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Guide to safeguarding common machinery and plant

Workplace Health and Safety Queensland

csq/05/2432

Workplace Health and Safety QueenslandTelephone: 1300369915Website: www.dir.qld.gov.au

ThinkSafe–Work Smart

Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland �

Contents

Section 1 – What is machinery and plant? 5

Section 2 – The risk management process 5

2.� Identifyingmachineryorplanthazards 5

2.2 Assessingtheriskofidentifiedhazards 9

2.3 Decidingoncontrolmeasures �0

2.4 Implementingcontrolmeasures �2

2.5 Monitoringandreviewingeffectivenessofcontrolmeasures �3

2.6 Keepingdocumentationandrecords �3

Section 3 – Guard design 18

3.� Typesofguards �8

3.�.� Fixedguards �8

3.�.2Interlockingguards �8

3.�.3Automaticguards �9

3.�.4Distanceguards 20

3.�.5Tripguards 20

3.2 Basicrulesforguarddesign 2�

3.3 Servicingconsiderations 2�

3.4 Ergonomicconsiderations 2�

3.4.�Reachmeasurements 2�

3.4.2Guardplacement 22

Section 4 – Guards for different machine types 24

4.� Exposedrotatingcuttingprocesses 24

4.2 Pulleysanddrives 24

4.3 Rotatingshaftsandrollers 25

4.4 Safetydevices 25

4.5 Combinationofguardingandsafetydevices 26

4.6 Safeworkrulesandpractices 26

4.6.�Isolation 26

4.6.2Emergencystopdevices 26

4.6.3Inspection,cleaning,repair,maintenanceandemergencyprocedures 27

4.6.4Openingandremovingguards 27

Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland2

4.6.5Weight 27

4.6.6Interactions 27

4.6.7Colourcoding 27

Section 5 – Safeguarding of power presses, conveyors and robotics 28

5.� Powerstampingpresses 28

5.�.�Hazardsandrisks 28

5.�.2Controlmeasures 28

5.2 Pressbrakes(mechanicalandhydraulic) 30

5.2.�Hazardsandrisks 30

5.2.2Controlmeasures 30

5.3 Conveyors(bulkhandling) 3�

5.3.�Hazardsandrisks 3�

5.3.2Controlmeasures 3�

5.4 Robotics 33

5.4.�Hazardsandrisks 33

5.4.2Controlmeasures 34

Section 6 – Other machinery safety issues 37

6.� Workorganisation 37

6.�.�Layout 37

6.�.2Housekeeping 37

6.�.3Workpractices 38

6.2 Workenvironment 38

6.2.�Dust 38

6.2.2Lighting 38

6.2.3Noise 39

6.2.4Hotandcoldenvironments 39

6.2.5Ventilation 39

6.2.6Confinedspaces 40

6.2.7Electricalsafety 40

6.3 Minimisinghumanerror 40

6.4 Registrableplant 42

6.5 Registrableplantdesign 42

Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland 3

Section 7 – Further information 43

7.� StandardsAustralia 43

7.2 Consultingengineers 43

7.3 Workers 43

7.4 Industryassociationsandsimilarworkplaces 43

7.5 WorkplaceHealthandSafetyQueensland 43

Appendix 1 – Machinery and plant hazard list 44

Appendix 2 – Dictionary of defined terms 47

Appendix 3 – Risk Assessment Form 50

Appendix 4 – Risk Assessment Template 52

Appendix 5 – Australian Standards 53

Disclaimer

TheinformationprovidedinthispublicationisdistributedbytheQueenslandGovernmentasaninformationsourceonly.

Theinformationisprovidedsolelyonthebasisthatreaderswillberesponsibleformakingtheirownassessmentofthemattersdiscussedhereinandareadvisedtoverifyallrelevantrepresentations,statementsandinformation.

ForspecificinformationonmattersdiscussedinthispublicationpleaserefertotheWorkplace Health and Safety Act 1995.

©TheStateofQueensland(DepartmentofIndustrialRelations)

April2006


PurposeThe Guide to safeguarding common machinery and planthasbeendevelopedtohelppeopleconductingabusinessorundertaking(includingemployersandself-employedpeople)andworkerstoensurecommonmachineryandplantintheworkplaceissafeandwithoutrisktohealthandsafety.

Thisguideraisesawarenessofarangeofhazardsassociatedwithcommonmachineryandplant,aswellasrisksthatmayresultfromthesetypesofhazards.Practicaladviceisprovidedinrelationtothemethodsthatcanbeusedtosafeguardcommonmachineryandplantintheworkplace,andadviceonhowtoselectandimplementtheappropriatesafeguards.

Thisisachievedbyusingariskmanagementapproachwherebyhazardsareidentified,thedegreeofriskofeachhazardisassessed,controlmeasuresareidentifiedandimplementedandfinally,monitoringandreviewoftheeffectivenessofthechosencontrolmeasuresisperformed.

Itshouldbenotedthattheinformationcontainedinthisdocumentisintendedforguidanceonly,andthattheremaybeadditionalhazardsandsubsequentrisksatyourworkplacewhichhavenotbeenspecificallyaddressedinthisguide.YouarestillrequiredundertheWorkplace Health and Safety Act 1995toidentifyandassesstheserisksandensurethatappropriatecontrolmeasuresareimplementedandreviewedtopreventorminimiseexposuretotheserisks.

Note: This guide should be read in conjunction with the primary source document, the Plant Code of Practice 2005. In addition to this, other important documents that should also be read in conjunction with this guide are the Workplace Health and Safety Act 1995, Risk Management Advisory Standard 2000, Australian Standard 4024.1 – 1996 Safeguarding of machinery - General principles, other Australian Standards as identified in Appendix 5 and relevant manufacturer’s instructions and operator’s instructions/manuals.


Section 1 – What is machinery and plant?Machineryisacollectivetermformachinesandtheirparts.Amachineisconsideredtobeanyapparatusthathasinterrelatedpartsandisusedtoperformwork.

Planthasabroadermeaningandincludesmachinery.Otheritemsofcommonplantintheworkplaceincludeequipment,implementsandtools.Fittings,connectionsandaccessoriesarealsoconsideredtobeplant.

Thisguidefocusesontheguardingofmachinerycommonlyfoundinworkplaces,butalsoconsidersotheritemsofplant.Toremindreadersofthis,theguidediscussesmachineryandplanttogether.

Section 2 – The risk management processThehazardsassociatedwithoperatingcommonmachineryandplantarenotalwaysobvious,andtherearegenerallyanumberofelementsthatwillaffectsafeoperation.Theriskmanagementapproachwillhelpyoumakeajudgmentabouttherisksassociatedwiththesehazardsandimplementappropriatecontrolmeasures.

TheriskmanagementapproachisoutlinedundertheWorkplace Health and Safety Act 1995andinvolves:

�. identifyinghazards2.assessingrisksthatmayresultbecauseofthehazards3.decidingonappropriatecontrolmeasurestopreventorminimisetheleveloftherisks4. implementingthechosencontrolmeasures5.monitoringandreviewingtheeffectivenessofthechosencontrolmeasures.

Thesefivestepsarecommonlyknownastheriskmanagementprocess.ThisprocessisoutlinedcomprehensivelyintheRisk Management Advisory Standard 2000.

2.1 Identifying machinery or plant hazardsThefirststepinassessingtherisksassociatedwithmachineryandplantistoidentifyallitemsofplantusedintheworkplace.Aninspectionoftheworkplaceshouldbecarriedoutlookingforanyoftheseitems.Thedesiredoutcomeofthisstepisalistofallitemsofmachineryandplantthatposepotentialhazards.

Thehazardsassociatedwithmachineryandplantincludemechanical,biological,chemical,psychologicalandergonomichazards.Mechanicalhazardsareamajorcauseofinjuryassociatedwiththeoperation,maintenanceandrepairofmachineryandplant.Mechanicalhazardsincludecuttingandsevering,crushing,shearing,impactandentanglement.

Startbyidentifyingallmachineryandplantoperatedattheworkplaceandassociatedwithanyworkperformed.Includecommonitemsthatposepotentialhazardsthatmaynotnormallybethoughtofas‘machines’orplant.Theseitemsmayincludeofficemachines,suchaspaperguillotinesandautomaticstaplers.

Checkbothinsideandoutsidetheworkenvironmentformachineryandplantthatmayposearisktopeopleintheworkplace(e.g.garbagecompactorsoperatedoutside).Ifworkisnormallydoneatotherlocations,mobileplantandtoolsusedattheselocationsshouldalsobeincluded.


Onceallmachineryandplanthasbeenidentified,thehazardsassociatedwiththeseitemscanbeidentified.Critically inspect each piece of machinery and plant and the way it is operated to identify any parts, processes or operating procedures that may cause harm.

Amethodofidentifyingmachineryandplanthazardsistoconsiderthefollowingfactors:

• tasks(operating,cleaning,adjusting,setting-up,maintaining,repairingorworkingonamachine,e.g.powerpress,foodslicer)—considerallactivitiesthattakeplace

• locations(proximitytoothermachinesandworkprocesses,fixedplant,portableplantandtools)• installationofplant(safeandcorrectinstallation)• productionprocesses(forming,finishing)• useofmobileplantatotherlocations• safetransportationofmobileplant.

Byconsideringthesefactors,thefullrangeofhazardsassociatedwiththemachineryorplantcanbeidentified.

Wheremachineryandplanthazardsarenotimmediatelyobvious,therearemanyotheractivitiesthatcanbeundertakentohelpidentifythem.Theseinclude:

• testing,particularlyofplantandotherequipmentandnoiselevels• scientificortechnicalevaluation• analysingrecordsanddataincludingworkers’compensationclaims,incidentsandnearmisses,

workercomplaints,sickleaveandstaffturnover• acquiringinformationfromdesigners,manufacturers,suppliers• acquiringinformationfromotherorganisationssuchasunions,employerbodies,occupational

healthandsafetyconsultants• environmentalandmedicalmonitoring• undertakingworkersurveys.

Examining the activities performed at the workplace and the related danger zones (such as moving parts) of plant and machinery will assist in identifying hazards.Thesehazardsmayinclude,butarenotlimitedtothoseillustratedbelow.

These machines and items of plant are shown in their unguarded state to demonstrate the hazards and danger zones.

Illustration 1-drawinginpointsbetweentwocounter-rotatingparts


Illustration 2–in-runningnippointsbetweenrotatingandtangentiallymovingsurfaces

Illustration 3-shearpointsbetweenamachinerypartandaworkpiece

Illustration 4-cuttingareasonabandsaw

Illustration 5-impactandcrushingareas


Illustration 6-entanglementcausedbycontactwithasinglerotatingsurface

Illustration 7-stabbingpointscausedbymovingpartsofmachineryormaterial

Illustration 8-abrasionareas Illustration 9-flyingparticles

Illustration 10-protrusionscancauseinjuryfromentanglement


Manyofthetypesofhazardsillustratedcanusuallybeeffectivelymanagedbytheinstallationofphysicalbarriers.Examplesofwaystocontrolthesehazardsareaddressedinsection3(Guarddesign)andsection4(Guardsfordifferentmachinetypes).

Beforeproceedingtothenextstepofassessingrisk,youshouldidentifyifthehazardsareissuesaboutwhichthereisaregulationorcodeofpractice(madeundertheWorkplace Health and Safety Act 1995)orguidancematerial(producedbyWorkplaceHealthandSafetyQueensland).TheCode of Practice for Plant 2005 alsoencouragespeopletoconsultarangeofAustralianStandardsandoverseasstandardstoassistintheprocessofensuringmachinesafetyandsafeoperation.

Itisalsoimportanttoconsiderthatthereareotherspecifichazardsassociatedwithmachineryandplantthatarenotassociatedwiththeactualmechanicaloperation.Therisksassociatedwiththesehazardsshouldalsobeidentified,assessedandmanaged.Theserisksinclude:

• releaseofsubstances—machineryorprocessesmayreleaseorproducesubstancesormaterials,maybeasaby-product,whichishazardous.Examplesincludefumes,chemicalsandmetalfilings

• noise—noiselevelsmaychangeatdifferentstagesofuse• hotorcoldmachineryorplantparts—sourcesofheatcanincludefriction,moltenmaterial,hot

metalshavings,hotgases,nakedflames,radiantheat.

Section6(Othermachinerysafetyissues)providesmoreinformationinrelationtothesespecificissues.

2.2 Assessing the risk of identified hazardsAriskassessmentseekstoprioritiseidentifiedhazardssothatrisksassociatedwitheachhazard(thosethathavethepotentialtocauseharm)canbeeliminatedorreduced.Identifiedhazardsareassessedtodeterminetheirrealpotentialtocauseinjury.

Whereahazardisidentified,anassessmentofrisksassociatedwiththehazardshouldbeundertaken.Separateriskassessmentsshouldbecarriedoutforeachmachineandanyassociatedsystemofworkusedwiththatmachine.Ifanyalterationormodificationismadetothemachine,ariskassessmentshouldberepeated.

Therearethreestepsinassessingrisks:

Step�Foreachhazard,estimatethelikelihoodofanincidentoraccidentoccurringattheworkplaceorwhileconductingtheworkactivity.Existingcontrolmeasuresshouldbeconsideredseparately,astheymaynotnecessarilycontroltherisk,butcreateadditionalhazards.

Step2Foreachhazard,estimatetheconsequencesofanincidentoraccidentoccurringattheworkplaceorwhileconductingtheworkactivity.Existingcontrolmeasuresshouldbeconsideredseparately,astheymaynotnecessarilycontroltherisk,butcreateadditionalhazards.

Step3Combinetheseestimatesoflikelihoodandconsequencetodetermineariskratingforeachhazard.ThiscanbeeasilyreadfromtheRiskAssessmentPriorityChart.Thischartrankstherisksintermsoftheirpriorities.

ForexampleifthepossibilityofinjuryfromaparticularitemofplantormachineryplantisPOSSIBLE(couldhappen,butrarely)andtheconsequencesofsuchaninjuryareMAJOR(seriousinjuries),thentheriskscoreis4.

Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland�0

Risk Assessment Priority Chart

Likelihood: ProbabilityHowlikelythatitcouldhappen?

Consequences:Howseverelycouldithurtsomeone?

EXTREMEdeath, permanent disablementcatastrophickills,disables,permanentinjury

MAJORserious bodily injurymajorsignificantinjury,notpermanent

MODERATEcasualty treatmentminorfirstaidonly,nolosttime

MINORfirst aid only, no lost time

Very likelyCouldhappenfrequently

� 2 3 4

LikelyCouldhappenoccasionally

2 3 4 5

PossibleCouldhappenbutrarely

3 4 5 6

UnlikelyCouldhappen,probablyneverwill

4 5 6 7

Thefollowingscoresindicatehowimportantitistodosomethingabouteachrisk:

Score Action

�,2or3 Dosomethingabouttheserisksimmediately

4or5 Dosomethingabouttheserisksassoonaspossible

6or7 Theserisksmaynotneedimmediateattention

Onceeachriskhasbeenrated,aprioritisedlistofworkplacerisksrequiringactioncanbedeveloped.

