A Guide to Practical Machine Guarding

This Guide has been produced by the members the Metals Manufacturing and Minerals Processing Industry
Committee. The committee consists of representatives of Employers, Employees and Health and Safety Experts
from the Metal Manufacturing Industry
 Contents

Practical Machine Guarding 3

Identify the Hazards 4

Assess the Risks 5

Control the Risks 7
Risk Assessment Form 8
Select the Guard 9
Types of Guard 9

Design the Guard 10

Ergonomic Considerations 10

Guards far Different Machine Types 13

Exposed Rotating Cutting 13
Pulleys and Drives 14
Rotating Shafts and Rollers 15
Conveyors (bulk handling) 16
Power Presses 18

Your Obligations 21
Workplace Health & Safety Obligations 22

Other Issues around Machinery 23

Human Error 23
Simple Rules 26

Further Assistance 28
Others 28
Division of Workplace Health and Safety 29
Australian Standards 30

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 Practical Machine
Guarding

Practical Machine Guarding

Machinery is a major hazard at work. About 8 out of 10 workplace fatalities and 1 in 4 of workplace injuries
involve mechanical equipment. Many workplaces with machinery have unnecessary injuries.

Where there is a risk of exposure to dangerous parts during operation, examination, lubrication, adjustment or
maintenance, that risk must be eliminated, or, where it cannot be eliminated, minimised.

All machinery must be securely guarded to prevent access to dangerous parts.

Make sure machine guards are in place. All guards should be correctly and securely fitted BEFORE operating
a machine.

Machine guarding is vital to every workshop using machinery. It is an essential protection you can and need to
provide for your workers. Guards need not be complicated nor interfere with productivity.

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 Identify the Hazards

A hazard is something which could cause injury.

A risk is the likelihood of the hazard causing an

injury, and how severe the injury could be

What parts of a machine do you look at to find the danger areas? Typically, the following areas on machinery
are dangerous, and can be a risk to anyone near the machine:

Parts which move or transmit power Parts that do the work

# belts & pulleys # tools & dies

# flywheels & gear wheels # guillotine blades
# shafts & spindles # milling cutters
# slides & cams # circular saws
# chain & sprocket gears # drills & chucks

To help identify dangerous machine parts, look for:

# 'drawing in' points

# shear points
# impact and crushing areas
# cutting areas
# entanglement areas
# stabbing points
# abrasion areas
# flying particles
# any protrusions which could cause injury

Machine Hazards which may be controlled by Guarding:

# Contact or entanglement with machinery

# Trapped between machine and material or fixed structure
# Contact with material in motion
# Being struck by ejected parts of machinery
# Being struck by material ejected from machine
# Release of potential energy

Once you have identified the danger areas, you should assess the risk (how likely it is to cause injury, and how
severe the injury could be), and control these risks by guarding or in some other effective way.

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 Assess the Risks

Where a hazard is identified, an assessment of risks associated with the hazard must be made. Employers
should conduct a separate risk assessment for each machine and any associated system of work used with that
machine.

Risk assessment seeks to prioritise identified hazards so that effort can be directed to eliminate or control risks
that have a high potential to cause harm.

Identified hazards are assessed to determine their real potential to cause injury. Consider the likelihood of the
hazard causing an injury (probability), and how severe the injury could be (consequence).

Probability How likely could it happen?

Very likely could happen frequently
Likely could happen occasionally
Unlikely could happen but rare
Very unlikely could happen but probably never will

Consequence How severely could it hurt someone

Catastrophic kills, disables, permanent injury
Major maiming, significant injury, NOT permanent
Minor first aid only, no lost time

The two categories of the assessed risk are then plotted on the risk chart to determine its priority for action.

Priority 1 urgent action is required to control this risk; down to

Priority 6 deal with other priorities first

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RISK PRIORITY CHART

PROBABILITY CONSEQUENCE: How severely could it hurt someone?

How likely COULD CATASTROPHIC MAJOR MINOR

it happen kills, disables permanent significant injury, NOT first aid only, no lost
injury permanent time
VERY LIKELY
could happen
1 2 3
LIKELY
could happen
2 3 4
occasionally
UNLIKELY
could happen but rare
3 4 5
VERY UNLIKELY
could happen, probably
4 5 6
never will

Once you have assessed the risk (how likely it is to cause injury, and how severe the injury could be), you will
need to control these dangers by guarding or in some other effective way.

A blank Risk Assessment Form is included on page 4 to help you assess the risks on your machinery. This can
be photocopied as many times as you need. It is suggested that you use one page per machine, or part of a
machine if it has several hazards.

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 Control the Risks

Where an assessment identifies a requirement to

control a risk to health and safety, that risk must be
eliminated or, where it cannot be eliminated,
minimised.

