Sgehs Implementation Guide Machinery Safety 20220804 en

IMPLEMENTATION GUIDE
Machinery Safety
July 2022
Machinery Safety (July 2022)

Using This Guide
This guide give an overview of a complex

technical topic. It does not replace the
requirement to meet relevant local and
international regulations and applicable norms.
Its content is designed to assist and inform users of
major machinery safety issues and how to
conduct a detailed machinery safety risk
assessment. It does not replace expert advice.
When designing, installing or modifying
SAFEGUARDING it is recommended to seek expert
assistance.

1 Machinery Safety Concepts
2 Machinery Hazards
3 Machinery Risk Assessment
4 Risk Control Strategies
5 Useful References

General Concepts
Limits of Machinery
Machinery Life Cycle

CONCEPTS HAZARDS ASSESSMENT CONTROL REFERENCE
Machine / Machinery
MACHINERY means:
An assembly consisting of linked parts or components, at
least one of which moves and which are joined together
for a specific application.
For Example:
• Single machines such as drilling machines, circular
saws, photocopiers, forklift trucks etc;
• A series of machines connected together for example
a production line or robot cell
• Interchangeable equipment which can be used to
change the basic functions of a machine (eg lifting
attachments)
• Partially completed machines

Inherent Safe Design
Protective measures which either eliminate

hazards or reduces the risks associated with the
hazards by changing the design or operational
characteristics of a machine without the use of
GUARDS or PROTECTIVE DEVICES.

Safeguards
SAFEGUARDS are protective measures such as

GUARDS and PROTECTIVE DEVICES that are used
to protect persons from hazards. They are most
effectively implemented during the design stage
of a machine. When hazards cannot reasonably
be eliminated or risks cannot be sufficiently
reduced through INHERENT SAFE DESIGN
additional safeguards are required.
The safety principle behind all SAFEGUARDS is that
they should permit the safe operation of
machinery without risk to the health and safety of
the operator.

Guard
A physical barrier designed as part of a

machine to provide physical protection of a
person from hazards.
There are many different types of GUARD
including permanent, fixed, mobile, interlocked,
tunnel, distance, adjustable, self-closing as well
as combinations of these types.
If hazards cannot be eliminated by using
GUARDS they should be reduced to a minimum
by using suitable PROTECTIVE DEVICES in
combination with GUARDS.

Protective Device
A PROTECTIVE DEVICE is a SAFEGUARD other than a

GUARD used to provide physical protection from
hazards.
There are many different types of PROTECTIVE
DEVICES and they generally fall into two
categories:
Presence Sensing Devices
(Trip Devices, Optical, Pressure mats etc)
Control Devices
(Hold to Run, Enabling, Two handed control,
mechanical restraints, emergency operation Pressure sensitive matting
devices etc)

Hazard or Danger Zone
Any space in, on or around a machine in which

a person can be exposed to a hazard is known
as the HAZARD or DANGER ZONE.
INHERENT SAFE DESIGN and SAFEGUARDS should
be implemented in such a way as to ensure
access to a HAZARD ZONE is not possible while
the hazard is present.

General Concepts
Limits of Machinery

Machine Limits & Life Cycle
It is important to ensure a machines LIMITS and its

LIFE CYCLE are taken into account when
performing a machinery safety risk assessment.
While LIMITS are most often defined by the
machine designer / manufacturer they need to
be understood by end users as breaching them
can create additional hazards. Additionally any
modifications to a machine may require a
redefinition of its LIMITS.
By examining each stage of a machine’s LIFE
CYCLE we can ensure we build a complete
picture of the tasks and activities involving human
machine interaction and then examine the
associated hazards.

Machine LIMITS
To assist in the identification of the hazards of a

machine, it is important to define or understand the
limits of its safe operation. These consist of operating
parameters such as:
• Its mechanical and physical properties,
• Its functional capabilities,
• its intended use and reasonably foreseeable
misuse
• the type of environment in which it will be used
and maintained.
They are normally defined during the machine’s
design and manufacture.

LIMITS of the Machine
A machine’s LIMITS can be broadly split into 4

categories:
• Use
• Space
• Time
• Other
These LIMITS need to be considered at all stages of
its LIFE CYCLE.
The next section will discuss each of these
categories in a little more detail.