AtemplateforaRiskAssessmentFormisincludedinappendix3.Thiswillhelptoassesstherisksposedbymachinery.Thisformcanbephotocopiedasmanytimesasneeded.Itissuggestedthatoneformbeusedpermachine,orpartofamachineifthereareseveralhazards.Thisformmaybeadaptedforotherthingssuchaspurchase,installation,maintenanceandworkprocessesrelevanttomachinesintheworkplace.

2.3 Deciding on control measuresOnceeachhazardhasbeenrated,aprioritisedlistofworkplacerisksrequiringactioncanbedeveloped.TheRiskAssessmentForm(appendix3)willhelptoassesstherisksposedbymachinery.

Onceaprioritisedlisthasbeenmade,controlmeasurestoeliminateorreducetheassessedriskscanbedecidedon.Whereanassessmentidentifiesaneedtocontrolarisktohealthandsafety,

Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland ��

thatriskshouldbeeliminated,orwhereitcannotbeeliminated,minimisedtoasafelevel.Controlmeasuresshouldbechosenfromthemostpreferredmethodtotheleastpreferredmethodbyusingthehierarchyofcontrol.

UndertheWorkplace Health and Safety Act 1995,apersonmustconsidertheappropriatenessofcontrolmeasuresinthefollowingorder:

A.eliminatethehazardorpreventtheriskB.ifeliminatingthehazardorpreventingtheriskisnotpossible,minimisetheriskbythecontrol

measureslistedbelow.Thesecontrolmeasuresmustbeconsideredinthefollowingorder:�. substitutethehazardwithahazardoflesserrisk2.isolatethehazardfromanyonewhomaybeatrisk3.minimisetheriskbyengineeringmeans4.applyadministrativemeasures5.usepersonalprotectiveequipment.

Thehierarchyofcontrolmeasuresisexplainedinmoredetailbelow.

Elimination—thisisthemosteffectivemethodofcontrolandshouldalwaysbeattemptedfirst.Forexample,discontinuedangerouspracticesorremoveordisposeofdangerousequipment.

When elimination is not practicable Eliminatingamachineorprocessfromyourworkplacemaynotalwaysbepracticable.Inthesesituationsthefollowingcontrolmeasuresshouldbeconsideredinthefollowingorder.

Substitution—replacingamaterialorprocessassociatedwithplantwithalesshazardousonewillreducerisk.Forexample,replaceanunstablepedestalfanwithawallorceilingmountedmodel,orusealesshazardousprocessorpartsuchasmouldedplasticprocessinsteadofpressedmetalmanufacturingprocess.

Isolation—isolating(orseparating)aprocessormachinefromworkerscanbeachievedbyeitherdistancingtheprocessormachinewiththerestoftheworkplace,orbyinsertingaphysicalbarrierbetweentheprocessormachineandworker.Forexample,installacousticboothsaroundnoisyequipmentoruseremotehandlingequipmentsuchasapush-stick.

Engineering—thedesign/redesignandinstallationofequipmenttocounteracthazardsareconsideredengineeringcontrols.Forexample,installanexhaustventilationsystemtoextractdangerousfumes,orredesignanelectricalsystemtoallowfortheinstallationofemergencystopbuttonswithineasyreachofoperatorsofmachineryorplant.

When exposure is not or cannot be minimised by other means?Controlbytheabovemeansisnotalwayspracticable.Evenwhereoneormoreoftheabovecontrolmeasureshasbeenimplemented,additionalcontrolmeasuresshouldbeconsidered.

Thefollowingmethodsshouldnotberelieduponastheprimarymeansofriskcontrol,untiltheabovecontrolshavebeenconsidered.Theyaredependentonhumanbehaviourandrequiremanagement,enforcementandcommitmenttoworkeffectively.Theymaybeusedasaninterimmeasureuntilhigherlevelcontrolsareimplemented.

Administration—administrationcontrolsareproceduresorinstructionsyoucanputinplacetominimiseexposuretoarisk.Thesecontrolscanincludethetimeofwork,hoursofwork,whodoestheworkandwhohasaccesstoworkareas,machineryorplant.Forexample,trainworkersintheproperproceduresandprocessesforoperatingmachineryorplant,andlimitexposuretoortheamountoftimespentdoinghazardousworkactivities.


Personal protective equipment—personalprotectiveequipmentmeansclothing,equipmentorsubstanceswhich,whenworncorrectly,protectpartorallofthebodyfromrisksofinjuryordiseaseatworkorintheworkplace.Forexample,itincludesprotectiveeyewear,protectivehearingdevices,sturdyglovesormeshglovestopreventcuttinginjuries.Thecontrolofexposuretomachineryorplantrisksshouldbesecuredbyoneormoremeasuresotherthantheprovisionofpersonalprotectiveequipment.Useofpersonalprotectiveequipmentistheleasteffectivemethodofcontrollingrisk,althoughalong-termstrategyusingothermethodsmayrequiretheshort-termuseofpersonalprotectiveequipmenttoattainthisaim.Forexample,youmaydecidetoreplacenoisymachineryorplantwithaquieterversion.Intheinterim,protectivehearingdevicesareprovidedtoworkersexposedtothenoisymachineryorplant.

Topreventorminimiseexposuretoarisk,acombinationoftheabovemethodscanbeimplementedconcurrently.Forexample,acombinationofisolation,administrativeandpersonalprotectiveequipmentcontrolmeasurescanbeusedatthesametime.Byusingacombinationofcontrolmeasures,riskisreducedfurtherandthereislessrelianceonasinglecontrolmeasureshoulditfail.

Thechosenmethodofcontrollingtheriskshouldberecorded.AsampleformatofrecordingcontrolmeasurescanbefoundintheRisk Assessment Form(appendix3).Ifthepreferredcontrolmeasurecannotbeimplementedimmediately,theformcanbeusedtonotethecontrolsintendedtobeusedimmediatelyasashort-termsolution,andwhatisintendedtobedonelaterasalong-termsolution.Implementationtimeframesshouldberecordedandthedocumentreviewedregularly.

2.4 Implementing control measuresTheselectedcontrolmeasuresneedtobeimplementedformachineryorplantrequiringsafeguardingtoensurethereisnorisktoworkersorothers.Thismeansundertakingthoseactivitiesnecessarytoallowthecontrolmeasurestofunctionoroperateeffectively.Implementingcontrolmeasuresinvolves:

• Developing work procedures Workproceduresshouldbedevelopedinrelationtothenewcontrolmeasurestoensuretheir

effectiveness.Management,supervisionandworkerresponsibilitiesneedtobeclearlydefinedintheworkprocedures.Inrelationtotheuseofmachineguarding,themanager’srolemayinvolveensuringtheappropriateguardingispurchasedandthatitisinstalledcorrectly.Thesupervisor’srolemayinvolveensuringtheworkersoperatethemachineonlywiththeguardinginplace.Theroleofworkersmayinvolveusingthemachinewithguardinginplaceasinstructedorthemaintenanceofthemachineandguard.

• Communication Workersshouldbeinformedaboutthecontrolmeasurestobeimplemented.Itisimportantto

clearlycommunicatethereasonsforthechanges.Informationmayalsoneedtobeprovidedtootherswhomayentertheworkplace,includingcleaners,visitorsandcontractstaff.

• Providing training and instruction Trainingandinstructionshouldbeprovidedfortheworkers,supervisorsandothersinrelation

tothenewcontrolmeasures.Thismayincludesafeuseandoperationofguards,breakdownprocedures,andrepairandmaintenanceasappropriate.

• Supervision Adequatesupervisionshouldbeprovidedtoensurethatthecontrolmeasuresarebeingused

correctly.

Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland �3

• Maintenance Maintenancerelatingtocontrolmeasuresisanimportantpartoftheimplementationprocess.

Workproceduresshouldclearlyidentifymaintenancerequirementstoensuretheongoingeffectivenessofthenewcontrolmeasures.

2.5 Monitoring and reviewing effectiveness of control measuresThefinalstepintheriskmanagementprocessistomonitorandreviewtheeffectivenessofcontrolmeasures.Forthisstep,itcanbeusefultoaskquestionssuchas:

• Havecontrolmeasuresbeenimplementedasplanned?• Arethesecontrolmeasuresbeingused,ifso,aretheybeingusedcorrectly?• Arecontrolmeasuresworking?• Havechangesmadetocontrolexposuretotheassessedrisksresultedinwhatwasintended?• Hasexposuretotheassessedrisksbeeneliminatedoradequatelyreduced?• Haveimplementedcontrolmeasuresresultedintheintroductionofanynewhazards?• Haveimplementedcontrolmeasuresresultedintheworseningofanyexistinghazards?

Inordertoanswerthesequestions,youcan:

• consultwithworkers,supervisorsandhealthandsafetyrepresentatives• measureexposure(e.g.takenoisemeasurementsinthecaseofisolationofanoisesource)• refertooccupationalhealthandsafetyconsultantsandrepresentativesofindustryassociations,

unionsandgovernmentbodies• refertomanufacturer’sinstructions• monitorincidentreports.

Youshouldsetadatetoreviewtheentireworkplacehealthandsafetyriskmanagementprocess.Reviewsshouldbeconductedatleastonceevery�2months,howevermayberequiredmorefrequentlydependingonindividualvariablesattheworkplace.Thefrequencyofreviewsshouldbedeterminedbytheriskmanagementprocess.

Riskmanagementisongoingandtheresultsofriskmanagementshouldbeupdated,whetherornottheprocessiscomplexandwhetherornottheresultsarerecorded.Theriskmanagementprocessshouldberepeatedatintervalsandwheneverthereisreasontosuspecttheresultsarenolongervalidbecause:

• newplantisintroduced• plantismodifiedsoitdeviatesfromtheoriginaldesign• thereisachangeinworkpracticesassociatedwithplant• thereisacomplaintfromworkers.

2.6 Keeping documentation and recordsAdequaterecordingoftheriskmanagementprocessundertakeninregardstoplantandmachinerywillhelpyoutodemonstratethatyouhavebeenactivelyworkingtoensureworkplacehealthandsafety,shouldyouneedtoprovethis.

Keepingrecordswillalsohelpyoukeeptrackofwhatyouhavedoneandareplanningtodo.Thisshouldmaximisetheeffectivenessoftheprocess.Atemplateforrecordingtheentireriskmanagementprocessisprovidedinappendix4.Thistemplatecanbephotocopiedasmanytimesasneeded.Itissuggestedthatoneformbeusedpermachine,orpartofamachineifthereareseveralhazards.ThistemplateshouldbeusedinconjunctionwiththeRiskAssessmentForm(appendix3).


Thedetailandextentofrecordingwilldependonthesizeofyourworkplaceandthepotentialformajorworkplacehealthandsafetyissues.

Case studyThereareanumberofwaysinwhichtheriskmanagementprocesscanbecarriedout.Acasestudyhasbeenusedinthissectionoftheguidetodemonstrateonemethodofconductingtheriskmanagementprocess.Thiscasestudyassessestheriskfrommechanicaltypehazards,specificallycuttingandseveringhazardsassociatedwithusingamachiningcentre.

Amachiningcentreisanumericallycontrolledmachinetool,capableofperformingmultiplemachiningoperationsandabletochangetoolsautomaticallyfromamagazineorsimilarstorageunit.Theoperationsthatmaybeperformedincludemilling,boring,drilling,cuttingandtapping.

Itshouldbenotedthatcuttingandseveringhazardsarejustoneofthemanymechanicalhazardsassociatedwithmachineryandplant.Othermechanicalhazardsincludecrushing,shearing,impactandentanglement.Therearealsoothertypesofhazards,otherthanmechanicalhazards,whichareassociatedwithmachineryandplant.Thesehazardsincludebiological,chemical,psychologicalandergonomichazardtypes.Forthepurposeofthecasestudy,onlycuttingandseveringhazardsareoutlined.

Whenidentifyinghazardsassociatedwithplantandmachinery,itisbeneficialtolistthesituationsortaskswherethehazardmayoccur,anyassociatedactivitywiththesesituationsandtherelateddangerzones.

Appendix�containsalistofhazardsandsomedescriptionsofthesehazardsastheyrelatetomachineryandplant.Thislistshouldbeconsultedwhenundertakingariskassessmentonmachineryandplantandwillassisttoidentifyhazards,associatedactivitiesandsituationsanddangerzones.

Thecasestudybelowliststhehazardoussituations,associatedactivitiesandrelateddangerzonesrelevanttocuttingandseveringhazardspresentwhenusingamachiningcentre.

1. Identify hazards

Description of hazard Example of related hazardous situation

Associated activity Related danger zone

Cuttingandsevering Spindleortoolrunningorcutting

Spindlerunning Atspindleortool

2. Assess risks

Therearethreepartstothisstep:

(a) Estimatethelikelihoodofanincidentoraccidentoccurringattheworkplace.

Likelihood: How likely that it could happen?

Very likely couldhappenfrequently

Likely couldhappenoccasionally

Unlikely couldhappenbutrare

Very unlikely couldhappen,probablyneverwill


Inthisexample,thepossibility(likelihood)ofinjuryfromapersoncomingincontactwitharunningorcuttingspindleortoolisassessedaslikely,i.e.itcouldhappenoccasionally.

(b) Estimatetheconsequencesofanincidentoraccidentoccurringattheworkplace.

Consequences: How severely could it hurt someone?

Extreme death,permanentdisablement

Major seriousbodilyinjury

Moderate casualtytreatment

Minor firstaidonly,nolostworktime

Theconsequenceoftherunningorcuttingspindleortoolcomingincontactwithapersonisassessedasextreme,i.e.deathorpermanentdisablement(suchasanamputation).

(c) Combinetheseestimatesoflikelihoodandconsequencestodetermineariskratingforeachrisk.ThiscanbeeasilyreadfromtheRiskAssessmentPriorityChartbelow.Thischartrankstherisksintermsoftheirpriorities.


Likelihood: ProbabilityHowlikelythatitcouldHappen?


EXTREMEdeath, permanent disablement

MAJORserious bodily injury

MODERATEcasualty treatment



� 2 3 4


2 3 4 5


3 4 5 6


4 5 6 7

Thefollowingscoresindicatehowimportantitistodosomethingabouteachrisk:

Score Action

�,2or3 Dosomethingabouttheserisksimmediately

4or5 Dosomethingabouttheserisksassoonaspossible

6or7 Theserisksmaynotneedimmediateattention


Inthisexample,ariskratingof2iscalculated.Thisscoremeansthatsomethingmustbedoneaboutthisriskimmediately.Theassessmentcannowberepeatedforallotheridentifiedhazardsandsituations.

3. Determine controls

Associated activity

Related danger zone

Risk assessment Control

Score Action

Spindlerunning

Atspindleortool

2 Dosomethingabouttheserisksimmediately

Eliminationnotpossible.Substitutionnotpossibleatthispointintimeandwillbeconsideredasalong-termsolutionattheendofthemachiningcentre’slife.

Machiningcentreswillbesafeguardedwhereverpossiblebyfixedand/orinterlockingmoveableguards.Iffloor-mounted,theguardsshallbesecurelyfixed,ofadequateheightandfixedatasufficientdistancefromthedangerzones.Protectivedevicesmaybeusedwherefixedandinterlockingguardsarenotpossible(seeAS4024).

Meansshallbeprovidedforthemovementofmachineaxesforemergencypurposes(e.g.releaseoftrappedpeople).Thesemeansareforexample:

a) withpoweroff:-reliefvalvestodepressurisesystemsunderpressure

-manualreleaseofpower-actuatedbrakesprovidedthatweight-balancingexists

b) withpoweron:-manualcontrolfacilitiesofpower-pilotedvalves/drives

-controlfacilitiestostartcountermotions.

