIPMENTANDPROTECTINGEMPLOYEESFROMA M P U TAT I O N S9

available with safeguards installed by the manufacturer, but used equipment may not be.If machinery has no safeguards, you may beable to purchase safeguards from the originalmachine manufacturer or from an after-marketmanufacturer. You can also build and install thesafeguards in-house. Safeguarding equipmentshould be designed and installed only by technically qualified professionals. If possible, the originalequipment manufacturer should review the safeguard design to ensure that it will protect employees without interfering with the operation of themachine or creating additional hazards.Regardless of the source of safeguards, theguards and devices used need to be compatiblewith a machine’s operation and designed to ensuresafe operator use. The type of operation, size, andshape of stock, method of feeding, physical layoutof the work area, and production requirements allaffect the selection of safeguards. Also, safeguardsshould be designed with the machine operator inmind as a guarding method that interferes with theoperation of the machine may cause employees tooverride them. To ensure effective and safe operatoruse, guards and devices should suit the operation.The Performance Criteria for Safeguarding[ANSI B11.19-2003] national consensus standardprovides valuable guidance as the standardaddresses the design, construction, installation,operation and maintenance of the safeguardingused to protect employees from machine hazards.The following safeguarding method descriptionsare, in part, structured like and, in many ways aresimilar to this national consensus standard.The Performance Criteria for Safeguarding [ANSIB11.19-2003] defines safeguarding as the protection of personnel from hazards by the use ofguards, safeguarding devices awareness devices,safeguarding methods, or safe work procedures.The following ANSI B11.19 definitions describethe various types of safeguarding:Guard: A barrier that prevents exposure to anidentified hazard.Safeguarding device: A device that detects orprevents inadvertent access to a hazard.NOTE: The 1990 ANSI B11.19 term Safeguardingdevice was modified to Safeguarding (Protective)Device in the revised 2003 ANSI standard and thenew term includes a detection component. Devices that detect, but do not prevent employeeexposure to machine hazards are not consideredby OSHA to be primary safeguarding methods.Awareness device: A barrier, signal or sign thatwarns individuals of an impending, approachingor present hazard.Safeguarding method: Safeguarding implemented to protect individuals from hazards by thephysical arrangement of distance, holding, openings, or positioning of the machine or machineproduction system to ensure that the operatorcannot reach the hazard.Safe work procedures: Formal written instructions developed by the user which describe howa task is to be performed.Primary Safeguarding MethodsTwo primary methods are used to safeguardmachines: guards and some types of safeguardingdevices. Guards provide physical barriers that prevent access to danger areas. Safeguarding deviceseither prevent or detect operator contact with thepoint of operation or stop potentially hazardousmachine motion if any part of an individual’s bodyis within the hazardous portion of the machine.Both types of safeguards need to be properlydesigned, constructed, installed, used and maintained in good operating condition to ensureemployee protection.Criteria for Machine Safeguarding Prevents employee contact with the hazardarea during machine operation. Avoids creating additional hazards. Is secure, tamper-resistant, and durable. Avoids interfering with normal operation ofthe machine. Allows for safe lubrication and maintenance.GuardsGuards usually are preferable to other controlmethods because they are physical barriers thatenclose dangerous machine parts and preventemployee contact with them. To be effective,guards must be strong and fastened by any securemethod that prevents the guard from being inadvertently dislodged or removed. Guards typicallyare designed with screws, bolts and lock fastenersand usually a tool is necessary to unfasten and1 0Occupational Safety andHealth Administration

remove them. Generally, guards are designed notto obstruct the operator’s view or to preventemployees from doing a job.In some cases, guarding may be used as analternative to lockout/tagout because employeescan safely service or maintain machines with aguard in place. For example, polycarbonate andwire-mesh guards provide greater visibility and canbe used to allow maintenance employees to safelyobserve system components. In other instances,employees may safely access machine areas, without locking or tagging out, to perform maintenancework (such as machine cleaning or oiling tasks)because the hazardous machine componentsremain effectively guarded.Guards must not create additional hazards suchas pinch points or shear points between guardsand other machine parts. Guard openings shouldbe small enough to prevent employees fromaccessing danger areas. (See Table 1 and Figures9 through 12 for commonly used machine guards.)Figure 11 Self-Adjusting Guard on a Radial SawHandleAntiKickbackDeviceGuardBladeFigure 12 Interlocked Guard on a Roll Make-up MachineFigure 9 Fixed Guard on a Power nt InsertFigure 10 Power Press with an Adjustable Barrier SFROMA M P U TAT I O N S11

Table 1. Commonly Used Machine GuardsTypes of Machine GuardsTypeMethod ofSafeguardingAdvantagesLimitationsFixedBarrier that allows forstock feeding but does notpermit operator to reachthe danger area. Can be constructed to suitmany applications. Permanently enclosesthe point of operation orhazard area. Provides protectionagainst machine repeat. Allows simple, in-plantconstruction, with minimal maintenance. Sometimes not practicalfor changing productionruns involving differentsize stock or feedingmethods. Machine adjustment andrepair often require guardremoval. Other means of protectingmaintenance personneloften required(lockout/tagout).AdjustableBarrier that adjusts fora variety of productionoperations. Can be constructed tosuit many applications. Can be adjusted to admitvarying stock sizes. May require frequentmaintenance oradjustment. Operator may makeguard ineffective.SelfAdjustingBarrier that movesaccording to the size of thestock entering point ofoperation. Guard is in placewhen machine is at restand pushes away whenstock enters the point ofoperation. Off-the-shelf guards areoften commercially available. Does not providemaximum protection. May require frequentmaintenance andadjustment.InterlockingBarrierGuardsShuts off or disengagespower and preventsmachine start-up whenguard is open. Shouldallow for inching ofmachine. Allows access for someminor servicing work, inaccordance with the lockout/tagout exception,without time-consumingremoval of fixed guards. May require periodicmaintenance or adjustment. Movable sections cannotbe used for manual feeding. Some designs may beeasy to defeat. Interlock control circuitrymay not be used for allmaintenance and servicing work.1 2Occupational Safety andHealth Administration

Safeguarding DevicesSafeguarding devices are controls or attachmentsthat, when properly designed, applied and used,usually prevent inadvertent access by employees tohazardous machine areas by: Preventing hazardous machine component operation if your hand or body part is inadvertentlyplaced in the danger area;Restraining or withdrawing your hands f

the General Duty Clause of the Act, employers must provide their employees with a workplace free from recognized hazards likely to cause death or serious physical harm. Employers can be cited for violating the General Duty Clause if there is a recognized hazard and they do