Appropriate control measures must be put in place

to eliminate the risk or where it is not practical to do
so, the identified risk must be minimised. Control
measures must be chosen from the highest possible
level in the following hierarchy:

LEVEL 1: Eliminate the risk

LEVEL 2: Minimise the risk by one or a

combination of:
# substitution of a less hazardous
machine
# modify the design of the
machine
# isolation of the machinery

LEVEL 3: Where risk not minimised:

# introduction of administrative
controls
# appropriate personal
protective equipment

Control measures adopted should be monitored, on

a regular basis, to ensure their effectiveness.

Write your chosen method of controlling the risk on a

copy of the Risk Assessment Form which can be
found on page 4 of this document. If the control
measure cannot be instituted now, you can use the
form to note the controls to use now, and what you
intend to do later.

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 Risk Assessment Form (May be photocopied and used)

Type of Machine: ...............................................................................................................................................

Identification: ...............................................................................................................................................
Hazard: ...............................................................................................................................................

On the following chart, circle the most likely harm to a person if the risk happens (along the top)
Next, circle how often it COULD happen (down the left hand side)
The risk priority (score)is the number where the two intersect.
RISK PRIORITY CHART

PROBABILITY CONSEQUENCE: How severely could it hurt someone?

How likely COULD CATASTROPHIC MAJOR MINOR

it happen kills, disables significant injury, first aid only, no
permanent injury NOT permanent lost time
VERY LIKELY
could happen
1 2 3
LIKELY
could happen occasionally
2 3 4
UNLIKELY
could happen but rare
3 4 5
VERY UNLIKELY
could happen, probably never will
4 5 6
What is the risk priority? (score 1 - 6 from the above chart)
# If you score a 1 or 2, do something NOW. # If you score 3 or 4, do something soon.

Chose control measures from the highest possible level in the following list:
LEVEL 1: Eliminate the risk LEVEL 2: Minimise the risk LEVEL 3: Where risk not
# substitution of a less minimised:
hazardous plant # use administrative controls,
# modification of the design of and
the plant work # appropriate personal
# isolation of the plant protective equipment
# engineering controls such as
guarding.

CONTROL MEASURES - action to take:

NOW: ............................................................................................................................................................
...................................................................................................................................................................................
LATER (Date: / / ). ......................................................................................................................................
...................................................................................................................................................................................
In many cases, GUARDING is the best form of control for the health and safety risks of a machine, particularly in
most smaller businesses.
This Risk Assessment Form can be used to prioritise the risks found in a workplace.
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 Select the Guard

TYPES OF GUARD

There are a number of different types of guards, all suited to particular purposes. You must consider which type
of guard is best suited for your needs. The different types include:

# fixed guards - have no moving parts and prevent contact between moving machinery part and any part
of the body. They offer protection only when properly fixed in position. Fixed guards should be easy to
remove and replace, but only be able to be opened or removed with a tool.

# interlocking guards - are moveable, with the moving part interconnected with the control system.
Interconnections are usually either electrical, mechanical, hydraulic or pneumatic. The interlock
prevents the machinery from operating unless the guard is closed.

# automatic guards - automatically move into position as the machine, or cycle, is started. They are also
known as push away guards. These are only suitable on slow machines.

# distance guards - prevent access to dangerous area through a barrier or fence.

# trip guards (presence sensing devices) - these stop the machine when a person gets into in a
position where they are liable to be injured. A photo-electric curtain is an example of this type of guard.

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 Design the Guard

The primary function of a guard is to provide a physical barrier which prevents access to dangerous parts of a
machine.

SOME BASIC RULES FOR GUARD DESIGN

Having a guard is not enough. Poorly designed or inappropriate guarding has often contributed to machinery
injuries.

Guards should be designed for easy removal and replacement. This will make tasks such as cleaning, machine
adjustment or belt changes easier, particularly if this needs to be done regularly. However, guards shall only be
able to be removed with the aid of a tool.

Hinged guards may be used, however, their use should be restricted to instances where guard weight or
restricted access for removal is a consideration. An interlock device may need to be used in conjunction with
hinged guarding.

Avoid second best when designing a guard. If you use a guard from another machine, ensure it is not defective
and it is appropriate for the machine.

When making your own guards ensure the materials used are of good quality.

Guarding can play a useful role in both dust and noise reduction. In many cases, issues of wear, heat and
ventilation affect operating efficiency, health and safety. Careful attention to design and layout at the outset can
avoid problems later on.

Technical assistance may be bund in Australian Standards. The standards with particular relevance to machine
guarding are listed on page 17, together with a brief description of their contents.

ERGONOMIC CONSIDERATIONS

The illustrations and table below will help you assess where and what sort of guarding is needed to keep a
danger point on a machine safely out of reach.

Reach Measurements

The design and positioning of guards should provide at least the following clearance:

Reach Minimum distance assumed

Arm reach 1000mm from under arm to fingertip

Elbow reach 500mm from the inside elbow to fingertip
Wrist reach 280mm from wrist to tip of middle finger
Finger reach 150mm
These dimensions include and allowance for clearance form danger points.