Controlswouldnowneedtobechosenforallotherhazardsassociatedwiththemachiningcentre.Thesewouldbeconsideredinorderofthehazards,withthehighestrisksfirst.


4. Implement controls

Associated activity Related danger zone Implementation

Spindlerunning Atspindleortool Priortointerlockingmoveablesafeguardsbeingfitted,thefollowingactivitieswillbeperformed.Theseactivitiesrelatetotheuseofthemachiningcentreafterbeingfittedwiththesafeguards:

(a) workprocedureswillbedeveloped,withinputfromworkers,formachinecentreuse,cleaning,maintenanceandemergencies

(b) training,instructionandinformationwillbeprovidedtoworkersregardingoperating,cleaning,maintenanceandemergencies

(c) supervisionwillbeprovidedtoensurecorrectuseandthatproceduresarefollowed.

5. Monitor and review controls

Associated activity Related danger zone Monitoring and reviewing

Spindlerunning Atspindleortool Supervisortocontinuallymonitorcompliancewithdevelopedprocedures.

Retraining(includinginstructionandinformationprovision)tobeprovidedwhenthereisachangetoworkpracticesormachineuseandatleastevery6months.

Operation,cleaning,maintenance,emergencyandotherprocedureswillbereviewedwhenthereisachangetoworkpracticesormachineuseandatleastevery6months.

Safeguardtobemaintainedregularly(atleasteverymonth).

Safeguardtobereviewedascontrolwhenthereisachangetoworkpracticesormachineuseandatleasteverysixmonths.

Whenthetimecomestoreplacethemachine,eliminationandsubstitution(saferalternatives)willbeconsidered.

Monitoringandreviewprocedureswouldnowbedevelopedforallhazardsassociatedwiththemachiningcentre.


Section 3 - Guard design3.1 Types of guards

TechnicalassistancemaybefoundinrelevantAustralianStandards.ThestandardswithparticularrelevancetosafeguardingcommonmachineryandplantarelistedinAppendix5,togetherwithabriefdescriptionoftheircontents.Thesestandardsshouldbeconsultedforadditionalinformation.

Thereareanumberofdifferenttypesofguardsavailable,allsuitedtoparticularpurposes.Dependingonthesituation,acombinationoftwoormoreofthefollowingmeasuresmaybeusedtoensureworkers’safety.Therangeofguardsincludesbutisnotlimitedtofixed,interlocking,hinged,movablebarrier,automatic,distanceandtripguards.Examplesofthesetypesofguardsaredetailedbelow.

3.1.1 Fixed guardsFixedguardsarestationaryguardsandpreventcontactbetweenmovingmachinerypartsandanypartofthebody.Theyofferprotectiononlywhenproperlyfixedinposition.Fixedguardsshouldbeeasytoremoveandreplace,butonlybeabletobeopenedorremovedwiththeaidofatoolandwhenthemachineisnotinoperation.

Illustration 11-Anexampleofafixedguard.

3.1.2 Interlocking guardsInterlockingguardspreventmachineryandplantfrombeingoperated,unlesstheguardisinplace.Interlockingguardssuchasenclosureguardsareknownasmovableguardsandhavethemovingpartinterconnectedwiththecontrolsystem.Interconnectionsareusuallyelectrical,mechanical,hydraulicorpneumatic.


Examplesofmovableinterlockingguards,whichareinterlockedwiththepowersourceofthehazardtoensurethatwhenevertheguarddoorisnotclosedthehazardpowerisswitchedoff,areshownbelow:

Illustration 12-Anexampleofahingedoorguard(interlockingmovableguard)

Illustration 13-Anexampleofaslidingdoorguard(interlockingmovableguard)

3.1.3 Automatic guardsAutomaticguardsareself-adjustingandautomaticallymoveintopositionasthemachineorcyclestarts.Theyarealsoknownaspush-awayguards.Theseareonlysuitableonslowmachines.

Illustration 14-Anexampleofapush-awayguard(automaticguard)


3.1.4 Distance guardsDistanceguardspreventaccesstodangerousareasthroughabarrierorfence.Anyaccesspointsthroughtheguard(e.g.gatesanddoors)mustbesecuredwithalockorinterlockingsystem.

Illustration 15-Anexampleofadistanceguardfittedtothepressbrake

3.1.5 Trip guardsTripguardsarepresence-sensingandstopthemachinewhenapersongetsintoapositionwheretheyareliabletobeinjured.Photoelectriccurtains,laserscannersandpressurematsareexamplesofthistypeofguard.

Illustration 16-Anexampleofaphotoelectriclightcurtainusedasatripguard.Whenanyofthebeamsareblockedbyintrusiontowardsthehazardarea,thelightcurtaincontrolcircuitswitchesoffthehazardpower.

AS4024.1Safeguarding of machinery – General principlesprovidesmoreinformationinrelationtotypesofguardsandcategoriesofreliability.Thisstandardshouldbeconsultedforadditionalinformation.

AS61508.1 Functional safety of electrical/electronic/programmable electronic safety-related systems – General requirementsprovidesmoreinformationinrelationtosafetyintegritylevels.Thisstandardshouldbeconsultedforadditionalinformation.

Guide to safeguarding common machinery and plant | Workplace Health and Safety Queensland 2�

3.2 Basic rules for guard designTheprimaryfunctionofaguardistoprovideaphysicalbarrierbetweenaworkerandthedangerouspartsofmachineryorplant.Whenselectingcontrolmeasures,carefulattentiontodesignandlayoutattheoutsetcanavoidlaterproblems.Basicrulesforguarddesigninclude:

• ensurethematerialsusedareofsuitablestrengthandgoodquality• havinganysortofguardmaynotbeenough.Poorlydesignedorinappropriateguardinghas

contributedtoinjuriesfrommachineryorplant.Ideallyaguardshouldbecustom-designedforthemachineandtheworkprocess

• interlockdevicesmayneedtobeusedinconjunctionwithothertypesofguardingtoensuresafety

• avoidsecondbestwhendesigningaguard.Ifaguardisusedfromanothermachine,itmustbecheckedcarefullytoensurethatitisnotdefective,thatitfitsthetargetmachine,isofsuitablestrengthandqualityforthenewapplicationandthatitachievestheaimofcontrollingtheriskpresentedbythetargetmachine.

Indeterminingthemostappropriatecontrolmeasureforthehazard,riskandmachine,otherissuesorrisksshouldalsobetakenintoconsideration.Guardingcanplayausefulroleinbothdustandnoisereduction.Inmanycases,issuesofwear,heatandventilationaffectoperatingefficiencyandmayalsohaveconsequencesforworkerhealthandsafety.

3.3 Servicing considerationsGuardsshouldbedesignedforeasyremovalandreplacement.Thesetypesofguardmaketaskssuchasregularcleaning,maintenanceandmachineadjustmentorbeltchangeseasier,particularlyifthisworkneedstobedonefrequently.Safeproceduresforremovalofguardsforrepair,ortoclearjamsorbreakdownsmustbeconsidered.Inallcases,guardsshouldbedesignedsotheycanonlyopenorberemovedwiththeaidofatoolandwhenthemachineisnotinoperation.

Servicingissuesinclude:

• documentedsafeworkprocedures,includingreferencetomanufacturer’srecommendations• proximitytohotorsharpparts• cooldownorwarmupperiods• lock-outprovisionsorpermissionforguardremoval• sufficientroomtoperformtaskswithoutriskofinjuryorstrain• anyadditionalhazardsarisingfrommaintenanceprocedures(e.g.testingwhilemachineis

unguarded[‘dryrun’],workingatheights,useofsolvents)• maintenanceofservicingrecords.

3.4 Ergonomic considerationsThefollowingtablesandillustrationswillprovidehelptoassesswhereandwhatsortofguardingisneededtokeepadangerpointonamachinesafelyoutofreach,takingintoaccountthephysicalcharacteristicsofworkers.

3.4.1 Reach measurementsMachinesaredesignedforanaverageworker—typicallya�72cm(5ft8in)male.Ifworkersaresignificantlytallerorshorterthan�72cm,thenemployersshouldconsiderwhetherthestandardmachineguardingmethodsandworkprocessesarestillsafe.


Thedesignandpositioningofguardsshouldprovideatleastthefollowingclearance:

Reach Minimum distance assumedArmreach Greaterthanorequalto850mmfromunderarm

tofingertip

Elbowreach Greaterthanorequalto550mmfromtheinsideelbowtofingertip

Wristreach Greaterthanorequalto230mmfromwristtotipofmiddlefinger

Fingerreach Greaterthanorequalto�30mmVerticalreach 2500mmmaximumwhenstandingontoes

3.4.2 Guard placement

Thesizeofmeshorotheropeningsintheguardandthedistanceoftheguardfromthedangerpointcanbeselectedbasedonthefollowingguide:

Meshsizeopeningsuptoandincluding9mm Distanceofguardfromdangerpointvirtuallythesame

Meshsizeover9mmbutlessthan40mm Guardatleast200mmfromdangerpoint

Alltypesofguards Distancebetweenbottomopeningandfloornottoexceed250mm

Simple gap/distance formula

Thefollowingformulaprovidesaneasymethodfordeterminingtherequiredgapormeshopenings,andthedistancetheguardshouldbefromthedangerpoint:

Gap = Distance + 6mm �0

Noadmittance Reachrestrictedtorootoffinger

Reachrestrictedtorootofthumb

Reachrestrictedtohandthickness


Reaching down and over

Inthefollowingdiagramandtable:

A =distanceofdangerpointfromthefloororworkingsurfaceB =heightofthebarrierC =horizontaldistancetobemaintainedbetweenedgeofbarrieranddangerpoint

Note: Barriers must not be able to be stepped over.

A – distanceofdangerpointfromfloor(mm)

B - heightofthebarrier(mm)

2400 2200 2000 �800 �600 �400 �200 �000

C - horizontaldistancetobemaintainedbetweenbarrieranddangerpoint(mm)

2400 - �00 �00 �00 �00 �00 �00 �00

2200 - 250 350 400 500 500 600 600

2000 - - 350 500 600 700 900 ��00

�800 - - - 600 900 900 �000 ��00

�600 - - - 500 900 900 �000 �300

�400 - - - �00 800 900 �000 �300

�200 - - - - 500 900 �000 �400

�000 - - - - 300 900 �000 �400

800 - - - - - 600 900 �300

600 - - - - - - 500 �200

400 - - - - - - 300 �200

200 - - - - - 200 ��00


Section 4 - Guards for different machine types 4.1 Exposed rotating cutting processesExposedrotatingcuttingmachineryincludescut-offsaws,millingmachines,frictioncuttingandboringequipment.Thehazardarisesfromtheexposedblades,andrisksincludecuttingfleshorlimbs,orentanglement.

Themostappropriatetypesofguardsarefixedormovingguards.

Illustration 17-Self-adjustingguardforadropsaw

Aparticularpointtonoteistheself-actuatingvisorfittedtothefixedguard.Ifthisvisorisnotaffixed,thecuttersteethareexposedwhenthemachineisatthetopofitsstroke.Asthecutterisloweredthevisorautomaticallyrises.

4.2 Pulleys and drivesPulleysanddrivesareusedinarangeofmachinery.Themainhazardisnip-points,andallneedtobeguardedsoastobeoutofreachforoperatorstopreventtheriskofentanglement.

Fixedguardsarepreferredforpulleysanddrives.Insomecases,ahingedsectionmaybeappropriatetoenableaccessduringmachinesetting.Suchcontrolmeasuresmustbedesignedandinstalledsothatatoolisrequiredtoremoveandreplaceaguard.

Illustration 18-Fixedguardforapulleyanddriveconstructedofwiremeshandanglesectionpreventingaccesstotransmissionmachinery


4.3 Rotating shafts and rollersFixedguardsarepreferredforrotatingshaftsandrollers.Guardsmustprovideprotectionagainstlooseclothingandlonghairgettingentwinedwithrotatingshafts.Appropriateworkprocessesmayincludetherequirementthatoperatorsnotwearlooseclothing,andtielonghairbackorwearheadcovering.Examplesofrotatingshaftsincludecouplings,spindles,fan-shaftsandironingrollers.

Illustration 19-Fixedguardonrotatingshaft/coupling

4.4 Safety devicesSafetydevicesaredesignedtosenseapersonorpartofthebodyandinitiatethestoppingofadangerousmotionperformedbythemachinebeforeaccesscanbegainedtoadangerousareasurroundingthemachine.Safetydevicesalsoensurethatapersonorpartofthebodycannotgainaccesstoadangerousareaofthemachineasaresultofthedesign,placementorjunctionofmachinecontrols.Someexamplesofhowsafetydevicescanbeusedareillustratedbelow.

Illustration 20 -Anexampleofaphotoelectriclightcurtainusedasatripguard.Whenanyofthebeamsareblockedbyintrusiontowardsthehazardarea,thelightcurtaincontrolcircuitswitchesoffthehazardpower.

Illustration 21–Two-handedcontrols


Illustration 22-Pressuresensitivemat

4.5 Combination of guarding and safety devicesAcombinationofguardingandsafetydevicescanbeusedtoensureallhazardsandrisksassociatedwiththemachinehavebeenaddressed.Illustratedbelowisanexamplewhereacombinationofguardingandsafetydeviceshasbeenused.

Illustration 23-Papercuttingguillotinefeaturingacombinationofguardingandsafetydevicessuchasphotoelectricguarding,fixedsideguardandtwo-handedpushbuttoncontrols.

4.6 Safe work rules and practices4.6.1 IsolationWiththeexceptionofthosecircuitsrequiredforsafetysystems,allmachineryshouldbefittedwithameansofisolationfromallenergysources.Suchisolatorsshouldbeclearlyidentifiedandbecapableofbeinglockedifreconnectioncouldplacepeopleatrisk.

Anappropriateisolationmethodisalock-out/tag-outsystem,inwhichoneormorepadlocksarefittedtotheisolationswitch,withkeysbeingheldbytheoperatorsormaintenancepersonnel.Theirnameandreasonforthelock-outarewrittenonthetagsattachedtothepadlock.Whenthetaskiscompleted,thelocksandtagsareremovedandpowercanberestored.

4.6.2 Emergency stop devicesEmergencystopdevicesmustbelocatedwhereanoperatorcaneasilyreachthem.Poorlylocateddevicesmayencouragedangerouspractices,suchasreachingacrossmovingparts,afailuretoshutdownmachineryorplantwhenaproblemoccurs,orsituationswherethemachineorplantcanbestartedbyoneworkerwhileanotherisinadangerouslocation(e.g.cleaningabin).


Thenumberofemergencystopdevicesrequiredneedstobeconsidered.Ifthemachineorplantislarge,severaldevicesmaybenecessary.Whentherearemultipledevices,safeoperatingpracticesmustbeadoptedsothatmachineryorplantisnotrestartedwhenitisundergoingmaintenanceorothertemporaryoperations.Alock-out/tag-outsystem,asoutlinedabove,isthereforeanessentialpartofisolatinganenergysourcetopreventaccidentalplantstart-up.

