Conveyors are among the most efficient equipment in factories and other industrial worksites. They may also be called belt conveyors, conveyor belts or belt conveyor systems. Tasks that usually take minutes to perform by twenty or more workers can be accomplished by a single conveyor in a matter of seconds. That’s why it helps employers save a lot on labor and equipment costs.

But conveyors, like other heavy equipment, pose several hazards to employees. These hazards are often dependent on the operation and maintenance of workers. That is why employers must provide proper and complete training to conveyor operators. Employees who work near or around conveyors must also be trained to prevent hazards posed by this equipment.

General Requirements

Let’s get the general requirements concerning conveyors first. Here are some regulations set by OSHA for conveyor operators and employees working near this equipment:

• Only properly trained workers are allowed to operate, repair, and service conveyor equipment.

• Never exceed the maximum load rating indicated on the conveyor by the manufacturer.

• Never step on/over, climb, sit or ride on conveyors.

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• Keep tools and other equipment away from the conveyor.

• Keep all body parts, including hair, away from parts of the conveyor.

• Make sure that the area around the conveyor is free from tools and objects that may cause trips or slips. This is especially true for areas around the loading and unloading points of the conveyor.

• Appropriate guards must be provided for conveyors that pass over work areas, aisles, pathways or thoroughfares. These guards must be conspicuously marked with appropriate signs to warn employees of hazards.

• If the conveyor passes overhead exposure, employees must wear hard hats.

• The operator must never leave the conveyor unattended.

• Inspect all conveyors and transmission devices at a regular basis. The inspection intervals must not exceed 60 days.

Requirements in Braking

Too many accidents have happened in the past just because operators don’t follow proper procedures in starting and stopping conveyors. Some conveyors also lack appropriate switches or devices for emergency situations, making the equipment even more dangerous for operators and employees working near them.

Here are some safety standards concerning conveyor stop and start controls/devices:

• Conveyors equipped with electrically released brakes must be designed in such a way that the brakes cannot be released unless power is applied.

• The design of the conveyor must have the ability to automatically engage the brakes or return the operating control to the “stop” position in case there is a power failure.

• Means for stopping the motor or engine must be within reach from the operator’s station.

• Operators must sound an audible warning signal before starting up a conveyor.

• Emergency stop devices must be within reach of the operator.

• Emergency stop switches must be designed in such a way that the conveyor system cannot be started unless the actuating stop switch is reset to running or “on” position.

• Never start powered conveyors until the area around the conveyor is free of employees. If employees have to work near the conveyor, they must be warned when the conveyor is about to start.

Standards in Lockout and Tagout

Operators must be trained to perform the proper procedures in locking or tagging a conveyor. Otherwise, all employees are exposed to hazards such as getting their fingers (and other body parts) cut, having their bones crushed, or getting killed on the spot.

Whenever a conveyor is under repair or maintenance, it should be stopped with their power sources locked out and tagged out. The same is true for a conveyor that needs servicing. Exceptions are given to conveyors that need power for testing or making minor adjustments.

If a conveyor is jammed, it must be locked out and tagged out in the stop position before removing the cause of the jam, unless the conveyor needs to be turned on to remove the jam.

Related Links:

Better Safety with Machine Guards: Basics and Proper Use

Lockout Tagout Basics : Machinery Tags (When Absence Means Trouble)

OSHA Announces Top 10 Most Cited Violations

Common Workplace Safety Terms – Part 1

What Every Employer and Employee Must Know: Complete Scope of Safety Training