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Guard Placement

The size of mesh or other openings in the guard and the distance of the guard from the danger point shall be:

Mesh size openings up to and Distance of guard from danger point virtually the same as sheet
including 9mm metal, working clearance only required
Over 9mm but less than 50mm Guard at least 150mm from danger point
All types of guards Distance between bottom opening and floor not to exceed 250mm

Simple Gap / Distance Formula

The following formula provides an easy method for determining gap or mesh openings, and the distance the
guard should be from the danger point.
Distance
Gap = + 6mm
10

no admittance reach restricted to root of reach restricted to root of reach restricted to hand
finger thumb thickness

Reaching Down and Over

In the following diagram and table:

a = distance of danger point from the floor or working
surface
b = height of the barrier
c = horizontal distance between edge of barrier and danger point

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

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a - distance of danger b - height of the barrier (mm)
point from floor (mm)
2400 2200 2000 1800 1600 1400 1200 1000
c - horizontal distance between barrier and danger point (mm)
2400 - 100 100 100 100 100 100 100
2200 - 250 350 400 500 500 600 600
2000 - - 350 500 600 700 900 1100
1800 - - - 600 900 900 1000 1100
1600 - - - 500 900 900 1000 1300
1400 - - - 100 800 900 1000 1300
1200 - - - - 500 900 1000 1400
1000 - - - - 300 900 1000 1400
800 - - - - - 600 900 1300
600 - - - - - - 500 1200
400 - - - - - - 300 1200
200 - - - - - 200 1100

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 Guards for Different Machine
Types

Exposed Rotating Cutting

Exposed rotating cuffing machinery includes Cut-off Saws, Milling Machines, friction Cutting and Boring
equipment. Fixed and moving guards should be fitted where appropriate.

Self-adjusting guarding arrangement for a cut-off saw.

A particular point to note is the self actuating visor fitted to the fixed guard. If this visor is not affixed, the cutters
teeth are exposed when the machine is at the top of its stroke. As the cutter is lowered the visor automatically
rises.

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Pulleys and Drives
Fixed guards are preferred for Pulleys and Drives. All nip-points are to be guarded so as to be out of reach for
personnel.

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Rotating Shafts and Rollers

Fixed guards are preferred for Rotating Shafts and Rollers. Examples of rotating shafts include couplings,
spindles, fan-shafts and ironing rollers.

Provide protection against loose clothing and long hair getting entwined with rotating shafts.

ROTATING SHAFTS/COUPLINGS

DRAWING-IN HAZARDS BETWEEN ROTATING

AND TANGENTIALLY MOVING SURFACES

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Conveyors (bulk handling)

Belt Conveyors, Screw Conveyors and Bucket Conveyors typically require guarding - usually with fixed guards.

THIS ILLUSTRATION SHOWS THE NUMEROUS DANGER POINTS ON A STANDARD CONVEYOR.

The following examples show ways to guard the head and tail sections of conveyors. All guards should be
designed for easy removal and should require the use of a tool for this removal.

It is important to note that physical guarding is not the only safety aspect of conveyor systems Other safeguards
are:

üElectrical isolation - (lock-out/tag-out)Although safeguards are provided which prevent access during most
phases of machine life, they may not be effective at all times because of the need to gain access to
hazardous areas during maintenance, set-up, etc. Isolation procedures should be developed by the employer
which are appropriate for the particular machine. These procedures could include various types of locks, keys
and danger tags. A typical lock-out/tag-out system for conveyor drives would be to apply a lock to the
isolation switch, as well as a danger tag with the maintenance person's name on it.

üStart and stop controls - Conveyors should be provided with appropriate drive power isolation, whether
electrical, hydraulic, pneumatic or mechanical. Isolation should be secured by means of a lock-out/tag-out
system. At each conveyor start location, a clearly labelled Stop control should be provided. Where the Start
control is in a position from which the whole of the conveyor operation cannot be viewed, a visible or audible
signal should be provided to warn persons in the vicinity.

üEmergency stop controls - All conveyors should be fitted with emergency Stop controls. Where conveyors
are readily accessible, these controls should be located at intervals not exceeding 30m. A lanyard type pull-
wire is considered appropriate. These controls must be manually reset before the conveyor can be started.

üAccess provisions - Machinery design should allow all routine adjustment, lubrication and maintenance to
be carried out without removing guards or extensive dismantling of components. Lubrication and routine
maintenance facilities should be incorporated outside the danger area wherever practical. However, when
persons require access to the danger area, for example for machine setting, safe isolation procedures should
be used.

üLighting - Provide local lighting on the machine for lighting the work area when the machine or guards
render normal lighting inadequate for safe operation. Local lighting should also be provided in areas of

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 regular maintenance which are poorly lit, for example inside certain electrical compartments where electrical
isolation is necessary for access.