4.6.3 Inspection, cleaning, repair, maintenance and emergency proceduresTosafeguardoperatorsandotherstaff,cleaning,repair,maintenanceandemergencyproceduresmustbeinplaceandunderstoodbyworkers.Aregularinspectionregimeshouldbeinplacetoidentifyanyproblemswithplantandmachineryandsafeguards.Anyadditionalhazardsassociatedwiththeseactivitiesmustbeidentifiedandassessedaspartoftheriskmanagementprocess.Specialprecautionsneedtobetakenwhereworkersundertakingthesetasksareobscured,orwheretherearemultipleoperatingswitches.Applyisolationprocedureswhenevermaintenanceorrepairrequirespeopletoenterthedangerareaaroundmachinery.

4.6.4 Opening and removing guardsGuardsmustonlybeabletobeopenedorremovedwiththeaidofatoolandwhenthemachineisnotinoperation.

4.6.5 WeightLargemachineryorplantmayrequireextensiveguarding,andtheseguardsmayneedtoberemovedformaintenanceaccess.Whilesomesectionsmayremainfixed,itispreferablethattheguardbedividedintoeasilyremovablesections.Sectionsshouldbedesignedtoberemovedandhandledeasilybyoneperson.Appropriateplacementofhandlesonmovablesectionswillfacilitateeaseofremoval,liftingandhandlingandthusreducetheriskofmanualhandlinginjuries.

4.6.6 Interactions Guardsthatmoveoutofthewayforeachoperation(automaticguards)needspecialconsideration.Watchforpotentialrisksintheinteractionsbetweenguardandmachine,betweenguardandpersonandbetweenguardandwork-piece.

4.6.7 Colour codingItisgoodpracticeforallsafetyguardstobepaintedthesamecolour.Forexample,usehighvisibilityyellow(provideditisdifferenttothegeneralmachinerycolour)sothatitcanbeclearlyseenwhenaguardhasbeenremovedorwhenitisnotinitsproperplace.Itisalsogoodpracticetopaintthesurfacesbehindtheguardadifferentcolour(e.g.blueorred),sothatwhentheguardhasbeenremoved,theexposedcolourisclearlyvisible.Itistheneasytoidentifythattheguardhasbeenremovedandworkersarealertedtopossibledanger.


Section 5 – Safeguarding of power presses, conveyors and roboticsDuetotheirinherentrisks,somemachineryandplantrequiresspecificguarding.Specificguardsandpracticesareprovidedhereforconveyorsandforroboticsandforthetwocategoriesofpowerpresses—powerstampingpressesandbrakepresses.Thesemachinespresentanumberofhazardsandrisksrequiringcontrol.

5.1 Power stamping presses Powerstampingpressesaremachinesusedforstampingvariousmaterialsbytheclosingactionoftwoparts—onemoving(punch)andonestationary(die).Theproductisformedwhenthepunchanddiearebroughttogetherbyforcegeneratedbyamotorandflywheel.Therearetwomaindrivesystems—keyclutchandhydraulic.Operationmybeeitherbyautomaticfeedorbymanualoperation,whereeachindividualpieceofmaterialtobeformedisplacedintothedieareabytheoperator.Itisinthismodeofoperationthatmostpowerpressinjuriesoccur.

5.1.1 Hazards and risksThemainhazardofapowerstampingpressiswherethepunchanddiecometogethertoformtheproduct.Theimpactwouldhaveacrushing,cuttingorshearingmotionwhichcreatesariskofhavingapartofthebodycrushedorcut.Drivebeltshavein-runningnippointswhichpresentariskofentanglementandabrasion.

5.1.2 Control measuresDependingonthetypeofjobtobecarriedout,therearevariouswaysofguardingthesepresses.Optionsinclude:

• Fixed guarding:Afixedguardhasnomovingpartsandoffersprotectiononlywhiletheguardisinitscorrectposition.Operatoraccesstothehazardousareaisprevented,howeverwiththeaidofatool,slidescanbeadjustedtoallowworktobefedthroughtheguardintothestampingarea.

• Interlocked guarding: Aninterlockingguardisaguardwhichhasamovablepart,whichisinterconnectedwiththe

powerorcontrolsystemofthemachinesothatuntiltheguardisclosed,theinterlockpreventsthemachinefromoperating.Withthekey-clutchtypeofpressfittedwithinterlockedguarding,itisalsonecessarytofitananti-repeatdevicetopreventapowerstrokeintheeventofaclutchfailure.

• Presence-sensing devices (photoelectronics):Presence-sensingdevices(photoelectronics)detectthepresenceofaperson,orpartofaperson,inadefinedarea,andpreventthedangerouspartsofmachineryfrommovingwhileanyoneisinthatarea.Presence-sensingdevicesareonlysuitableforhydraulicmachines,andinstallationofthesedevicesshouldcomplywithAS4024.1 Safeguarding of machinery – General principles.

• Two-handed controls:Two-handedcontrolsareonlysuitableforhydraulicmachines.Thissystemrequiresbothhandstooperatethemachinecontrolsandshouldbedesignedinaccordancewiththefollowing:• controlsshouldbeseparatedandprotectedtopreventspanningwithonehandonly• itshouldnotbepossibletosetthedangerouspartsinmotionunlessthecontrolsareoperated

withinhalfasecondofeachother• ifoneorbothcontrolsarereleased,movementofthedangerouspartsshouldbestopped

immediately


• thecontrolsshouldbepositionedatsuchadistancefromthedangerpointthat,onreleasingthecontrols,itisnotpossiblefortheoperatortoreachthedangerpointbeforethemotionofthedangerouspartshasbeenstopped

• rearandsideguardingofthemachineisrequired.

• Administrative controls:Regularmaintenanceof‘key-clutch’pressesisextremelyimportant.Inspectionandmaintenancerecordsshouldbekepttodemonstratethatmaintenancehasbeencarriedout.Regularsystemsauditsandsafetyinspectionsshouldbecarriedouttoensurethatstandardpracticematchesstatedprocedures.Safetyinspectionsshouldincludetheconditionandoperationofthefollowing:• flywheelbearingandshaft• extractorcamandkey• anti-repeatdevice• brakes• guards• safetydevices• controls.

Maintenance problem areas

�.Clutchmechanism 6.Guardcontrol2.Brake 7.Linkageandattachments3.Fywheelbearing 8.Toolsetter'sdisconnection4.Pitmanscrew 9.Distortionanddeteriorationofguardgates5.Clutchinterlock �0.Guardoverfootpedal

Illustration 24-Thisisapowerstampingpress.Performingmaintenanceonpowerpressescanbringmaintenancepeopleintocontactwithhazardousareasonthepowerpress.Theaboveillustrationidentifiescommonproblemareasonapowerpress.


Flywheel seizure:Theflywheeljournalbearingsmustbekeptwell-lubricatedandclean.Themajorityofpresseshaveballorroller-bearings,butsomeimportedmachinesdohaverollingkeys.Thedesignofrollingkeyclutchesissuchthatplainbronzebearingsareanecessity.Anymetallicfragmententeringthebearing,orasimplelackoflubrication,couldcausethebearingtoseizeonthejournalofthecrankshaftandanuninitiatedstroketooccur.

5.2 Press brakes (mechanical and hydraulic)Apressbrakeisamachinegenerallylimitedtolinearbendingandformingofmaterial(e.g.sheetmetalandheavygaugematerial).

5.2.1 Hazards and risksThemainhazardofapressbrakeiswherethepunchanddiecometogethertoformtheproduct.Theimpactwouldhaveacrushing,cuttingorshearingmotionwhichcreatesariskofhavingapartofthebodycrushedorcut.Drivebeltshavein-runningnippointswhichpresentariskofentanglementandabrasion.Hydraulichosesmayposeariskiftheyleakorburst.Risksmayincludespillscreatingasliphazardandhydraulicfluidscomingintocontactwithworkers.

5.2.2 Control measuresDependingonthetypeofjobtobecarriedout,therearevariouswaysofguardingthesepresses.Wherepressbrakesarebeingusedforspecificrepetitivejobs,fixedguardsmaybeappropriate.However,forgeneraluse,whereworkershavetoholdorstabilisethematerial,orneedfrequentaccesstoclosingdies,thesemachineswouldrequirepresence-sensingdevicestoensuresafeoperation.Presence-sensingdevicesmaybelightcurtainsorlightbeams.Automaticstopsmustalsobeguardedandback-gaugingequipmentisrecommended.

Presence-sensing systems—light curtains

Lightcurtainsconsistofseveralpairsoflightboxunitsandacontrolbox.Eachlightboxpairhasatransmitterandreceiver.Thetransmittergeneratesacurtainofhighintensity,micro-secondinfra-redlightpulses,acrossthemachineoperator’sworkarea.ThiscurtainoflightistransmittedanappropriatedistancefromthehazardousareaasdeterminedinaccordancewithAS4024.1 Safeguarding of machinery – General principles,orasdeterminedbyariskassessment.Anyintrusionintothislightcurtainproducesasignalforthecontrolboxtostopthemachine.Inordertoassisttheoperator,theselightcurtainsystemshaveavarietyofoperatingmodeswhichmaybesetaccordingtothetypeofworkbeingdone.Forexample:

• continuousstrokingmode—whenthecontrolpedalisdepressed,themachinewillmovefromthetopofthestrokeandcontinuetostrokewhilethepedalisdepressed.Ifthelightcurtainispenetratedwhilethemachineisdown-stroking,themachinewillstop

• top-to-topmode—themachineoperatesasinthecontinuousmode,exceptthat,regardlessofwhethertheoperatorreleasesthefootpedal,themachinewillstopatthetopafteronecycle

• bottomstopmode—themachinestartsfromthetopofthestrokewhenthepedalisdepressed,andstopsleavingadaylightgapbetweenthetopandbottombeam,inaccordancewithAS4024.�Safeguardingofmachinery–Generalprinciplesorasdeterminedbyariskassessment.Atthispointthelightcurtainismutedorbypassed.Depressingthepedalagainmovesthemachinetothebottomofthestrokeandreturnsittothetopwhereitstopsandatthispointthelightcurtainisreactivated


• bottomstop-to-bottomstopmode—similartothebottomstopmodeexceptthemachinedoesnotstopatthetopofthestroke.Itstopsatthe6mmgapmuteposition,orwhenthelightcurtainisobstructedonthedownstroke

• pulsingmode—thelightcurtainismutedorbypassedandthemachinecanbemoveddownin�0mmincrementswitheachdepressionofthepedal.Thismodeallowstheoperatortostandinsidethecurtainforclosework

• linkmode—isusedformechanicalpressesandissimilartothebottom-stopmode,excepttheinitialdownstrokeiscontrolledbyanelectricfoot-switchandatthe6mmmutepoint,thepedalcontrollingthemechanicalfrictionclutchisoperatedtofinalisethestrokeofthemachine.

Presence-sensing systems—light beams

Thistypeofguardingsystemconsistsofthreeinfra-redlightbeamsmountedonthepress-brakeblade.Thefrontbeamprotectstheoperator,whileallowingworktobeperformedclosetotheblade.Thecentrebeamsetsthemutebypasspoint.Therearbeamprotectspeopleattherearofthemachine,eliminatingtheneedformechanicalguarding.

Onoccasionsitmaynotbepossibletoperformworkwiththeguardingsysteminplace.Specificguidanceforthesystemstobeimplementedwhenguardingisremovedorswitchedoff(muted),isdetailedinClause6.4.3ofAS1219 – 1994 Power presses – Safety requirements.However,iftheworktobeperformedrequiresguardingtoberemovedonaregularbasis,themachinemaynotbesuitablefortheapplication.Measuresshouldthereforebetakentouseanothermachineortomodifytheexistingmachinesothattheguarddoesnothavetoberemoved.

Intheeventoftheneedtoinvokeclause6.4.3,andregardlessofwhetheroption(a),(b)or(c)inthatclauseisselected,thereisstillarequirementtoinstallsuitableguardingtoprotectoperatorsfromhazardsattherearandsidesofthemachine.Intheeventthatoption(c)ofclause6.4.3isselected,allsevenrequirementslistedin(c)mustbemet.

Additionally,asafesystemofworkshouldbedocumentedandtheoperationsupervisedbyacompetentperson.

AS1219 - 1994 Power presses – Safety requirementsprovidesmoreinformationinrelationtoguardingdevices,theirdesign,manufactureandthesafeguardingofpowerstampingpressesandbrakepresses.Thisstandardshouldbeconsultedforadditionalinformation.

5.3 Conveyors (bulk handling)Conveyorsareameansoftransportingmaterialsfromonepointtoanother.Differenttypesincludebeltconveyors,screwconveyorsandbucketconveyors.

5.3.1 Hazards and risksThemainhazardsofaconveyorarethenumerousin-runningnippointswhichpresentariskofentanglement,crushingandabrasion.Thedrivesystemitselfmayalsoposerisksofentanglementorabrasion.

5.3.2 Control measuresFixedguardswhichenclosein-runningnippointsandthedrivemechanismareoftenthemosteffectivewaysofsafeguardingconveyors.Thefollowingexamplesshowthenumerousdangerpointsonastandardconveyorandwaystoguardtheheadandtailsectionsoftheconveyor.Allguardsshouldbedesignedforeasyremovalandshouldrequiretheuseofatoolforremovalandreplacement.


Illustration 25-Dangerpointsonastandardconveyor

Illustration 26-Typicalguardforheadandtailsectionofaconveyor

Itisimportanttonotethatphysicalguardingisnottheonlyguardingoptionforconveyorsystems.Othersafeguardsinclude:

• Electrical isolation (lock-out/tag-out)Althoughsafeguardsareprovidedwhichpreventaccessduringmostphasesofmachineryorplantlife,theymaynotbeeffectiveatalltimesbecauseoftheneedtogainaccesstohazardousareasduringmaintenance,set-up,etc.Isolationproceduresshouldbedevelopedbytheemployerwhichareappropriatefortheparticularmachine.Theseprocedurescouldincludevarioustypesoflocks,keysanddangertags.Atypicallock-out/tag-outsystemforconveyordriveswouldbetoapplyalocktotheisolationswitch,aswellasadangertagwiththemaintenanceperson’snameonit.

• Start and stop controlsConveyorsshouldbeprovidedwithappropriatedrivepowerisolation,whetherelectrical,hydraulic,pneumaticormechanical.Isolationshouldbesecuredbymeansofalock-out/tag-outsystem.Ateachconveyorstartlocation,aclearlylabelled’stop’controlshouldbeprovided.Wherethestartcontrolisinapositionfromwhichthewholeoftheconveyoroperationcannotbeviewed,avisibleoraudiblesignalshouldbeprovidedtowarnpeopleinthevicinity.

• Emergency stop controlsAlanyardtypepull-wireemergencystopisthemostsuitableemergencystopforexposedbelttypeconveyorswhereworkersarerequiredtoaccessthebeltareawhentheconveyorisinuse(e.g.placingandremovingparcelsatatransportdepot).Thelanyardtypeallowsaccesstotheemergencystoppingfacilityfromallofthepointswhereapersonmaybeworkingduringtheconveyor’suse.Emergencystopcontrolsmustbemanuallyresetbeforetheconveyorcanberestartedfromitsnormalstartcontrol.