LIMITS of the Machine:

1.Use Limits
USE LIMITs detail the way the machine is supposed to

be used.
When determining these LIMITS it is important to
consider reasonably foreseeable misuse to ensure the
impact of such misuse is accounted for in the machine
design.
For example, the purpose of a shredder is to shred
material. However, it can only do this within certain
defined limits. If the wrong material is used it may
become blocked.
USE LIMITS also detail the expected characteristics of
the user (eg level of training, specific physical skills or
other characteristics).


1.Use Limits – Reasonably Foreseeable Misuse
Reasonably foreseeable misuse includes:
• Loss of control over the machine
• Pressure to keep the machine running
• Normal carelessness (not intentional)
• Reflex behavior, involuntary actions
• Complacency/assumptions
These could lead to misuse such as:
• Use of materials that the machine is not designed for
• Maintenance work on an unsecured machine
• Non-compliance with the operating instructions
• Processing material that is too large or too heavy


2. Space Limits
Space LIMITS are:

• The space required by the machine due to its
physical dimensions and range of movements
• The space required for operators to access in and
around the machine
• The different interfaces between the operator
and machine (i.e. machine controls)
• The Machine-Power supply interface


3. Time Limits
Time LIMITS refer to aspects of the service life of the

machine and its components (tools, parts, safety
components).
• How long should the machine be able to
function safely?
• What is the service life of tools, wearing parts,
safety components, etc?
• What maintenance intervals are recommended?


4. Other Limits
Other LIMITS include aspects such as:

• The properties of the material to be processed,
• Cleaning requirements
• Environmental factors such as minimum and
maximum temperature, indoor or outdoor
operation, direct sunlight, dust and moisture
tolerance, etc

General Concepts
Limits of Machinery

Machine Life Cycle
A Machine’s LIFE CYCLE consists of the main

phases of its life from when it leaves the
manufacturer until it is decommissioned. The
main phases of most machine life cycles consist
of:
• Transport, assembly, installation &
commissioning
• Set-up, Teaching/Programming,
• Operation, Process Changeover,
Maintenance, Cleaning & Troubleshooting
Machine
• Disabling, Dismantling & Scrapping Life Cycle
Machine LIMITS need to be respected in all
phases of its LIFE CYCLE.

Phases of a Machine’s Life Cycle
The next section briefly examines the different phases

of a machine’s LIFE CYCLE.
A machine will have a number of activities that are
unique to a particular phase. These need to be
considered to ensure that any human interaction is
safe.
It is important to consider different populations that
may be exposed to the machine during each phase
(eg machine operators, installers, maintenance
engineers, co-workers, neighbors etc).

Life Cycle Phases:

TRANSPORT
This phase should cover all transport task that will be
undertaken involving the machine. It should consider both
internal and external transport.
ASSEMBLY, INSTALLATION & COMMISSIONING
This includes:
• removal of any transport related parts/protections (eg
covers, fixing bolts etc),
• fixing the machine into position
• Checking that the installation is correct
• connecting to a power supply and
• checking the functioning of all controls and the ability of
the machine to perform its required operations

Life Cycle HAZARDS ASSESSMENT CONTROL REFERENCE
Life Cycle Phases:
SET UP, TEACHING/PROGRAMMING

This phase should cover all the tasks required to set up the
machine for use.
Activities required to set up the machine for first use,
including both the training of users and the machine (in
the case of a robot or Artificial Inyelligence).
PROCESS CHANGEOVER & OPERATION
This phase should cover all of the different tasks involved
in operating the machine making adjustments and
changes for different activities or products.
This phase should largely be detailed in the machine’s
operating procedures.

Life Cycle HAZARDS ASSESSMENT CONTROL REFERENCE
Life Cycle Phases:
MAINTENACE, CLEANING, & TROUBLESHOOTING

These phases need to cover all the tasks required to keep
the machine in good working order.
This includes how to access the machine safely to clean it
and perform maintenance or troubleshooting on it’s
components
DISABLING, DISMATLING & SCRAPPING
These phases cover the tasks required by the user to take a
machine out of operating and safely dispose of it or any of
its constituent parts.