TYPICAL GUARD FOR A HEAD AND TAIL PULLEY

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 Power Presses

Power presses can be divided into two categories 1. Power stamping presses 2. Press Brakes

1. STAMPING PRESSES (KEY CLUTCH AND HYDRAULIC)

Depending on the type of job to be carried out, there ore various ways of guarding these presses:

a. Fixed Guarding

A fixed guard has no moving parts and offers protection only while the guard is in its correct position.
Operator access to the hazardous area is prevented, however with the aid of a tool, slides can be adjusted to
allow work to be fed through the guard into the stamping area.

b. Interlocked Guarding

An interlocking guard is a guard which has a moveable part, that is interconnected with the power or control
system of the machine so that until the guard is closed, the interlock prevents the machine from operating.
With the key-clutch type of press fitted with interlocked guarding, it is also necessary to fit an anti-repeat device
to prevent a power stroke in the event of a clutch failure.

c. Presence Sensing Devices (Photoelectronics)

Hydraulic Machine only. This device detects the presence of a person, or part of a person, in a defined area and
prevents the dangerous parts of machinery from moving while anyone is in that area.
The installation of these devices should comply with AS 4024.2.

d. Two-Handed Controls

Hydraulic machines only. This is a device which requires both hands to operate the machine controls and should
be installed in accordance with the following:

n The controls shall be separated and protected to prevent spanning with one hand only
n It shall not be possible to set the dangerous parts in motion unless the controls are operated within
.5sec of each other
n If one or both controls are released, movement of the dangerous parts shall be arrested immediately
n The controls should be positioned at such a distance from the danger point that, on releasing the
controls, it is not possible for the operator to reach the danger point before the motion of the
dangerous parts has been arrested.
n Rear and side guarding of the machine is required.

Regular maintenance of 'key-clutch' presses is extremely important. For maintenance to be effective, inspection
records should be kept.

Safety inspections should include the condition and operation of the following:

1. Flywheel bearing and shaft

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2. Extractor cam and key
3. Anti- repeat device
4. Brakes
5. Guards

Flywheel seizure. The flywheel journal bearings must be kept well-lubricated and clean the majority of presses
have ball or roller-bearings but some imported machines do have rolling keys. The design of rolling key clutches
is such that plain bronze bearings are a necessity. any metallic fragment entering the bearing, or a simple lack of
lubrication, could cause the bearing to seize on the journal of the crankshaft and an uninitiated stroke to occur.

MAINTENANCE PROBLEM AREAS

1. Clutch mechanism 7. Linkage and attachments

2. Brake 8. Toolsetter's disconnection
3. Flywheel bearing 9. Distortion and deterioration of guard gates
4. Pitman screw 10. Guard over foot pedal
5. Clutch interlock
6. Guard control

2. PRESS BRAKES (MECHANICAL & HYDRAULIC)

A Press-Brake is a machine generally limited to linear bending and forming of material eg. sheet metal and heavy
gauge material.

If Press-brakes are being used for specific repetitive jobs, fixed guards may be fitted. However, for general use,
these machines would require presence sensing devices, ie. light curtains or light beams fitted to comply with AS

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1219, the Australian Standard for power presses. These light beams and light curtains would enable employers
to fully utilise their presses.

Presence Sensing Systems - Light Curtains

Light curtains consist of several pairs of light box units and a control box. Each light box pair has a transmitted
and receiver. The transmitter generates a curtain of high intensity, micro-second infra-red light pulses across the
machine operators work area approximately 600mm from the hazardous area. Any intrusion into this light curtain
produces a signal for the control box to stop the machine.

In order to assist the operator these light curtain systems have a variety of operating modes for example:

Continuous Stroking: In this mode, when the control pedal is depressed, the machine will move from the top of
the stroke and continue to stroke while the pedal is depressed. If the light curtain is penetrated while the machine
is downstroking, the machine will stop.

Top-to-Top: In this mode the machine operates as in the continuous mode, except that regardless of whether
the operator releases the foot pedal, the machine will stop at the top after one cycle.

Bottom Stop: In this mode the machine starts from the top of the stroke when the pedal is depressed, and stops
leaving a daylight gap of 6mm between the top and bottom beam. At this point the light curtain is muted or
bypassed. Depressing the pedal again moves the machine to the bottom of the stroke and returns it to the top
where it stops. At this point the light curtain is reactivated.

Bottom Stop-to-Bottom Stop: This mode is similar to the bottom stop mode except that the machine does not
stop at the top of the stroke. It stops at the 6mm gap mute position or when the light curtain is obstructed on the
down stroke.

Pulsing: In this mode the light curtain is muted or bypassed and the machine can be moved down in 10mm
increments with each depression of the pedal. This mode allows the operator to stand inside the curtain for close
work.