• Access provisionsMachinerydesignshouldallowallroutineadjustment,lubricationandmaintenancetobecarriedoutwithoutremovingguardsorextensivedismantlingofcomponents.Lubricationandroutinemaintenancefacilitiesshouldbeincorporatedoutsidethedangerareawhereverpractical.However,whenpeoplerequireaccesstothedangerarea,forexampleformachinesetting,safeisolationproceduresshouldbeused.

• LightingProvidelocallightingonthemachineforlightingtheworkareawhenthemachineorguardsrendernormallightinginadequateforsafeoperation.Locallightingshouldalsobeprovidedinregularmaintenanceareasthatarepoorlylit,forexampleinsidecertainelectricalcompartmentswhereelectricalisolationisnecessaryforaccess.

AS1755 – 2000 Conveyors - Safety requirementsprovidesmoreinformationinrelationtominimumsafetyrequirementsforthedesign,installationandguardingofconveyorsandconveyorsystems.Thisstandardshouldbeconsultedforadditionalinformation.

AS1680.1 – 1990 Interior lighting – General principles and recommendationsprovidesmoreinformationinrelationtothegeneralprinciplesandrecommendationsforlighting.Thisstandardshouldbeconsultedforadditionalinformation.

5.4 Robotics Acommonmisconceptionisthatroboticoperationsare‘safe’becausethereislittleornoworkerinteraction,howevermosthealthandsafetyissueswithrespecttoroboticsareinrelationtoinstallation,repairandmaintenance.Whileoperationmaybesafe,ariskassessmentmustbeundertakentoensureworkers’safetyduringallphasesofthemachinerylifeanduse.Robotshaveoftenbeenusedtoremovethemoretraditionalhazardsassociatedwithmachineryandalsotoperformsomehigh-riskoperations,forexampleinthebiotechnologyfield.

Theriskmanagementprocessshouldbefollowed,withreferencetomanufacturer’sinstructions,duringinstallation(commissioning),testingandstart-up,repairandmaintenance.

5.4.1 Hazards and risksRobotshaveinherentdangersincludingunpredictableactionpatterns,highspeedoperations,abilitytomoveinfreespace,andabilitytobereprogrammedorreconfiguredtochangetheiruseandapplication.Someofthehazardsassociatedwithindustrialrobotoperationinclude:

• ImpactRobotsmaymoveinadirectionnotanticipatedorplanned,athighspeedinlinearorrotarydirections.Therobotmayalsoejectwork-pieces,off-cutsormoltenmetal.Workersareatriskfrombeinghitbytherobotorpartsofthework.

• Trapping pointsTrappingpointsmaybecreatedbymovementsoftherobotorassociatedequipmentsuchasworkcarriages,palletsortransfermechanisms.Ontherobotitself,trappingpointsmaybeidentifiedonthearmoftherobot,betweenthearmandthecolumn,andbetweenthearmandfixedobjects.Workersmaybecrushedorbecomeentangledbytherobotortheprocess.

• Control errorsControlerrorsresultfromintrinsicfaultswithinthecontrolsystemoftherobot(e.g.software,electricalinterference,programcorruptionandsub-controlsassociatedwiththeelectrics,hydraulicsandpneumatics).


• Human errorHumanerrorcouldoccurduringprogramming,teaching,andmaintenanceandrepair,orinworkhandlingclosetotherobotoratload/unloadstations.

• Failure or malfunctionFailureormalfunctionofelectrics,hydraulicsandpneumatics.

• Biological or chemical hazardsHazardsmayoccurwhererobotsarebeingusedtoreducetherisksfromhazardousorinfectiousprocesses.Workersmayriskinhalingorabsorbinghazardoussubstances.Inthiscase,particularattentionmustbepaidtotheprocessitselfandtoanybreakdownoremergencyproceduresthatmayresultfromspillage,contaminationorbreachofthesystem.

• Environmental hazardsHazardsincludedustvapour,fumes,lasers,radiations,andflammableandexplosiveatmospheres.Workersmayriskinhalingorabsorbinghazardoussubstances,burnsandotherinjuries.

5.4.2 Control measuresHazardsassociatedwithmovingparts,otherthanatpointofoperation,shouldbeeliminatedbydesign,orelseprotectionmustbeprovidedagainstthehazards.Industrialroboticinstallationsmaybesafeguardedbyoneormoreguardingandpresencesensingdevices.Enclosureisafrequentcontrolmeasureforroboticsystems.

Thehighlytechnicalandprogrammablenatureofrobotsmeansthatadditionalsafeguardsshouldbeconsideredinadditiontotheguardingofdangerousmovingparts.Measuresshouldbetakentopreventunauthorisedaccesstocontrolsandtoprotecttherobotsystemfromunintendedoperation.

Attentionmustalsobepaidtocontrollinghazardsinadjacentareas—forexample,loadingorunloadingstationsandassociatedequipment.Inparticular,removalofassociatedequipmentsuchasconveyors,transfersystemsandtrolleys,mustnotallowaccesstorestrictedareas.Ifso,thesepointsmustbeguarded.

Control systems

Actuating(start)andcontrolsystemsforroboticsareusuallyoftheprogrammableelectronictype.Thesemustbeprotectedagainstunauthorisedaccess,forexamplebylocationinalockablecontrolcabinetorroom.Controlsshouldbeconstructedorlocatedtopreventunintentionaloperation.Thiscanbeachievedbyshrouding,guarding,gating,appropriatelypositionedorotherwisedesignedtopreventaccidentaloperation.

Master switches

Masterswitchesmustbeprovidedtoisolateallmotivepowerfromtherobotandmaybethesamedeviceasanemergencystopdevice.Thismasterswitchshouldbecapableofbeinglockedintheisolatingpositionandrequiremanualresetting.

Fixed or distance guards

Guardsmaybeusedwheretheguardwillnotinterferewiththemechanismoftherobot.Itmustbenecessarytousetoolstoremovetheguardsinordertogainaccesstotherestricteddangerarea.Guardsorfencesmustbelocatedtopreventpeoplefromreachingintoarestrictedarea.Anyopeningsprovidedforfeedingmaterialintotheprocessshouldbedesignedtopreventaccessbyanypartofaperson.


Interlocked guards

Interlockedguardsinitiateanemergencystopwhenopened.Whilesuchaguardmustpreventinitiationofautomaticoperation,itmaymaintainpowerforotherfunctions.Returntoautomaticoperationwouldthereforerequireboththeclosingoftheinterlockedguardandtheactivatingofastartprocedure.

Presence-sensing devices

Presence-sensingdevicesmustbedesignedandpositionedtodetectentryintoarestrictedspaceordangerareaandtocausetheautomaticoperationoftherobottoceasewhenentryisdetected.Thefailureofthisdevicewouldalsocausetherobottoceaseoperation.

• Photoelectricsystemsconsistofacombinationofaphotoelectricdevice(e.g.alightcurtainorbeam),robotcontrolsystem,driveandbrakeunitsand,whereappropriate,anoverallperformancemonitor.Interruptionofthelightcurtainwillcausetheoperationoftherobottocease,thereforeitshouldnotbepossibletostandorplaceabodypartbetweenthelightcurtainandthehazardouspartoftheprocess.Photoelectricdevicescanbesettocontrolthesizeofanypenetration(e.g.ahandbutnotthearmoranarmbutnotthebody).

• Pressure-sensitivematsoperatebymeansofanumberofsuitablyspacedelectricalorfluidswitchesorvalvescontainedwithinamatcoveringtheapproachestoarestrictedspace.Pressureonthematwillcausetheautomaticoperationofthemachinetocease.Suchaguardmustbedesignedsothatitisnotpossibletocircumventoroverstepapressure-sensitivematintoarestrictedarea.

Training

Inadequatetrainingmayincreasetherisksatmoststagesofrobotoperation.Appropriatetrainingisconsideredessentialwhencontrollingtherisksassociatedwithindustrialrobotmachines.

Safe work systems

Safeworksystemsarearecommendedcontrolmeasuretominimisesomeoftherisksassociatedwithrobotics.Adocumentedsafeworksysteminvolvesrecordingproceduresforentry(includingwhoispermittedtoperformidentifiedtasks),access,maintenanceandrepair.

Inspectionandmaintenanceactivitiesmayprovideadifferentsetofhazardstoperformanceormonitoringofwork,andmustalsobeassessedintermsofhazardsandrisks.


Illustration 27-Typicalmanufacturingsystemusingarobotasthematerialhandlingsystemwhereperimetermarking/barrier,fixedbarrierswithinterlockedgates,presence-sensingdevices,warningdevicesandadditionalsystememergencystopdevicesareused.

AS2939 – 1987 Industrial robot systems – Safe design and usageprovidesmoreinformationinrelationtotherequirementsofthedesign,construction,safeguardingandinstallationofindustrialrobots.Thisstandardshouldbeconsultedforadditionalinformation.


Section 6 - Other machinery safety issues

Itshouldbenotedthatthefollowingsub-sectionsarenotanexhaustivelistof‘othermachinerysafetyissues’.AS4024.1 Safeguarding of machinery – General principles providesmoreinformationinrelationtoanumberofotherissuesnotmentionedinthissection.Thisstandardshouldbeconsultedforadditionalinformation.

6.1 Work organisation Managementhasakeyroleinestablishingandmaintainingsystemsandprocessesthatmonitorandevaluatepotentialhazards.Followingtheriskmanagementprocesswillassistemployersandpeopleconductingabusinessorundertakingtoensurethesafetyoftheirworkersandthoseconductingworkactivities.Commitmentisrequiredfromallworkers,fromseniormanagementrightdowntotheshopfloor.Productionratesanddeadlinesshouldbeplannedsothattheycanbeattainedwithoutcompromisingsafeworkpractices.

Formachineguardingtoworkeffectively,themovementofmaterialson-siteandthejobproceduresappropriatetothemachinerymustbethoroughlyunderstood.Safemachineryoperatingproceduresorinstructionsformachineryorplantshouldbedeveloped,andworkersappropriatelytrainedtoensuresafeworkpracticesaremaintained.

Newrisksshouldnotbeintroducedintotheworkplacebecauseoftheintroductionofnewtechnology,newmachineryorplant,ormodificationstoexistingmachineryofplant.Atthesetimesriskassessmentsmustbeperformed,ideallyinconsultationwithworkers.

6.1.1 LayoutMachineguardingwillbemoreeffectiveifitisusedinconjunctionwithproperattentiontolayout.Machineswhicharepoorlylocatedortooclosetogethermaynotbesafe,evenifguarded.Thereareanumberofbasicpointstoconsiderinrelationtolayout:

• avoidcongestionsorworkermovementsnearmachinerythatarelikelytoincreasetheriskofinjury

• thelayoutshouldeliminateorminimisehazardousmovementsinrelationtooperation,cleaningormaintenance(e.g.blockage)

• wherewastematerialsaregenerated,thelayoutshouldincludespaceforstorageoraccumulationuntilcleared.Theyshouldnotbeallowedtoclutterwalkwaysorworkareas

• thelayoutshouldconsider‘trafficflow’byidentifyingthemovementsoftrucks,materialsandpeople.Bydefiningsimple,wellmarkedandwellunderstoodtrafficareasanddirections,thelikelihoodofpeoplecomingneardangerousmachinery,andthereforetheriskofinjury,canbereduced

• proximityofmovingpartsinrelationtoothermachineryorplantandfixturesinbuilding.

6.1.2 HousekeepingUntidinesscancauseslips,tripsandfalls.Injuriescanbeavoidedby:

• keepingworkareas,walkwaysandotheraccesspathsclearandclean.Theyshouldbeclearlymarked

• preventingspillswhichmaycauseslips.Designmachineryandworkprocessestominimiselubricationoillossorspillage.Cleanupspillsassoonaspossibleaftertheyoccur,andavoidanyoilyresiduesonthefloor.Providearoughanti-slipfloorwherethisisnotpractical.


6.1.3 Work practicesAllprocessesrelatingtomachineryorplantshouldbedocumented.Inparticular,directionsaboutoperation,cleaning,maintenance,andproblemsthatmaybeencounteredshouldbeclearlystatedinawaythatensuresthesafetyoftheworker.Systemsshouldbeinplacethatpreventworkersfrombypassingguardingmechanisms.

Supervisionisessentialtoensurethatasystemofsafeguardsisusedcorrectly.

Changestomachinery(newplantormodifications)mayrequirechangestoexistingworkproceduresandprocessestoensuretheguardingdoesnotcreatenewproblems.Documentationandworkmanualsshouldbeupdatedatthesametime.

6.2 Work environmentThereareanumberofgeneraltypesofworkplacehazardsassociatedwithmachinery.Theseincludenoise,energy(electricityorhydraulics),manualhandling(lifting,repetitivemovements),substances(solvents,cleaners,chemicals),theworkenvironment(suchasconfinedspaces,lighting,ventilationandaccess),andtheactualplantandequipmentinuse.Therisksassociatedwiththesehazardsmustalsobeassessedandcontrolled.

6.2.1 DustAdustyworkplacecanbedangerous.Dustandotherairbornecontaminantscanhavedirectandseverelong-termeffectsonworkers’health,whichcouldincluderespiratoryproblems,skindisordersandevencancer.Dustcanalsocauseinjurybycloggingmachinery,inducingsuddenbreakdownsandobscuringmovingpartsandotherhazards.Thediscomfortcausedbydustontheskin,clothingandprotectiveequipmentcanalsocompromisesafety.

Somemeasuresforreducingtheriskofinjuryorillnessresultingfromdustinclude:

• installingadustcollectionsystemthatremovesdustfromtheenvironmentandcansavecleanuptime

• useofasimplelid,coverorshieldonsaws,augersandothermachinerytoreducedustlevels• housekeepingproceduressuchasfrequentcleaningordampingdown.

Suchguardingmayalsoreducethelevelofnoiseandimproveworkercomfortandproductivity.

6.2.2 LightingAmplelightingisneededfortheoperationofmachinerysothatmachinemovements,controlsanddisplayscaneasilybeseen.Poorlightingcanaffectpeoplebothphysicallyandpsychologically,causingeye-strainandtiredness.

Thefollowingissuesshouldbeconsideredwithrespecttolightingandmachinery:

• directionandintensityoflighting• contrastbetweenbackgroundandworkarea,applicabletobothworkenvironmentandcontrol

panels• colourofthelightsource• reflection,glareandshadows• thestroboscopiceffectoffluorescentlightingonmovingmachinerywhichmakesmovingparts

ofmachinerylookasiftheyarestopped• thestroboscopeeffectofrotatingbeaconsinmobileplantintheinternalenvironment.


AS�680.�–�990/Amdt�–�990Interiorlighting–Generalprinciplesandrecommendationsprovidesmoreinformationinrelationguidanceonlightingquantities.Thisstandardshouldbeconsultedforadditionalinformation.

6.2.3 NoiseNoise,particularlyexcessivenoise,interfereswithconcentrationandcancauseoperatorstress(itselfasourceoferrors),whichcanleadtomistakes.Noisemayalsopreventaverbalwarningbeingcommunicated.TheWorkplaceHealthandSafetyRegulation�997includesprovisionswithrespecttonoiselevelsintheworkplace.Noiselevelsshouldbemeasuredtoensurecompliancewithrecommendedstandards.

Controlmeasuresfornoisyplantandmachineryinclude:

• providingsound-proofenclosures,whichmaybecombinedwithmachinesafeguarding• limitingexposureperiods• providingappropriate,properlyfittedhearingprotectionforoperatorsandotheraffectedworkers.

