Chapter 5 Protection by Distance
Chapter 5 Protection by Distance
Protection of the human body against crushing hazards can be ensured in two ways.
A minimum gap can be left between moving components in order to avoid all contact between
the moving components and the human body, or the forces or energy levels of the moving
components can be reduced in order to limit the consequences of contact with the human
body. The first of these two approaches is an inherently safe design measure because the
hazard is eliminated, while the second reduces the risk to an acceptable level, namely, it does
not create irreversible harm to the human body.
The following minimum “d” gaps (see Figure 4-1) must be provided in order to avoid the risk
of crushing parts of the human body [15].
Body Head
Hand
Figure 4-3: Minimum gap between the robot and the guard
(safety zone provided in the safety enclosure)
anthropometric dimensions;
kinetic energy;
If the moving components are not equipped with a device for sensing the presence of a human
body (for example, box strapping machine, in Figure 4-4), then the data14 in the “permanent
maximum values” column must be used (see Table 4).
If the moving components are equipped with a protective device (sensing edge) for detecting
the human body (see Figure 4-4) and can retract automatically15 to a safe position, then the
data in the “temporary maximum values” column must be used (see Table 4). In this case, the
reliability of the control system16 that returns the moving components to a safe position must
be taken into account.
In both cases, one must take into consideration the parts of the body (fingers, hands, etc.) that
can accidentally come into contact with the moving component of the machine, and determine
whether the forces that come into play are acceptable.
* In the case of elevators, The Safety Code for Elevators (CSA B44-00) [18] states, in section 2.13.3.1.1, that the force necessary
to prevent closing of a horizontally sliding car door or gate from rest shall not be more than 135 N. Also, section 2.13.4.2.1 c)
mentions that “where a reopening device is not used or has been rendered inoperative […], the kinetic energy computed for the
average closing speed […] shall not exceed 3.5 J.”
** In the case of box strapping machines, PR EN 415-8:2004 prescribes that the maximum contact pressure must be 25 N/cm2
for permanent maximum values.
Pressure-sensitive edge
Safeguarding by distance involves the use of a fixed or movable guard. Several situations are
possible (see Figure 5-1).
In all of the following cases, the established safety distance takes into account the fact that
no voluntary movement will be made to reach the danger zone and that no accessory
(tool, glove, pole, etc.) or object serving as a step (stepladder, chair, etc.) will be used to
reach the danger zone.
Any danger zone located less than 2.5 m [19] from the
ground, catwalk or permanent working platform must be
made inaccessible by a guard or by a protective device.
Some “c” values represent a sufficiently large distance to allow a person to get between the
distance guard and the danger zone. This possibility must be taken into consideration when
the distance guard is chosen. A device preventing the machine from restarting must be
provided21.
18. CSA Z432-04 [21] mentions in section 10.2.1 that “Barriers shall […] be positioned so that […] the top of the barrier is no
lower than 1.8 m above adjacent walking surfaces […].”
19. The most accessible part of the danger zone (the bottom or top of the danger zone) must be taken into consideration.
20. New versions of ISO 13852:1996 [19] and ISO 13853:1998 [22] have been published in the new reference ISO 13857.
21. This measure does not eliminate the need for applying the provisions of sections 185 and 186 of the ROHS [9].
36 Safeguarding by distance
Table 5-1: High risk – Reaching over a guard [19]
Height of danger
Height of the guard “b”* (mm)
zone “a” (mm)
* Distance guards less than 1400 mm in height mentioned in ISO 13857:2008 are not taken into consideration because they do
not sufficiently limit movement.
** The abbreviation ”sd” means safety distance. It is defined in point 5.3.
22. According to ISO/DIS 13857 [20], section 4.1.2, note 1, “Low risks arise from hazards such as friction or abrasion where long
term or irreversible damage to the body is not foreseeable.”
38 Safeguarding by distance
Table 5-3 is used to determine:
the maximum acceptable opening (shape and dimensions) in relation to the chosen
safety distance “sd”;
the safety distance “sd” as a function of the existing opening (shape and dimensions).
Table 5-3: Relationship between maximum opening and safety distance “sd”
Slot or groove shaped opening (from CSA Z432-04 [21])
Minimum safety distance
Safety distance “sd” (mm) Maximum opening (mm) Opening (mm)
“sd” (mm)
Note. – CSA Z432-04 does not discuss the case of circular or irregular-shaped openings, and hence the reference to
ISO 13852:1996. However, note that these two standards contain different limit values.
40 Safeguarding by distance
Figure 5-9 illustrates safeguarding by
distance for a worm drive [16].