Link: This mode is used for mechanical presses and is similar to the bottom-stop mode, except that the initial
down stroke is controlled by an electric foot-switch and at the 6mm mute point, the pedal controlling the
mechanical friction clutch is operated to finalise the stroke of the machine.

Presence Sensing Beams - Light Beams

This type of guarding system consists of three infra-red light beams mounted on the Press-brake blade.
The front beam protects the operator, while allowing work to be performed close to the blade.
The centre beam sets the mute bypass point.
The rear beam protects persons at the rear of the machine, eliminating the need for mechanical guarding.
For work with an unusual profile where the beam may be obstructed, the machine can be operated in the pulse
mode. This mode mutes the guard and permits the blade to descend in 10mm increments.

This type of system cannot be used on mechanical presses.

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 Your Obligations

Your obligation in relation to guarding is not only personal and financial, there are also important legal
requirements to adequately guard dangerous machinery.

Why should you treat machine guarding seriously?

n You have a "common law" duty of care to the people who come into contact with your business.

n Temporary, or permanent, loss of an experienced staff member through injury can be very costly, especially
in terms of loss of expertise to the business. You will, however, suddenly discover all the little things you
relied on them for in the past. Getting back to where you were is often a lengthy process.

n Injuries are bad for business. The legal, medical and other costs often go uncalculated. Even one incident
involving litigation may bankrupt a small employer. Larger employers face increased premiums. You also
need to be aware of the costs of adverse publicity (including worker morale)that often is associated with
death, severe injury and subsequent prosecution for breaches of workplace health and safety laws- as well
as the potential common law claims. Have you factored these costs into your business?

Employers are responsible for providing all necessary machine guarding and safety equipment throughout a
factory, workshop, or other workplace.

Workers are responsible for using the guards and other safety measures as required by the employer.

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 Workplace Health and Safety
Obligations

1. The Queensland Workplace Health and Safety Act 1995 obliges all employers to ensure the health and safety
of workers and other persons at work. A key element in a safe system of work is safe and properly maintained
machinery- this includes the provision of adequate guarding.

2. As well as the employers obligations under the Workplace Health and Safety Act 1995, the Advisory Standard
for Plant deals with machine guarding. It advises you how to comply with the law (it used to be called the
Code of Practice for Plant).

3. Failure to properly guard machinery can lead to prosecution under the Workplace Health and Safety Act
1995. An improvement or prohibition notice may be placed on an employer who has a machine or work
process which is unsafe. Unsafe machinery is one of the most frequent sources of workplace health and
safety prosecution. Because it is so fundamental and the risks of severe injury so high, this is an area treated
very seriously.

4. As an employer, you are obliged to provide a safe workplace. If a worker or a visitor is injured because of
inadequate machine guarding, then you could face o common law damages claim. A breach of the
Workplace Health and Safely Act 1995 can also form the basis for a common law action. This form of legal
action is becoming increasingly common - and expensive.

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 Other Issues around
Machinery
Getting Started

What is the risk? This document gives a few ideas and concepts for guarding. After reading it encourage your
staff to walk through the work areas and look for those items where moving components or exposed items could
cause injury. It is usually not possible get everything fixed at once, so draw up a plan to rectify everything that
has been listed, in order of priority. In prioritising items for attention consider not only the likelihood of injury but
also the severity of injury (see risk assessment on page 2).

It is sometimes a good idea to arrange inspections by someone who is not familiar with your plant but is familiar
with your industry.

In some cases you may want to look to longer term as well as immediate solutions. For example, guarding o
particular machine may the best solution now but look for a better machine or better solution when you come to
replace that machine. Look at the safety characteristics of machines when purchasing new equipment, try to get
suppliers and manufacturers to fit guards to your specifications. Where you see a problem is widespread see if
your industry association can put some pressure on suppliers.

Work Organisation and Work Processes

In order to guard machinery effectively you need to know what are the movement of materials on site and what
are the job procedures appropriate to the machinery. In many cases where injury arises from machinery or
inadequate machine guarding it becomes clear that production rates and job procedures had not been assessed,
monitored or systematised.

You may need to modify existing work procedures and processes to ensure the guarding does not create new
problems. The desire for extra speed, less work and making tasks easier are the leading reasons why guards are
bypassed or removed. Your machine guarding solutions must take this into account. This is another reason to
get those using the machine involved in your solutions. In the long term a carefully considered solution will
almost always prove to be less costly and more efficient.

Avoid practices that encourage workers to remove or bypass guards. Bonus or incentive payment systems can
encourage these problems and therefore need to be used with caution. You need a system to ensure guards are
used.

HUMAN ERROR

Human error is not always the result of carelessness or negligence, but follows from normal human
characteristics. People naturally become bored and distracted with repetitious work. This causes the loss of
concentration, and this human error syndrome should be anticipated by designers, manufacturers and
employers.