Itshouldbenotedthatincorrectlyselectedhearingprotectioncanartificiallydistracttheworker,causingthemtolooseconcentration.

Guardingcanbemadeaspartofthenoisesolution.Inmanyinstances,carefullydesignedguardingofmovingpartscanaidnoisereductionandhelpremovethestressassociatedwithprolongednoiseexposure.

6.2.4 Hot and cold environmentsAcomfortabletemperatureissafertoworkin.Accidentsaremorelikelytohappenifpeopleneedtoworkwherethetemperatureisoutsideacomfortableworkrange.Extremeheatorextremecoldmayalsoeffectmachineryoperationinvariousways.

Someofthecontrolmeasurestoconsiderwhenworkisconductedinhotandcoldenvironmentsinclude:

• providingappropriatepersonalprotectiveequipment,selectedwithconsiderationofthetaskstobeperformed.Incoldenvironments,bulkyinsulatedclothingmayrestrictmovement,reducemanualdexterityandincreaseentanglementrisks

• limitingexposureperiods• providingsufficientdrinkingwaterandairflowforoutdoorworkersorhotworkplaces• followingmanufacturersinstructionsorseekingtheiradviceaboutmachineoperationinextreme

temperatures.

6.2.5 VentilationSomeprocessesandmachinesgenerateheatandfumesduringoperation.Peopleworkingnearbymustbeadequatelyprotectedfrominhalingdangerousfumesandfromcontactinghotparts.

Tocontroltherisks,guardingshould:

• allowadequateairflow,forexample,throughameshguardsothatequipmentdoesnotoverheat• beinsulatedordistanceguardedtoreducetheriskofburns• includeductingifnecessarytoventhotairorfumesawayfromworkers• includefilters,ifrequired,toremovedangerousparticulatesfromtheair.


6.2.6 Confined spacesConfinedspacescanbecreatedinoraroundmachineswhenguardingisremovedordeactivatedtoallowforcleaning,maintenanceoraccesstotheareasurroundingthemachine.

Confinedspacespresentarisktohealthandsafetyandcanpotentiallycontainmanyhazards,someofwhicharenotvisiblydetectable.

TheWorkplaceHealthandSafetyRegulation�997,part�5(Confinedspaces),section�45,dealswithusingconfinedspacesandidentifiesrelevantsectionsofAS/NZS 2865 – 2001 Safe working in a confined spacethatmustbecompliedwith.

AS/NZS 2865 – 2001 Safe working in a confined spacesetsouttheparticularrequirementsandprocedurestoensurethehealthandsafetyofallpeoplerequiredtoenterorworkinaconfinedspace.

AS4024.1 Safeguarding of machinery – General principlesalsoprovidesmoreinformationinrelationtotheenvironmentalfactorsdiscussedabove.Boththeregulationandthesestandardsshouldbeconsultedforadditionalinformation.

6.2.7 Electrical safetyDangeroussituationscanariseasaresultofthefailureofelectricalsafetycontrolsystems.Systemfailurecanbecausedbyseveralfactorssuchasenvironmentalconditions,suitabilityforthespecificsafetyapplicationandinsufficientsystemmonitoringandmaintenance.

The Electrical Safety Act 2002andtheElectricalSafetyRegulation2002providealegislativeframeworktopreventpeoplefrombeingkilledorinjuredandpropertyfrombeingdestroyedordamagedfromelectricity.TheActandtheregulationshouldbeconsultedforadditionalinformation.

AS1543 – 1985iscurrentlybeingreviewedandwillbecomeAS6024.1 – 200X Safety of machinery – Electrical equipment of machines Part 1: General requirements.Thisstandardwillproviderequirementsandrecommendationsfortheelectricalequipmentofindustrialmachineswithregardtosafetyofpeopleandproperty,consistencyofcontrolresponseandeaseofmaintenance.ThedraftisnottoberegardedasanAustralianStandardandshouldonlybeconsultedforadditionalinformationwhenStandardsAustraliahasreleaseditassuch.

AS4024.1 Safeguarding of machinery – General principlesalsoprovidesmoreinformationinrelationtothespecificrequirementsregardingoverallsystemdesigninrelationtoelectricalsafetycontrolsystems.Thisstandardshouldbeconsultedforadditionalinformation.

6.3 Minimising human error Humanorworkererrorisnotalwaystheresultofcarelessnessornegligence,butfollowsfromnormalhumancharacteristics.Thedesireforextraspeed,lessworkandmakingtaskseasier,aresomeoftheleadingreasonswhyguardsarebypassedorremoved.Also,peoplenaturallybecomeboredanddistractedwithrepetitiouswork,whichmaycauselossofconcentration.Designers,manufacturersandemployersshouldbeawareofthesefactorsindesigningmachinesanddevelopingsafeworkpractices.

Machineguardingsolutionsmusttakehumanissuesintoaccount,whichisanotherreasontogetthoseusingthemachineinvolvedindevelopingsolutions.Inthelongterm,acarefullyconsideredsolutionwillalmostalwaysprovetobelesscostlyandmoreefficient.


Factorscontributingtohumanerrorinclude,butarenotlimitedto:

• vigilance• informationhandlingcapacity• ergonomics• psychologicalorculturalenvironment• habit• fatigue• leveloftraining.

Vigilance

Referstoaworker’sabilitytobealerttodangerorproblemsduringoperationandisahigherrequirementthan‘stayingawake’.Itimpliesactiveinteractionwithandawarenessoftheworkenvironment.Havingregularrestbreakshasthepotentialtoimproveworkperformanceandassistworkerswithremainingalerttoanydangerorproblemsthatmayariseduringoperation.Workerscannaturallybecomeboredanddistractedwithrepetitiouswork,whichmaycauselossofconcentrationandanoveralldecreaseinalertnessandawarenesstodangerorproblems.Jobrotationprovidesworkerswithvarietysothattheydonotbecomeboredwithrepetitivetasks,andthereforeincreasesthelikelihoodofworkersmaintainingahighlevelofalertnessandawareness.

Information handling capacity

Vitalinformationcanbeoverlookedifitispresentedtooquickly,orifitcomestogetherwithotherinformation(informationoverload).Ifapersonhastomonitormorethanone‘channel’ofinformationatanyonetime,theyshouldhaveaclearorderofpriority.

Ergonomics

Ergonomicsisthestudyofhumanandmachineinteraction.Pooroperatorcomfort(e.g.noattentiontothelocationofstools,buttons)cancontributetolossesofconcentrationandresultinerrors.

HB59 – 1994 Ergonomics – The human factor – A practical approach to work systems designproducedbyStandardsAustraliaprovidesmoreinformationinrelationtodesigningtheworkplaceandtheenvironmentinsuchawaythatthemostefficientuseismadeofhumancapabilities,withoutsucceedinghumancapacities.Thehandbookshouldbeconsultedforadditionalinformation.

Fatigue

Thesafeuseofmachineryismorethanattendingtoguarding.Longhoursofwork,shiftworkorlongperiodswithoutadequatebreakscanleadtolossofconcentration,slowreflexesandincreasedriskoferror.Excessiveheat,poorventilation,lightingandshiftworkalsocontributetofatigue,lossesofconcentrationanderror,allofwhichshouldbetakenintoaccountwhenlookingatmachineguarding.

The Workplace Health and Safety Queensland Fatigue Management Guideprovidesmoreinformationinrelationtofatigueandstrategiesonhowtobestmanageitintheworkplace.


Psychological or cultural environment

Acorporatecultureofsafetycreatespositivebeliefsandvaluesregardingthemanagementofrisksintheworkplace,andconsequentlyreduceswork-relatedinjuryandillness.

Habit

Peoplecancontinueahabitualactivitydespiteindicationsofdanger.Clearlabellingofcontrolsandclear,simplewarningnoticescanhelp.Peoplealsogetusedtoaparticulararrangementofcontrols.Usestandardisedcontrolsasmuchaspossible,andensurethatlocationofthecontrolsisappropriate.Theactionusedtooperateacontrolshouldalsobecompatiblewiththeeffectonthemachinery,forexample,switchingacontroltowardstheleftmovesmaterialintothemachineinthesamedirection.Thiselementdeservesparticularattentionwhenconsideringthepurchaseofreplacementmachines,especiallyifthenewcontrolsarereversedorlocateddifferently.

Training

Itshouldnotbeassumedthatpeoplealreadyknoworcaninformallylearnaboutmachineryorplantsafety.Trainingmustbeprovidedtoworkersonanyrequiredpersonalprotectiveequipment,newlyintroducedequipmentormodificationstoexistingmachinery.Allpeoplewhosupervise,manageoroperatemachineryorplant,shouldreceiveappropriatetrainingandinstructionforhealthandsafety.Trainingshouldincludesafeoperatingproceduresandanyprecautionsthatmaybeneededtocontrolthehazardsofthemachinestheyoperate.

6.4 Registrable plantOwnersofplantlistedinschedule2oftheWorkplace Health and Safety Act 1995andschedule3oftheWorkplace Health and Safety Regulation 1997mustnotusetheplant,orpermittheplanttobeusedataworkplaceunlesstheplantisregistered.

OwnerswhowanttoregisterplantmustapplytoWorkplaceHealthandSafetyQueenslandontheprescribedform.Afeeispayableandacertificateofregistrationisissued,withregistrationbeingrenewedeachyear.Notificationofchangeofownershipofregisteredplantmustbegiven.

Registrableplantlistedinschedule3oftheRegulationincludesairconditioningunits,specifiedamusementdevices,buildingmaintenanceunits,coolingtowers,escalators,mobileelevatingcranes,towercranes,truck-mountedconcreteplacingboomsandspecifiedboilers,liftsandpressurevessels

6.5 Registrable plant designThedesignofplantlistedinschedule4oftheRegulationmustberegisteredwithWorkplaceHealthandSafetyQueensland.

AnapplicationforregistrationofdetailsofplantdesignwillberegisteredwithWorkplaceHealthandSafetyQueenslandifitismadeintheprescribedformandisaccompaniedbytheprescribedfeeandrepresentationaldrawingsoftheplantdesign.Anemployermustnotuseorpermittheuseof,anyplantlistedinschedule4unlesstheemployerpossessesacopyofthewrittennoticeoftheregistrationoftheplantdesignfromWorkplaceHealthandSafetyQueensland.

Registrableplantdesignappliestovehiclehoists,elevatingworkplatforms,specifiedcranesandhoists,lifts,escalators,domesticlifts,peoplemovers,amusementdevices(asclassified),andcertainboilersandpressurevessels.Applicabledesignstandardsarelisted.


Section 7 - Further information7.1 Standards AustraliaStandardsAustraliadevelopsandmaintainsmorethan7000AustralianStandardsandrelatedpublications.Thesedocumentsareusedincountlessdailybusinesstransactionsandfacilitatetradebetweenindividuals,corporationsandnations.ToobtainfurtherassistanceinrelationtoAustralianStandards,StandardsAustraliacanbecontactedthroughtheirCustomerServiceCentre:

National Customer Service Centre

Telephone:�300654646Facsimile:�300654949OverseasTelephonecalls(02)820660�0OverseasFaxes(02)82066020Email:[email protected]:www.standards.com.au

7.2 Consulting engineersThereareanumberofconsultantswhocanofferadviceonsafeguardingmachineryorplant.Ifitisdecidedtouseaconsultant,shoparoundandmakesuretheconsultantisfullyconversantwithQueenslandlegislativerequirements,andthattheytakeanapproachtotheproblemthatisconsistentwiththeprinciplesidentifiedinthisguide.Askthemforevidenceofpreviousworkintheareaandcheckouttheworkforyourself,talkingifpossiblewithotheremployers.Smallemployerscanpoolwithotheremployersintheareainordertospreadthecosts.Thistypeofcooperationmakessenseasitsavestimeandmoney.

7.3 WorkersRemembertheworkforcewhenitcomestoseekingsolutions.Theyworkwiththemachineryandplanteverydayandtheycanoftennotonlyhelpbetteridentifyaproblem,butalsohelpwithdevisingthemostefficientandcost-effectivesolutions.Workplacesafetycommitteesorhealthandsafetyrepresentativesshouldbeinvolved,butevenifthesedonotexistattheparticularworkplace,workersshouldstillbeinvolved.Intheend,theyhaveadirectinterestinsafeguardingtheirownhealth.

Evenifexpertsorconsultantsarebroughtin,therewillbeaneedtoensurethatworkersareinformedandinvolved.Aguardmaylookfinefromanengineeringviewpoint,butitalsoneedstotakeaccountofworkercomfortandeaseofoperation.Workersareinthebestpositiontojudgetheeffectivenessofguardsonthemachinestheyareusing.

7.4 Industry associations and similar workplacesIndustryassociations,unionsetc.canbeusedtoobtainadditionalinformation.Theirexistingnetworksandcontactscanbeusefulinidentifyingspecificworkplacesthatperformsimilartypesofworkandthereforemaybeexperiencingsimilartypesofissuesinrelationtosafeguardingmachineryorplant.

7.5 Workplace Health and Safety QueenslandWhenconsideringmachineguardingneeds,orifunsureabouthowtohandleaproblem,WorkplaceHealthandSafetyQueenslandshouldbecontactedon�3003699�5.Issuesandoptionscanbediscussedwithaninspectororadviser.


Appendix 1 – Machinery and plant hazard list

# Hazard Comments

Hazards, hazardous situations and hazardous events

1 Mechanical hazards�.� Generatedbymachinepartsorwork-pieces,caused,forexample,by:

�.�.� shape

�.�.2 relativelocation

�.�.3 massandstability(potentialenergyofelementswhichmaymoveundertheeffectofgravity)

�.�.4 massandvelocity(kineticenergyofelementsincontrolledoruncontrolledmotion)

�.�.5 inadequacyofmechanicalstrength

�.2 Accumulationofenergyinsidethemachinerycaused,forexample,by:

�.2.� elasticelements(springs)

�.2.2 liquidsandgasesunderpressure

�.2.3 theeffectofvacuum

�.3 Elementaryformsofmechanicalhazards

�.3.� crushinghazard

�.3.2 shearinghazard

�.3.3 cuttingorseveringhazard

�.3.4 entanglementhazard

�.3.5 drawing-inortrappinghazard

�.3.6 impacthazard

�.3.7 stabbingorpuncturehazard

�.3.8 frictionorabrasionhazard

�.3.9 highpressurefluidinjectionorejectionhazard

2 Electrical hazards, due to:2.� contactofpeoplewithliveparts(directcontact)

2.2 contactofpeoplewithpartswhichhavebecomeliveunderfaultyconditions(indirectcontact)

2.3 approachtolivepartsunderhighvoltage

2.4 electrostaticphenomena

2.5 thermalradiationorotherphenomenasuchastheprojectionofmoltenparticlesandchemicaleffectsfromshortcircuits,overloads,etc.

3 Thermal hazards, resulting in:3.� burnsandscaldsbyapossiblecontactofpeoplewithobjectsormaterials

withanextremetemperature,byflamesorexplosionsandalsobytheradiationofheatsources

3.2 healthdamagingeffectsbyhotorcoldworkenvironment


4 Hazards generated by noise, resulting in:4.� hearingloss(deafness),otherphysiologicaldisorders(e.g.lossofbalance,

lossofawareness)

4.2 interferencewithspeechcommunication,acousticsignals,etc.