The opening’s “e” dimension corresponds to one side of a square-shaped opening, to the
diameter of a circular opening, and to the smallest dimension of a slot-shaped opening
(see Figure 5-7).
5 < e ≤ 15 ≥ 10 0
Toe
15 < e ≤ 35 ≥ 80* ≥ 25
35 < e ≤ 60 ≥ 180 ≥ 80
Foot
not
180 < e ≤ 240 ≥ 1100
admissible
* If the length of the slot opening is ≤ 75 mm, the distance can be reduced to ≥ 50 mm.
42 Safeguarding by distance
5.4.2 Lower limbs only
If the risk assessment determines that a hazard exists only for the lower limbs, the minimum
safety distance “sd” must be taken from Table 5-4
Reasoning
The guard providing the greatest safety must always be chosen. Since height “a”
(1500 mm) of the danger zone does not appear in Table 5-2 (for low risks), the closest
smaller height “a” (1400 mm) and the closest larger height “a” (1600 mm) must be
considered. Then, for each of these two “a” heights, you must determine in which interval
of Table 5-2 is the horizontal distance “c” of 700 mm, as well as height “b” of the guard
corresponding to this interval:
Solution
The minimum height “b” of the fixed distance guard is therefore 1800 mm when height
“a” of the danger zone is 1500 mm, and its horizontal distance “c”* with respect to the
guard is 700 mm (see Figure D-1).
* Important: Distance “c” is sufficiently large to allow a person to get between the distance guard and the danger
zone. This possibility must be taken into consideration when the distance guard is chosen (see point 3.2).
If the horizontal distance “c”* between the danger zone and the planned guard exceeds
900 mm, the minimum height of the guard could then be 1400 mm.
* Important: Distance “c” is sufficiently large to allow a person to get between the distance guard and the danger
zone. This possibility must be taken into consideration when the distance guard is chosen (see point 3.2).
Reasoning
In Table 5-2 (for low risks), the “c” distances must be considered as permitted when the
guard is 1400 or 1600 mm high (the dimension immediately below or above 1500 mm)
and the danger zone is located 2000 mm and 2200 mm away. The safest distance must
then be chosen.
Solution
Minimum horizontal distance “c”* between the danger zone and the guard is therefore
700 mm when height “b” for the guard is 1500 mm and height “a” for the danger zone is
2100 mm (see Figure D-2).
Danger
zone
Fixed
distance guard
Reasoning
First, the data in Table 5-1 (for high risks) must be used, and then the horizontal
distances “c” that are permissible when the guards are 1600 mm and 1800 mm high
must be taken into account. Since the permissible “c” distances are greater for a guard
1600 mm high, only these numbers can be used as a basis, since the safest distance
must always be chosen.
One must then verify, among the “c” values, which ones are less than or equal to
850 mm. The danger zone can be located at the corresponding “a” heights.
Solution
The danger zone must be located less than 1000 mm or more than 2400 mm away when
height “b” of the guard is 1700 mm and horizontal distance “c”* with respect to the
danger zone is 850 mm.
Distance “c” can even be reduced according to the indications given in Table 5-1 while
remaining safe. Also, when the abbreviation “sd” is indicated in the table (for example,
when the danger zone is located at a height “a” less than 600 mm), the danger zone must
be separated from the guard by a distance that is a function of the size of the “e”
openings in the latter. The minimum distance “sd” between the danger zone and the
guard is 13 mm, even if the guard does not have an opening in it.
* Important: Distance “c” is sufficiently large to allow a person to get between the distance guard and the danger
zone. This possibility must be taken into consideration when the distance guard is chosen (see point 3.2).
Note. – The documents published by the CSST can be ordered by mentioning the document number (DC) or consulted on line at
www.csst.qc.ca. The majority of the documents can be consulted at the CSST’s Centre de documentation by mentioning the
call number. IRSST and INRS documents can be consulted on their respective websites: www.irsst.qc.ca and www.inrs.fr.
68 References
Bibliography
GOUVERNEMENT DU QUÉBEC. Safety Code for the construction industry, c. S-2.1, r. 6, 2003.
Can be consulted at the CSST’s website : www.csst.qc.ca.
Note. – The documents published by the CSST can be ordered by mentioning the document number (DC) or consulted on line at
www.csst.qc.ca. The majority of the documents can be consulted at the CSST’s Centre de documentation by mentioning the
call number. IRSST and INRS documents can be consulted on their respective websites: www.irsst.qc.ca and www.inrs.fr.