Machinery should be adequately guarded, taking into account the possibilities of human error.

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The following factors are known to affect human error:

n Short Term Memory

n Information Handling Capacity

n Habit

n Fatigue

n Layout

n Lighting

n Noise

n Heat & Cold

n Housekeeping

n Ventilation

n Training

Short-term Memory

After first observing a hazard, a person can soon forget about it, especially if they are distracted. Vital controls
have to be interlocked to ensure they can only be operated in the correct order or at appropriate times.

Information Handling Capacity

Vital information can be overlooked if it comes too quickly, or if it comes together with other information
(information overload). If a person has to monitor more than one "channel" of information at any one time, they
should have a clear order of priority.

Habit

People can continue a habitual activity despite indications of danger. Clear labelling of controls, and clear, simple
warning notices can help. People also get used to a particular arrangement of controls. Use standardised
controls as much as possible, and ensure that location of the controls is appropriate. The action used to operate
a control should also be compatible with the effect on the machinery, for example, switching a control towards the
left moves material into the machine in the same direction.

Fatigue

The safe use of machinery is more than attending to guarding. Long hours of work or long periods without
adequate breaks can lead to loss of concentration, slow reflexes and enhanced risk of error. Excessive heat,
poor ventilation and poor operator comfort (no attention to the location of stools, buttons etc) also contribute to
losses of concentration and error. You should take this into account when looking at machine guarding.

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Layout

Machine guarding will only be effective if it used in conjunction with proper attention to layout. Machines which
are poorly located or too close together cannot be safe even if guarded. There are a number of basic points to
consider in relation to layout.

n Avoid congestions or worker movements near machinery which are likely to cause problems.
n Make sure the layout doesn’t encourage hazardous movements in relation to operation, cleaning or
maintenance (eg blockage)
n Keep vicinity of machinery clear from rubbish, clutter etc.
n Try to have a layout which minimises unnecessary movements by trucks, people and materials. Simple and
well understood flow lines will reduce the likelihood of persons coming near dangerous machinery or being "in
the wrong place at the wrong time"

Lighting

The following issues should be considered in relation to providing adequate appropriate lighting for the safety of
people around machinery:

n direction and intensity of lighting

n contrast between background and local lighting
n colour of the light source
n reflection, glare and shadows
n the stroboscopic effect of fluorescent lighting on moving machinery (it can make moving parts of machinery
look as if they are stopped)

Noise

Noise, particularly excessive noise, interferes with concentration and can cause operator stress (itself a source of
errors). It can lead to mistakes and it can also prevent a verbal warning being communicated. Make sure efforts
have been made to minimise noise in the workplace and where noise is still high, that operators wear appropriate
properly fitted hearing protection.

You can make guarding part of the solution. In many instances carefully designed guarding of moving parts can
aid noise reduction and help remove the stress associated with prolonged exposure.

Heat & Cold

A comfortable temperature is safer to work in. Accidents are more likely to happen if it is too hot or too cold.
Personal protective equipment for heat or cold can also restrict movement and reduce the manual dexterity of
workers, as well as increasing the risk of being caught in machinery.

Housekeeping

Untidiness can cause trips and falls. Work areas, walkways and other access paths should be clearly marked,
kept clear and clean. Spills can easily cause falls, particularly if they are of an oily liquid. Design machinery to
minimise lubrication oil loss or spillage. Clean up spills as soon as possible after they occur, and avoid any oily
residues on the floor. Provide a rough anti-slip floor where this is not practical.

Ventilation

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Some processes generate heat. Design guarding to allow air flow through areas of mesh so that equipment does
not overheat.

Training

All persons who supervise, manage or operate machinery should receive appropriate training and instruction for
health and safety. Training should include safe operating procedures, and any precautions which may be needed
to control the hazards of the machines they operate.

Do not assume that people already know or can informally learn about machine safety. Include training on any
required personal protective equipment.

SIMPLE RULES

Isolation

with the exception of those circuits required for safety systems, all
machinery should be fitted with a means of isolation from all energy
sources. Such isolators should be clearly identified and be capable of
being locked if reconnection could place persons at risk.

An appropriate isolation method is a lock-out / tag-out system, in

which one or more padlocks are fitted to the isolation switch, as well
as danger tags with the exposed persons' names on them.

Safety Switches

Safety/stop switches must be located where they can easily be reached by an operator. Poorly located switches
may encourage dangerous practices such as reaching across moving parts, a failure to shut down machinery
when a problem occurs or situations where a machine can be started by one worker while another is in a
dangerous location (for example, cleaning a bin).

Inspection, Cleaning & Maintenance

To safeguard your operators and other staff you must have a regular inspection, cleaning and maintenance
procedure which is well understood throughout the workplace. Special precautions need to be taken where
workers undertaking these tasks are obscured or where there are multiple operating switches.