5 Hazards generated by vibration5.� useofhand-heldmachinesresultinginavarietyofneurologicaland

vasculardisorders

5.2 wholebodyvibration,particularlywhencombinedwithpoorpostures

6 Hazards generated by radiation6.� lowfrequency,radiofrequencyradiation,microwaves

6.2 Infra-red,visibleandultravioletlight

6.3 Xandgammarays

6.4 alpha,betarays,electronorionbeams,neutrons

6.5 lasers

7 Hazards generated by materials and substances processed, used by the machinery and by its constituent materials

7.� hazardsfromcontactwithorinhalationofharmfulfluids,gases,mists,fumesanddusts

7.2 fireorexplosionhazard

7.3 biologicalormicro-biological(viralorbacterial)hazards

8 Hazards generated by neglecting ergonomic principles in machinery design as, e.g. hazards from:

8.� unhealthyposturesorexcessiveeffort

8.2 inadequateconsiderationofhand-armorfoot-leganatomy

8.3 neglecteduseofpersonalprotectionequipment

8.4 inadequatelocallighting

8.5 mentaloverloadandunder-load,stress

8.6 humanerror,humanbehaviour

8.7 inadequatedesign,locationoridentificationofmanualcontrols

8.8 inadequatedesignorlocationofvisualdisplayunits(VDU)

9 Combination of hazards�0 Unexpectedstart-up,unexpectedover-run/over-speed(orsimilar

malfunction)from:

�0.� failure/disorderofthecontrolsystem

�0.2 restorationofenergysupplyafteraninterruption

�0.3 externalinfluencesonelectricalequipment

�0.4 otherexternalinfluences(gravity,wind,etc.)

�0.5 errorsinthesoftware

�0.6 errorsmadebytheoperator(duetomismatchofmachinerywithhumancharacteristicsandabilities,see8.6)


11 Impossibility of stopping the machine in the best possible conditions

12 Variations in the rotational speed of tools

13 Failure of the power supply

14 Failure of the control circuit

15 Errors of fitting

16 Break-up during operation

17 Falling or ejected objects or fluids

18 Loss of stability / overturning of machinery

19 Slip, trip and fall of people (related to machinery)

Additional hazards, hazardous situations and hazardous events due to mobility

20 Mechanical hazards

21 Linked to the working position (including driving station) on the machine

22 Due to the control system

23 From handling the machine (lack of stability)

24 Due to the power source and to the transmission of power

25 Lack or inadequacy of visual or acoustic warning means

26 Insufficient instructions for the driver/operator

Additional hazards, hazardous situations and hazardous events due to lifting

27 Mechanical hazards and hazardous events

28 Electrical hazard

28.1 from lightning

29 Hazards generated by neglecting ergonomic principles

Additional Hazards, hazardous situations and hazardous events due to underground work

30 Mechanical hazards and hazardous events:

31 Restricted movement of people

32 Fire and explosion

33 Emission of dust, gases etc.

Additional hazards, hazardous situations and hazardous events due to the lifting or moving of people

34 Mechanical hazards and hazardous events

35 Falling of person from carrier

36 Falling or overturning of person carrier

37 Human error, human behaviour


Appendix 2 - Dictionary of defined terms

Abrasion areas Abrasionareasinvolverelativelysmoothpartsoperatingathighspeed,e.g.therimofacentrifugebasketattheedgeofthecasingopening.Otherexamplesofabrasionareasincludetheperipheryofanabrasivewheel,beltsandingmachine,materialrunningontoareelorshaft,aconveyorbeltanditsdrumsorpulleys,andfast-movingropesorbelts.

Consequence Theoutcomeofaneventorsituationexpressedqualitativelyorquantitatively,beingaloss,injury,disadvantageorgain.

Cutting areas Cuttingareasmayinvolverotating,reciprocating,ortransversemotion.Thedangerofcuttingactionexistsatthepointofoperationwherefinger,armandbodyinjuriescanoccurandwhereflyingchipsorscrapmaterialcanstrikethehead,particularlyintheareaoftheeyesorface.Suchhazardsarepresentatthepointofoperationincuttingwood,metal,orothermaterials.Examplesofmechanismsinvolvingcuttinghazardsincludeallkindsofcuttingtools,bandandcircularsaws,boringordrillingmachines,planingandtenoningmachines,millingmachines,waterjetcutting,highenergylaseroredgesofmovingsheetmaterial.Thecuttingeffectmaybeaggravatedbythebodybeingunabletomoveawayfromthecutter.

Danger astateorconditioninwhichpersonalinjuryisreasonablyforeseeable.

Entanglement areas Entanglementareasoccursthroughbodilycontactthrough:

• contactwithasinglerotatingsurface,e.g.couplings,spindles,chucks,leadscrews,mandrels,bars,orrotatingwork-pieces

• catchingonprojectionsoringaps,e.g.fanblades,spokedpulleys,chainwheels,gearwheelsandflywheels,mixerandbeaterarms,spikedcylinders,beltfasteners,projectingkeys,setscrews,cotterpinsonshaftsorslatconveyors

• bycatchingbetweentwopartssuchasbetweencounter-rotatingparts(e.g.gearwheels,rollingmills),rotatingandtangentiallymovingparts(e.g.achainandchainwheel,apowertransmissionbeltanditspulley)orrotatingandfixedparts(e.g.revolvingmixerandmincingmechanismsincasingshavingunprotectedopenings)

• catchinginmaterialsinmotion,e.g.centrifuges,tumbledriersordoughmixers.

Fixed guards Permanentstationaryguardthatpreventsaccesstothedangerouspartsofmachinerybyenclosureorbyprovidingarigidbarrier.Mayalsototallyencloseamachine.Fixedguardsofferprotectiononlywhenproperlyfixedinposition,andshouldnotincorporateanymeansofretentionthatcreatestheimpressionoftheguardbeingsecurelyfixed,whentheyarenotsofixed.Fixedguardsmustbedesignedtorequireatoolforremovalandreplacement.


Flying particles Thebodymaybepenetratedbyflyingobjects,ejectionofpartsofmachinery(e.g.flyingshuttleofaloom)orejectionofmaterial(e.g.moltenmetalejectionfromadie-castingmachine,sparksgeneratedinaweldingprocess).Injectionoffluidsthroughtheskincancausetissuedamagesimilartocrushingandcanbeconsideredinthiscategory.Examplesarecompressedairjets,dieselfuelinjectors,paintsprayersandhighpressurehydraulicsystems.

Guard Aphysicalbarrierthatpreventsorreducesaccesstoadangerpointorarea.

Hazard Somethingwiththepotentialtocauseharm.

Impact and crushing areas Impactandcrushingareasoccurwhenonepartofmachinerymovesagainstanotherwithapartofthebodyinbetweenegtheramofaforginghammer,counterweightsorthetoolsofpowerpresses.Thetraversingmotionofamachinerypartegthetableofamachinetoolandafixedstructurenotbeingpartofthemachinerymayalsocreatethistypeofahazard,asmayascissorhoistortable.

In-running nip point In-runningnippointsoccurontherotatingpartsofmachinery.Therearethreetypes:

• partsrotatinginoppositedirectionsandparalleltoeachother,typicallywherematerialmaybefedintoarollingmill,orwherethereareintermeshinggears

• betweenrotatingandtangentiallymovingparts,forexamplechainandsprocket,rackandpinion

• betweenrotatingandfixedpartswhichcreateashearing,crushingorabradingaction,asinspokedhandwheels,flywheelsandscrewconveyors.

Interlocking guard Physicalbarrierwhichisinterconnectedwiththepowerorcontrolsystemofthemachine.Theinterlockpreventsthemachineryfromoperatingunlesstheguardisclosed.Interconnectionsareusuallyeithermechanical,electrical,hydraulicorpneumatic,andprovideaneffectivesafeguardwhereaccesstothepointofoperationisrequiredbetweeneachcycleofthemachineorwhereregularaccessisneeded.

Lock-out/tag-out Procedurewhichcanincludevarioustypesoflocks,keysanddangertagseg.applyingalocktotheisolationswitch,aswellasadangertagwiththemaintenanceperson’snameonit.

Presence-sensing guard Therearetwotypes:

• laserguards—photoelectricsafetysystemsoperateontheprincipleofthedetectionofanobstructioninthepathtakenbyabeamorbeamsoflight.Theintangiblebarrieroperatedbythissystemmayconsistofasinglebeam,anumberofbeamsoflight,acurtainoflightoranycombinationoftheseasnecessarytoprovidetherequiredsafeguard.Ifthelightfieldisbroken,themachinestopsandwillnotcycle.


Thisdevicemustbeusedonlyonmachineswhichcanbestoppedbeforetheworkercanreachthedangerarea

• lightbeams—usedinlaserguardingofmachinery.Maybeascanningbeamorbeams,oranumberoffixedbeams.Thelightmaybevisibleorinvisible,e.g.infra-red,andmaybecontinuousormodulated.

Risk Thelikelihoodthatdeath,injuryorillnessmightresultbecauseofthehazard.

Risk assessment Theprocessusedtodetermineriskmanagementprioritiesbyevaluatingandcomparingthelevelofriskagainstpredeterminedstandards,targetrisklevelsorothercriteria.

Risk priority Thelevelofimportanceplacedonariskwherethehighertheriskscorethehigherthepriorityofcontrollingtherisk.

Safeguarding Ameansofpreventingpeoplefromcomingincontactwithanyhazardouspartsofamachine.

Safety device Adevice,includingpresence-sensingdevices,otherthanaguardthateliminatesorreducesdanger.

Shear points Shearingactioninvolvesapplyingpowertoaslideorknifeinordertotrimorshearmetalorothermaterials.Shearpointsoccurwherestockisactuallyinserted,held,andwithdrawn.Partsofthebodymaybeshearedinthefollowingways:

• betweentwomachineparts,e.g.thetableofametalplaningmachineanditsbed,thebladeofaguillotine,nippointsbetweenconnectingrodsorlinksandrotatingwheels,oscillatingpendulummovements,orscissorliftsinshear

• betweenamachinepartandawork-piece,e.g.transfermechanisms,thetoolofabroachingmachine.

Stabbing points Stabbingpointsinvolvemovingpartsofmachineryorpieceofmaterial:

• flyingobjects,ejectionofpartsofmachineryorejectionofmaterial,e.g.timberejectedfromabenchsaw

• rapidlymovingpartsofmachineryorpiecesofmaterial,e.g.sewingmachines,drillingmachines.


Appendix 3- Risk Assessment Form

Typeofmachine:................................................................................................................................................

Identification:......................................................................................................................................................

Hazard:………........................................................................................................................................................

• Onthefollowingchart,circlethemostlikelyharmtoapersoniftheriskhappens(alongthetop).• Next,circlehowoftenitcouldhappen(downthelefthandside).• Theriskpriority(score)isthenumberwherethetwointersect.


Likelihood:Howlikelycouldhappen?


EXTREMEdeath, permanent disablement

MAJORserious bodily injury

MODERATEcasualty treatment



� 2 3 4


2 3 4 5


3 4 5 6


4 5 6 7

Whatistheriskpriority?(score�-7fromtheabovechart)

• Ifyouscorea�,2or3–dosomethingnow–considerallapplicablecontrolmeasures.• Ifyouscore4or5–dosomethingassoonaspossible.• Ifyouscore6or7–doesnotneedimmediateattention.Choosecontrolmeasuresfromthehighestpossiblelevelinthefollowinglist:

Level 1: Eliminate the hazard

Level 2: Prevent or minimise the risk by one or a combination of:

Level 3: When exposure to the risk is not or cannot be minimised by other means:

• Substitutealesshazardousmachine• Modifythedesignofthemachine• Isolate themachinery• Introduce engineeringcontrols,

e.g.guarding

Introduceadministrativecontrols,anduseappropriatepersonalprotectiveequipment


Control measures – action to take:Now:…………....................………………………………………………………………………………………..…………………………....................................................................................................................................................................................................................................................................................................................................................................Later (date and action):......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Inmanycases,guardingisthebestformofcontroltomanageexposuretorisksinvolvingtheuseofmachinery,particularlyinmanysmallerbusinesses.ThisRiskAssessmentFormcanbeusedtoprioritisetherisksidentifiedinaworkplace.


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Appendix 4 – Risk Assessment Template


Appendix 5 - Australian Standards

AustralianStandardsaretheacceptedstandardsforsafeguardingmachinery,plantandotherissues.Theyaredeveloped,publishedanddistributedbyStandardsAustralia.ContactdetailsforStandardsAustraliaare:

StandardsAustraliaLimited286SussexStreet,Sydney,NSW,2000GPOBox5420,Sydney,NSW,200�Telephone:+6�282066000

Email:[email protected]:www.standards.org.au

SomeofthemostusefulstandardsavailablefromStandardsAustraliarelatingtomachineguardingarelistedbelow.Thesestandardswerecurrentatthetimeofprinting.PleasecontactStandardsAustraliatoensurethatthesestandardsarestillcurrent.

Title Description

AS4024.�-�996Safeguarding of machinery

- General principles

Setsoutthegeneralunderlyingprinciplesformachineguardingandprovidesmeansforidentifyinghazardsandrisksarisingfromtheuseofmachineryduringallphasesofmachinelife.Methodsforeliminatingorreducingthesehazardsandrisks,forsafeguardingmachines,andforsafeworkingpracticesaredescribed.Guidelinesforassessingthesafetymeasuresneededinparticularcircumstancesareprovided.Itdoesnotprovideguidanceforsafeguardinganyparticularmachine.

AS4024.2–�998Safeguarding of machinery – Installation & commissioning requirements for electro-sensitive systems

– Optoelectronic devices

Specifiesrequirementsfortheinstallationandcommissioningofoptoelectronicdeviceswhicharetobeusedformachinerysafetyapplications.

AS4024.3–�998Safeguarding of machinery

– Manufacturing and testing requirements for electro-sensitive systems

– Optoelectronic devices

Specifiesrequirementsforthemanufactureandtestingofoptoelectronicsprotectivedeviceswhicharespecificallyusedformachinerysafetyapplications.

AS4024.4–�998Safeguarding of machinery – Installation and commissioning requirements for electro-sensitive systems – Pressure-sensitive devices

Specifiesrequirementsfortheinstallationandcommissioningofpressure-sensitivemats,floors,edgesandbarswhicharetobeusedformachinerysafetyapplications.

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haz

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Title Description

AS4024.5–�998Safeguarding of machinery

– Manufacturing and testing requirements for electro-sensitive systems – Pressure-sensitive devices

Specifiesrequirementsforthemanufactureandtestingofpressure-sensitivemats,floors,edgesandbarswhicharetobeusedformachinerysafetyapplications.

AS�2�9-�994Power presses - Safety requirements

Specifiessafetyrequirementsforthedesign,construction,operationandmaintenanceofpowerstampingpressesandbrakepresses.Incorporatesdetailsforsafeguardingpowerpresses,diedesignanddiesetting.Providesrecommendationsforoperation,maintenanceandinspectionofpresses,andthetrainingandsupervisionofoperators.