Machine LIFE CYCLE & LIMITS
By examining a machines LIMITS and LIFE CYCLE there should

be a clear understanding of:
• The safety functions of the machine
• Its operational characteristics (speed, force, cycle times
etc)
• Its environmental and space requirements
• All Operating modes & tasks (number and frequency)
• All foreseeable maintenance interventions (including
trouble shooting and malfunction)
• Reasonably foreseeable misuse of the machine
• Training, experience and other relevant characteristics of
the machine users
• Foreseeable exposure of others (eg adjacent workstations,
other nearby employees, contractors or service providers
and visitors)

2 Machinery Hazards
5 Useful References

2 Machinery Hazards
Mechanical Hazards
Non-Mechanical Hazards
Main Machinery Hazards

Hazard Identification
When identifying a machine’s hazards it is necessary to

consider ALL relevant phases of its LIFE CYCLE.
This is particularly important when designing a new machine or
when creating systems involving a number of machines. When
this is the case it is recommended to use formal analytical
methods to understand potential hazards and failure modes.
These methods include:
• “What If” analysis
• Preliminary Hazard Analysis (PHA)
• Fault Simulation of Control Systems (FSCS)
• Method Organised for a Systemic Analysis of Risks (MOSAR)
• Fault Tree Analysis (FTA)
• Hazard and Operability studies (HAZOP)
• Fault Mode and Effect Analysis (FMEA)

Hazard Identification
When a machine is already in use it is often enough

to perform to identify hazards in a more “traditional”
way. These take the machine’s LIMITS and LIFE
CYCLE into account in addition to other sources of
information such as:
• Review of accident reports involving the
machine
• Existing area or task risk assessments
• Hazard spotting on the machine while it is in use
• Review of reports and technical articles
concerning similar machines

Hazard Identification:
The process of Hazard Identification should:
• Examine each component part of the machine
to identify possible hazards
• Consider hazards that may be created during
specific operations such as setting up,
adjustment and maintenance
• Consider the manner in which machine
components move and how they are driven
(direct drive, chain, belt, clutch, etc.)
This process can be greatly assisted if it includes
people with extensive knowledge of the operation
and maintenance of the machine (including
“reasonably foreseeable misuse”).

Machinery Hazards: Mechanical Hazards
Machine parts generally move in one of three

ways: they rotate, they slide, or they can
rupture, fragment, and/or eject.
• Single rotating parts, such as shafts or
couplings, present a risk of snagging or
entanglement.
• Parts that slide or reciprocate, such as dies in
punch presses, create shearing or crushing
hazards.
• Parts that can rupture or fragment, such as
an abrasive wheel, may cause impact
injuries.

Mechanical Hazards: Entanglement
Bodily contact with the following features may

lead to ENTANGLEMENT:
Contact with a single rotating surface,
e.g., couplings, spindles, chucks, leadscrews,
mandrels, bars, or rotating work-pieces. These,
even when rotating slowly, are a source of Contact with a single rotating surface
danger.
Catching on projections or in gaps,
e.g., fan blades, spoked pulleys, chain wheels,
gear wheels and flywheels, mixer and beater
arms, spiked cylinders, belt fasteners, projecting
keys, set screws, cotter pins on shafts or slat
conveyors. Catching on projections or in gaps

Mechanical Hazards: Entanglement (cont.)
Bodily contact with the following features may lead

to ENTANGLEMENT:
Between rotating and fixed parts
e.g. spoked hand wheels or flywheels and the
machinery bed, screw or worm conveyors and their
casing, revolving mixer and mincing mechanisms in
casings having unprotected openings, Z-blade and
ribbon-blade mixers, extruder scroll and barrel, or
the periphery of an abrasive wheel and an
incorrectly adjusted work rest.
Catching on materials in motion
Between rotating and fixed parts
e.g., in centrifuges, tumble dryers, mixers and swarf
from machining

Mechanical Hazards: Drawing In/Nipping/Trapping
Bodily contact with the following features may lead to

being DRAWN-IN, TRAPPED or NIPPED by:
Catching between rotating and tangentially moving
parts
e.g., a power transmission belt and its pulley, a chain
and chain wheel, cable, rope or chain and its reeling
drum or a conveyor belt and its driving pulley.
Catching between rotating and tangentially moving parts

Mechanical Hazards: Drawing In/Nipping/Trapping (cont.)
Bodily contact with the following features may

lead to being DRAWN-IN, TRAPPED or NIPPED by:
Catching between two counter-rotating parts,
e.g., gear wheels, rolling mills, mixing rolls etc, or
materials being drawn between two rolls.
Catching between two counter-rotating parts

Mechanical Hazards: Friction and Abrasion
FRICTION burns can be caused by smooth parts

operating at high speed, e.g., the rim of
centrifuge basket at the edge of an easing
opening.
Other examples of friction and ABRASION
hazards include the periphery of an abrasive
wheel, belt sanding machines, materials
running onto a reel or shaft, a conveyor belt Friction and Abrasion hazards
and its drum or pulley, and fast moving ropes or

belts.