Apply isolation procedures whenever maintenance or repair requires people to enter the danger area around
machinery.

Opening & Removing Guards

Guards must only be able to be opened or removed with the aid of a tool.

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Hinged Guards

For ease of maintenance, hinged guards may be used. However, this type of guard may require the use of an
interlock system.

Weight

Big guards may need to be removed for maintenance access. Some sections may remain fixed but try to ensure
that the sections to be removed can be handled easily by one person. Put handles on moveable sections where
appropriate.

Interactions

Guards that move out of the way for each operation (automatic guards) need special
thought. Watch for problems in the following interactions:

n between guard and machine

n between guard and person
n between guard and workpiece

Colour coding.

You need to consider the number of switches. If the machine is large several switches may be necessary. On the
other hand, when there are multiple switches you must ensure safe operating practices are adopted so that
machine is not restarted when it is undergoing maintenance or other temporary operations. You should have a
lock-out/tag-out system.

It is good policy for all safety guards within a workplace to be painted the same colour. For example, high visibility
yellow, (but different to the general machinery colour) so that it can be clearly seen when a safety guard is not in
its proper place.

Dust

A dusty workplace could be dangerous. Dust and other airborne contaminants can have direct and severe long
term effects on your workers health, which could include respiratory problems, skin disorders and even cancer.
Dust can cause injury by clogging machinery, inducing sudden breakdowns and obscuring moving parts and
other hazards. The discomfort caused by dust on the skin, clothing and protective equipment can also
compromise safety.

A dust collection system can save clean up time and make your workplace much easier to work in. Furthermore,
a little thought can lead to solutions which solve the health and machinery hazards associated with dust. A
simple lid, cover or shield on saws, augers and other machinery can reduce the level of dust. Such guarding may
also reduce the level of noise and improve worker comfort and productivity.

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 Further Assistance

FURTHER ASSISTANCE - OTHERS

Consulting Engineers

There are a number of consultants that can offer advice on machine guarding. If you decide to use a consultant,
shop around and make sure that consultant is fully conversant with Queensland legislative requirements and that
they take an approach to the problem which is consistent with the principles identified in this guide. Ask them for
evidence of previous work in the area and check out the work for yourself, talking if possible with other
employers. As a small employer you can pool with other employers in your area in order to spread the costs. This
sort of co-operation makes sense as it saves time and money.

Your Workers

Don't forget your own workforce when it comes to getting solutions. They work with the machinery every day and
they can often not only help better identify a problem but also help with devising the most effective and cost-
efficient solutions. Workplace safety committees or health and safety representatives should be involved but
even if you don't have these in your workplace you should still involve workers. In the end they have a direct
interest in safeguarding their own health.

Even if you bring in experts or consultants you will need to ensure that workers are informed and involved. A
guard may look fine from an engineering viewpoint but if it also needs to take account of worker comfort and
ease of operation. Workers are in the best position to judge this.

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FURTHER ASSISTANCE - DIVISION OF WORKPLACE HEALTH AND SAFETY

When considering your guarding needs or if you are unsure abut how to handle a problem you can get
information from the Division of Workplace Health and Safety for advice. Such contact can be made over the
phone and it doesn't mean you’ll have an inspector or adviser at your workshop the next day unless you request
it. Assistance can be found through:

BRISBANE (Head Office) GLADSTONE MARYBOROUGH

Forbes House, 30 Makerston Street Level 2 Government Building 63 Ellena Street, PO Box 63
GPO Box 69, BRISBANE Q 4001 Corner Oaka Lane & Roseberry St MARYBOROUGH Q 4650
Tel: (07) 3247 4729 or (07) 3247 4728 Locked mail Bag 15, GLADSTONE Q Tel: (071) 23 7714
4680 Fax: (077) 23 1704
BROCHURES/BOOKLETS Tel: (079) 76 0767
Fax: (07) 3220 0143 Fax: (079) 72 6196 MOUNT ISA
Toll Free Tel: 1800 177 717 75 Camooweal Street, PO Box 2249
GOLD COAST MOUNT ISA Q 4825
BRISBANE NORTH 10 Cloyne Road Tel: (077) 44 6909
Lutwyche Shopping Village PO Box 91, SOUTHPORT Q 4215 Fax: (077) 43 8122
Lutwyche Road, PO Box 820 Tel: (07) 5583 5035
LUTWYCHE Q 4030 Fax: (07) 5583 5060 NAMBOUR
Tel: (07) 3247 9444 52 - 64 Currie Street
Fax: (07) 3247 9417 HOME HILL 1st Floor, Centenary Square Building
134 Eighth Avenue PO Box 501, NAMBOUR Q 4560
BRISBANE SOUTH PO Box 298, HOME HILL Q 4806 Tel: (074) 79 9455
Workers’ Compensation Rehabilitation Tel: (077) 82 2597 Fax: (074) 79 9474
Centre Fax: (077) 82 2566
Cnr Ipswich Road and Burke Street ROCKHAMPTON
WOOLLOONGABBA Q 4102 INNISFAIL Level 2 State Government Building
PO Box 317, ANNERLEY Q 4103 12 Fitzgerald Esplanade Bolsover Street, Locked Mail Bag 7
Tel: (07) 3896 1534 PO Box 558, INNISFAIL Q 4860 ROCKHAMPTON Q 4700
Fax: (07) 3393 1869 Tel: (070) 61 1666 Tel: (079) 31 4149
Fax: (070) 61 4371 Fax: (079) 31 4155
BUNDABERG
11 Bourbong Street IPSWICH TOOWOOMBA
PO Box 955, BUNDABERG Q 4670 6 Canning Street James Cook Centre
Tel: (071_ 53 7120 NORTH IPSWICH Q 4305 Cnr Herries & Ruthven Streets
Fax: (071) 53 1207 Tel: (07) 3281 2270 PO Box 234
Fax: (07) 3812 1064 TOOWOOMBA Q 4350
CAIRNS Tel: (076) 32 3100
10 - 12 McLeod Street MACKAY Fax: (076) 39 1702
PO Box 6665, CAIRNS Q 4870 1st Floor, Post Office Square
Tel: (070) 52 3920 Cnr Gordon & Sydney Streets TOWNSVILLE
Fax: (070) 31 2843 PO Box 1749, MACKAY Q 4740 32 Walker Street
Tel: (079) 51 8800 PO Box 211, TOWNSVILLE Q 4810
Fax: (079) 51 8066 Tel: (077) 71 6804
Fax: (077) 21 3370

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FURTHER ASSISTANCE - AUSTRALIAN STANDARDS

Standards Australia is responsible for the development, publication and distribution of Australian Standards- the
accepted standard for machine guarding and other issues in Australia. Some of the most useful standards
available from Standards Australia relating to machine guarding are:

TITLE DESCRIPTION
AS4024.1 - Safeguarding Sets out the general underlying principles for machine guarding and provides means for identifying
of machinery hazards and risks arising from the use of machinery during all phases of machine lib. Methods for
- General principles eliminating or reducing these hazards and risks, for safeguarding machines, and for safe working
practices are described. Guidelines for assessing the safety measures needed in particular
circumstances are provided. It does not provide guidance for safeguarding any particular machine.

AS 4024.2 - Safeguarding This interim standard sets out the requirements for presence sensing systems such as light beams
of machinery and pressure sensitive devices for use in machine guarding applications. It includes the means for
- Presence sensing systems determining the separation distance between persons and machinery, as well as detailing the test
requirements for the system.

AS 1219 Specifies safety requirements for the design, construction, operation and maintenance of power
- Power presses stamping presses and brake presses. Incorporates details for safeguarding power presses, die design
- Safety requirements and die setting. Provides recommendations for operation, maintenance and inspection of presses, and
the training and supervision of operators.

AS 1473 Specifies minimum requirements for the guarding and safe use of powered machines which cut or
- Guarding and safe use of abrade wood, wood products and like materials, to be observed by employers, trainers, employees,
woodworking machinery designers, makers and suppliers of woodworking machinery and other persons having an interest in
woodworking machine operations. Chainsaws, and machinery used in the milling of raw sawlogs,
together with debarkers and log peelers are not covered.

AS 1755 - Conveyors Specifies minimum safety requirements for the design, construction, installation and guarding of
- Design, construction conveyors and conveyor systems, with specific requirements for unit and bulk handling conveyors.
installation and operation Provides recommendations for inspection, maintenance, marking and identification, and the training of
- Safety requirements operators.

AS 1788.1 Specifies requirements for the design and construction of abrasive wheels and the manufacture and
- Abrasive wheels installation of abrasive wheels and ancillary equipment. Particular requirements are given for the
- Design, construction and construction of guards for all equipment fitted with abrasive wheels and for the construction of flanges
safeguarding for use with abrasive wheels. Includes sections covering standard (normal) maximum operating
speeds for all types of wheels. Extensively illustrated.

AS 1788.2 Specifies requirements for the application and operation of abrasive wheels. Includes sections on the
- Abrasive wheels storage, handling and mounting of abrasive wheels, as well as conditions for using special operating
- Selection, care and use speeds. Illustrations of suitable guards and guarding details are included.

AS 1893 - Code of practice Outlines the general requirements of guarding requirements, with
for the guarding & safe use specific requirements for the guarding of different types of machine. Fixed, interlocked, automatic and
of metal & paper cutting electronic guards are included.
guillotines

Australian Standards are available from:

Standards Australia, 67 St Pauls Terrace, SPRING HILL 4000
P.O.Box 290, SPRING HILL 4004
Phone (07)3831 8605 Fax (07) 3832 2140

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