AS�473-�99�Guarding and safe use of woodworking machinery

Specifiesminimumrequirementsfortheguardingandsafeuseofpoweredmachineswhichcutorabradewood,woodproductsandlikematerials,tobeobservedbyemployers,trainers,employees,designers,makersandsuppliersofwoodworkingmachineryandotherpeoplehavinganinterestinwoodworkingmachineoperations.Chainsaws,andmachineryusedinthemillingofrawsawlogs,togetherwithdebarkersandlogpeelersarenotcovered.

AS�473.�-2000Wood processing machinery –Primarytimbermillingmachinery

Specifiessafetyrequirementsforthedesign,manufacture,guardinganduseofmillingequipmentusedfortheprimarymillingofsawlogsintogreensawntimberproducts.

AS�473.2–200�Woodprocessing machinery – Safety – Finishing machinery – Common requirements

Specifiesrequirementswhicharecommontoallclassesofwoodforthedesign,manufacture,guardinganduseofmachinesforthemanufactureofcomponentsforfurniturejoineryandthelike.Thestandarddoesnotapplytomachinesusedfortheprimarymillingof

AS�473.3–200�Woodprocessing machinery – Safety – Finishing machinery – Circular sawing machines

Specifiessafetyrequirementsforthedesign,manufacture,safeguardinganduseofcircularsawingmachinesusedinthemanufactureofcomponentsforfurniture,joineryandthelike.TobeusedinconjunctionwithAS�473.2,whichcontainsgeneralsafetyrequirements.

AS�473.4–200�Woodprocessing machinery – Safety – Finishing machinery – Bandsawing machines

Specifiessafetyrequirementsforthedesign,manufacture,safeguardinganduseofbandsawingmachinesusedinthemanufactureofcomponentsforjoinery,furnitureandthelike.TobeusedinconjunctionwithAS�473.2,whichcontainsgeneralrequirements.

AS�473.5–200�Woodprocessing machinery – Safety – Finishing machinery – Moulding machines and routers with rotating tool

Specifiesthesafetyrequirementsforthedesign,manufacture,safeguardinganduseofmouldingandroutingmachinesusedinthemanufactureofcomponentsforjoinery,furnitureandthelike.TobereadinconjunctionwithAS�473.2,whichcontainsgeneralrequirements.


Title Description

DR0��45Wood processing machinery – Safety – Pt 6: Finishing machinery – Surface planers and thicknessing

Proposesthesafetyrequirementsforthedesign,manufacture,safeguardinganduseofsurfaceplanersandthicknessers,usedinthemanufactureofcomponentsforfurniture,joineryandthelike.TobereadinconjunctionwithAS�473.2,whichcontainsgeneralrequirements.

AS/NZS�677.�–�998Refrigerating systems

– Refrigerant classification

Specifiesasimplemeansofreferringtocommonrefrigerantsinsteadofusingthechemicalname,formula,ortradename.Italsoestablishesauniformsystemtobeusedinassigningtheproperreferencenumberandclassificationtorefrigerants.Thesystemforrefrigerantsclassificationisdefinedandphysicaldataofcommonrefrigerantslisted.

AS/NZS�677.2–�998Refrigerating systems

– Safety requirements for fixed applications

Specifiesrequirementsforthesafetyaspects,intermsofthedesign,construction,installationandinspectionofrefrigeratingappliances,systemsandancillaryequipmentintendedforuseorinstallationininstitutional,publicassembly,residential,commercialandindustrialoccupancies.Itappliestonewrefrigeratingsystems,toextensionsandmodificationsofexistingsystemsandtousedsystemsonbeingreinstalledandoperatedatanothersite.Italsoappliesinthecaseoftheconversionofasystemforusewithanotherrefrigerant.

AS�680.�–�990Interiorlighting

–Generalprinciplesandrecommendations

Specifiesgeneralprinciplesandrecommendationsforthelightingofinteriorsofbuildings.Primarilyrelatestointeriorsinwhichworkisundertakenandtakesintoaccountbothelectriclightinganddaylight.

AS�755–2000Conveyors - Safety requirements

Specifiesminimumsafetyrequirementsforthedesign,construction,installationandguardingofconveyorsandconveyorsystems,bothabovegroundandunderground.Itdoesnotapplytoplatformelevators,movingstairwaysorconveyorsspecificallydesignedfortheconveyanceofpeople.Providesrecommendationsforinspection,maintenance,markingandidentification,andthetrainingofoperators.

AS�788.�-�987Abrasive wheels - Design, construction and safeguarding

Specifiesrequirementsforthedesignandconstructionofabrasivewheelsandthemanufactureandinstallationofabrasivewheelsandancillaryequipment.Particularrequirementsaregivenfortheconstructionofguardsforallequipmentfittedwithabrasivewheelsandfortheconstructionofflangesforusewithabrasivewheels.Includessectionscoveringstandard(normal)maximumoperatingspeedsforalltypesofwheels.Extensivelyillustrated.

AS�788.2-�987Abrasive wheels - Selection, care and use

Specifiesrequirementsfortheapplicationandoperationofabrasivewheels.Includessectionsonthestorage,handlingandmountingofabrasivewheels,aswellasconditionsforusingspecialoperatingspeeds.Illustrationsofsuitableguardsandguardingdetailsareincluded.


Title Description

AS�893–�977Code of practice for the guarding & safe use of metal & paper cutting guillotines

Outlinesthegeneralrequirementsforguarding,withspecificrequirementsfortheguardingofdifferenttypesofmachines.Fixed,interlocked,automaticandelectronicguardsareincluded.

AS/NZS22��.�–2004Safety of laser products

- Equipment classification, requirements and user’s guide (IEC 608825-1:2001, MOD)

Specifiesrequirementsandproceduresdesignedtoprotectpeoplefromlaserradiation.Intendedforapplicationbothbyusersandmanufacturersoflaserproducts.Itspecifiessafeworkinglevelsofopticalradiation,classifieslasersaccordingtotheirdegreeofhazardandsetsoutdetailedprotectiveandcontrolmeasuresappropriatetoeachclass.Astatementontheeffectoflaserradiationonbiologicaltissuesisgiveninanappendix,andotherappendicescovermaximumpermissibleexposures,calculations,amedicalsurveillancechart,andthedesignofwarninglabelsandsigns.Itisbasedon,butnotequivalentto,IEC825-�:�993.

AS/NZS22��.4–2002Safety of laser products - Laser guards

Providesrequirementsforlaserguards,permanentandtemporary,whichenclosetheprocesszoneofalaserprocessingmachine,andspecificationsforproprietarylaserguards.ThisstandardisidenticalwithandhasbeenreproducedfromIEC60825-4:�997.

AS/NZS22��.6–2002Safety of laser products - Safety of products with optical sources, exclusively used for visible information transmission to the human eye

Providesanadaptedhazardcategorisationschemeandspecificguidanceforthesafeuseofvisibleopticalsourcesthatareusedexclusivelyfortransmissionofinformationtothehumaneye.ThisstandardisidenticalwithandhasbeenreproducedfromIECTS60825-6:�999.

AS2359.9-�995Powered industrial trucks

- High-lift rider trucks - Overhead guards - Specification and testing

Specifiestherequirementsandtestingforoverheadguardsdesignedtoprotecttheoperatorfromfallingobjects,butnotfromtheimpactofafallingload.ThisstandardistechnicallyequivalentwithandreproducedfromISO6055:�979,includingErratum:�980.

AS2397–�993Safe use of lasers in the building and construction industry

Setsoutsafetyrequirementsfortheuseoflasersinthebuildingandconstructionindustry.ProvisionhasbeenmadefortheuseofClass3B(Restricted)laserswherethelevelofilluminationisappropriate.Itisintendedforuseasareferencebypeopleconcernedwiththeuseoflasersforalignment,levelling,controlandsurveytasksinthebuildingandconstructionindustry,andsupplementstherequirementsofAS22��relevanttoworkinthatindustry.Itdoesnotcoverthedesignandmanufactureoflasers,northeuseoflasersinotherapplications.

AS2939–�987Industrial robot systems - Safe design and usage

Specifiesrequirementsforthedesign,construction,safeguardingandinstallationofindustrialrobotsystems.Inaddition,requirementsaregivenforthetrainingofpersonnel.Recommendationsforthesafeprogramming,maintenanceandoperationofindustrialrobotsarealsoincluded.Thestandardisextensivelyillustrated.


Title Description

AS266�–�983Vapour degreasing plant - Design, installation and operation - Safety requirements

Setsoutsafetyrequirementsforthedesign,constructionandinstallationofvapourdegreasingplantwithorwithoutultrasonicagitation.Providesalsorecommendedmethodsforthesafeoperationofsuchplantandprescribestheinspectionandmaintenanceproceduresrelevanttothesafetyofpeople.Appendicescoverarecommendedmethodforplantcleaning,andfirstaidinemergencies.Itdoesnotcoversurfacetreatmentprocessesoraqueousoralkalinedegreasing.

AS2958.0–2000Earth-moving machinery - Safety - General introduction and listing

ProvidestheintroductiontoandlistingofAustraliaStandardsgroupedunderthesubjectheading‘Safety’.

AS2958.�–�995Earth-moving machinery

- Safety - Wheeled machines - Brakes

Setsouttheminimumperformancecriteriaforservicebrakesystems,secondarybrakesystemsandparkingbrakesystemsforoperator-controlled,self-propelledearth-movingmachines.Appliestorubber-tyredbackhoeloaders,dumpers,excavators,graders,loaders,andtractorsortractorscrapers.Itincludesanappendixsettingoutrequirementsforin-servicetesting.

AS2958.2–�988Earth-moving machinery

- Safety - Guards and shields - Definitions and specifications

Givesdefinitionsandspecifiescharacteristicsofdifferentguardsandshieldstoprotectpersonnelfromaccidentalhazardsduetomechanical,thermal,chemicalorelectricalcauses.Coversbothrubber-tyredandtrack-typeoff-highwayearth-movingmachinery,butnotROPS,FOPSandcabs.

AS2958.3–�992Earth-moving machinery

- Safety - Roller compactors - Brake systems

Specifiesrequirementsforbrakesystemsthatarefittedtoself-propelledride-onrollercompactors.

AS37�0–�989Vibration and shock - Balancing machines - Enclosures and other safety measures

Specifiesrequirementsforenclosuresandothersafetymeasuresusedtominimisehazardsassociatedwiththeoperationofbalancingmachinesunderavarietyofrotorandbalancingconditions.Itdefinesdifferentclassesofprotectionthatenclosuresandotherprotectivefeaturesprovideanddescribesthelimitsofapplicabilityforeachclassofprotection.

AS3877–�99�Manipulating industrial robots

- Vocabulary

Definestermsrelevanttomanipulatingindustrialrobotsoperatedinamanufacturingenvironment.ItisidenticalwithandhasbeenreproducedfromISO/TR8373:�988.

AS3984–�99�Manipulating industrial robots - Performance criteria and related test methods

Describesmethodsofspecifyingandtestingtheperformancecharacteristicsofmanipulatingindustrialrobots.ThisstandardisidenticalwithandhasbeenreproducedfromISO9283:�990.


Title Description

AS3985.�–�99�Manipulating industrial robots - Mechanical interfaces - Circular (form A)

Definesthemaindimensions,designationandmarkingforthecircularmechanicalinterface(formA).ThisstandardisidenticalwithandhasbeenreproducedfromISO9409-�:�988.

AS3986–�99�Manipulating industrial robots - Coordinate systems and motions

Definesandspecifiesthreerobotcoordinatesystems.ThisstandardisidenticalwithandhasbeenreproducedfromISO9787:�990.

AS3987–�99�Manipulating industrial robots

- Presentation of characteristics

Specifiesrequirementsforhowcharacteristicsofrobotsshallbepresentedbythemanufacturer.ThisstandardisidenticalwithandhasbeenreproducedfromISO9946:�99�.

AS/NZS4486.�–�997Playgrounds and playground equipment - Development, installation, inspection, maintenance and operation

Specifiesrequirementsforthedevelopment,installation,inspection,maintenanceandoperationofplaygroundsandplaygroundequipmenttoensureacontinuingleveloffunctionandsafety.Italsocontainsrequirementsforinformationtobesuppliedbythemanufacturer.

AS6�508.�–�999Functional safety of electrical/electronic/programmable electronic safety-related systems

- General requirements

Specifiesgeneralrequirementsforagenericapproachforallsafetylifecycleactivitiesusedinelectrical/electronic/programmableelectronicdevicesusedinsafety-relatedapplications.ThestandardisidenticalwithandhasbeenreproducedfromIEC6�508-�:�998.

AS6�508.2–200�Functional safety of electrical/electronic/programmable electronic safety-related systems

- Requirements for electrical/electronic/programmable electronic safety-related systems

Specifiesthesafetylifecycleactivitiesinsystemscomprisedofelectrical/electronic/programmableelectronicdeviceswiththerequirementsfortechniquesandmeasuresthataregradedagainstsafetyintegritylevels,fortheavoidanceandcontroloffaultsandfailures.

AS6�508.3–�999Functional safety of electrical/electronic/programmable electronic safety-related systems

- Software requirements

Specifiessoftwarerequirementsforagenericapproachforallsafetylifecycleactivitieswhenappliedtosafety-relatedsoftware.ThestandardisidenticalwithandhasbeenreproducedfromIEC6�508-3:�998.


- Definition and abbreviations

Providesthedefinitionsandabbreviationsusedinotherpartsofthisseriesofstandards.ThestandardisidenticalwithandhasbeenreproducedfromIEC6�508-4:�998.


Title Description


- Examples of methods for the determination of safety integrity levels

Providesinformationontheconceptsandrelationshipofrisktosafetyintegritytogetherwithmethodsofdeterminingsafetyintegritylevels.ThestandardisidenticalwithandhasbeenreproducedfromIEC6�508-5:�998.


- Guidelines on the application of AS 61508.2 and AS 61508.3

Specifiesthesafetylifecycleactivitiesinsystemscomprisedofelectrical/electronic/programmableelectronicdeviceswithguidelinesontheapplications,calculationsandmethodologiesasoutlinedinpart2andpart3ofthisstandard.


Specifiesthesafetylifecycleactivitiesinsystemscomprisedofelectrical/electronic/programmableelectronicdeviceswithanoverviewofvarioussafetytechniquesandmeasuresasoutlinedinpart2andinpart3ofthisstandard.

AS/NZS2865:200�Safe working in a confined space

Setsouttheparticularrequirementsandprocedurestoensurethehealthandsafetyofanypeoplerequiredtoenterorworkinaconfinedspace.

HB6–�999Design standards for mechanical engineering students

ThishandbookcontainseditedextractsfromcurrentAustralianandBritishStandardsthatareofinteresttostudentsundertakingstudiesinmechanicalengineeringdesign.Itincludesextractsofstandardsconcerningdrives,structuraldesign,mechanicalhandlingequipment,andsafetyofmachinery,andisintendedtobeusedsolelyforthepurposeofstudentinstruction.

Australian Standards are available from:StandardsAustralia,55LittleEdwardStreet,SpringHill.

Phone (07) 3834 7460 or 1300 654 646 Fax (07) 3834 7461

Guide to safeguarding common machinery and plant

Workplace Health and Safety Queensland

csq/05/2432

Workplace Health and Safety QueenslandTelephone: 1300369915Website: www.dir.qld.gov.au

ThinkSafe–Work Smart

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