Mechanical Hazards: Cutting and Severing
CUTTING / SEVERING occurs as a result of bodily

contact with such items as cutting tools, saws,
routers, knives, or moving sheet metal
Cutting and Severing Hazards

Mechanical Hazards: Shearing
Parts of the body may be SHEARED in the

following ways:
• Between two machine parts, e.g., the table
of the metal plaining machine and its bed,
the blade of a guillotine, nip points between
connecting rods or links and rotating wheels,
or oscillating pendulum movements;
• Between moving part and stationary object.
Shearing Hazards

Mechanical Hazards: Crushing and Impact
CRUSHING occurs when one part of machinery

moves against another with a part of the body in
between, e.g. the ram of a forging hammer,
parts gripping mechanisms, parts of a conveyor,
etc. The traversing motion of a machinery part
and a fixed structure may also create this type of
hazard.
IMPACT hazards are caused by objects that act
against the inertia of the body but do not
penetrate it, e.g., the traversing motion of a
machinery part, oscillating pendulum movement,
Crushing and Impact Hazards
striking by projections or moving counterweights.

Mechanical Hazards: Stabbing, Puncturing & Ejection
STABBING and PUNCTURING hazards may be

created by:
• Rapidly moving parts or machinery or pieces of
material, e.g., drilling machines, sewing
machines, etc.
• Ejection of parts of machinery, e.g., a loose drill
bit on milling machine, broken tooling on a
press, bursting of an abrasive wheel, or
• Ejection of materials, e.g., ejection of a work
piece, flying metal chips and turnings, sparks
generated by grinding or welding process, Stabbing, Puncturing and Ejected Projectiles
molten metal ejection from die-casting
machine, etc.

2 Machinery Hazards
Mechanical Hazards

Non-Mechanical Hazards:
These include:
• Electricity, including static electricity
• Thermal
• Noise
• Vibration
• Radiation
• Harmful Materials / Substances
• Ergonomic
• Environmental

Non-Mechanical Hazards: Electrical

Contact between an electrical source of energy and
a conducting material (including people) can result in
serious damage or loss of life.
The hazards generated include:
• Electric shock
• Electric burns
• Electric fires and explosions
• Arcing
An accumulation of STATIC ELECTRICITY can also
generate similar hazards and can also cause serous
damage or loss of life.
STATIC ELECTRICITY may be generated by the rapid
separation of highly insulated materials by friction or
by transfer from one highly charged material to
another in an electric field.
Non-Mechanical Hazards: Thermal

Equipment and processes may present thermal
hazards such as:
• Flame and explosions
• Radiation of heat from sources
• Hot or cold surfaces (furnace walls, pipes, dry ice);
• Media (molten materials);
• Emissions (steam)
Direct skin contact or inhalation of media can lead to
severe tissue damage by frost-bite or burns/scalding.
Heat-shields and insulation materials, used to
complement physical barriers, guards and panels can
be used to lower the temperature outside of the
equipment, or to keep personnel at a safe distance
from the thermal hazard.

Non-Mechanical Hazards: Noise

Noise may be generated by equipment components (eg
cavitation, exhaust systems, scarping surfaces etc) or by the
processing of materials (metal grinding, stone crushing, etc.)
If this cannot be eliminated at design (or purchasing) stage
exposure may need to be controlled as they may lead to
one or a combination of illnesses:
• Permanent hearing loss,
• Tinnitus,
• Tiredness and stress,
• Other effects such as loss of balance or loss of awareness,
• Interference with speech communication.
Please refer to the Saint-Gobain Health & Safety Risk
Assessment and Control Standard for more details on how to
assess noise risk.

Non-Mechanical Hazards: Vibration
Vibration is generated both intentionally (gravity flow of

bulk materials) as well as unintentionally (unbalanced
rotating components, cavitation, worn parts) in various
industrial processes.
• Vibration can negatively affect the human body,
causing fatigue, muscle numbness or chronic
conditions such as vibration white finger;
• Vibration may also cause damage to the equipment,
process and structures potentially creating other
hazards.
Means of reducing vibration transfer include the
installation of shock absorbers, isolators or dampeners of
various designs and materials.

Non-Mechanical Hazards: Radiation
Radiation sources in industrial settings may include both

ionizing and non-ionizing radiation:
• Non-Ionizing – Ultra-violet, Infra-red and Microwaves;
• Ionizing – X-Rays.
Radiation Shielding may be both lead-based or lead-free
(bismuth, tungsten, antimony).
Laser shielding is designed to protect against harmful effect
of a beam and also metal fumes that may be generated
when lasers are used for metal processing (laser marking) or
other processes such as cutting.

Non-Mechanical Hazards: Chemicals
Many industrial blending, mixing, grinding and other

processes general particles that are harmful for the
respiratory system.
• Dusts and fines include inhalable and respirable fractions;
• Mists are liquid droplets suspended in the air
• Fumes includes smoke, vapours and gases
Well sealed vessels and hatches in combination with
negative pressure and dust collection systems should ensure
that harmful chemicals are not causing adverse health
effects.
Assessment and Control Standard for more details on how to
assess chemical risk.

Non-Mechanical Hazards: Ergonomic
Ergonomic hazards may be generated if Machinery is

designed or installed with the following hazards:
• Poor or awkward access
• Design or location of visual displays, indicators and
control devices leading to poor posture etc
• The level of physical effort needed to operate the
machine
• Lighting issues
• Flickering, dazzling, shadow or stroboscopic effects
• Mental overload or stress
• Repetitive activates
Assessment and Control Standard for more details on
how to assess ergonomic risk.

Non-Mechanical Hazards: Environmental
The machine’s operating environment may also

generate hazards that should be identified and
assessed. These may include:
• Dust, mist, fog
• Electromagnetic disturbance
• Lighting
• Moisture levels
• Pollution
• Temperature
• Presence of water
• Weather (snow, wind, rain)
• Oxygen levels.

2 Machinery Hazards
Mechanical Hazards

Main Machinery Hazards (1/3)

SOURCE HAZARD EXAMPLES
The following list is meant to help Rotation Entanglement Rotating parts (with or
users remember some key machinery without projections)
hazards. It is not a complete list so Nipping /Drawing Gears, in-running nips of
should not be used as a checklist. In rolls, chains, belts
Shear Sliding arts, spoked wheels,
rotary blades
Cut Rotary knives, abrasive
wheels, circular saws
Linear Sliding Trapping, Crushing Moving parts close to fixed
structures
Shear Adjacent machine parts
Puncture Nail guns, drills, stapling
Impact Moving parts


SOURCE HAZARD EXAMPLES SOURCE HAZARD EXAMPLES
Abrasion Friction burns Rotating drums Stored Energy Air, steam or gas Pressure storage vessel
Abrasions Abrasive wheels, rough under pressure
moving surfaces Springs Actuated cylinder, robots
Ejection Ejection of Grinding debris, oil, dust, Sudden release Relief valve, pipe failure
materials fume, steam Electrical Short circuit, discharge from
Ejection of Processed parts capacitors, static
components Weights & heavy Counterweights, lift cage
Ejection of machine Broken parts, excessive parts
parts speed Electricity Shock Exposed conductor,
Sharp Edges Burns Newly cut or formed metal, insulation failure, no earth
swarf (ground)
Cutting blades Exposed saw or knife blades, Short circuit Fire, explosion, burn
tools Overload Fire, burn


SOURCE HAZARD EXAMPLES SOURCE HAZARD EXAMPLES
Substances Ejection Leaking seals or joints Physical Noise Metal to metal contact
Escape Hazardous material, high Vibration Out of balance shafts
pressure steam, flammable Pressure / Vacuum Tunnelling
gas, liquids
Temperature Ovens, refrigeration, friction
Radiation Ionizing Non destructive testing, X-
ray Asphyxiation Confined space, oxygen
displacement or depletion,
Non-ionizing UV, IR, lasers, induction exhaust fumes
heating
Suffocation Free flowing solids

Risk Assessment Process
Saint-Gobain Risk Assessment Tool

Machinery Risk Assessment:

Nominated Person
There should be a Nominated Person in charge of

the implementation of and compliance with the
Saint-Gobain Machinery Safety Risk Assessment
Standard.
This person should adequately resourced
(including time to perform their duties) and be
considered competent to discharge their duties.
It is important that they have sufficient authority to
ensure that the required actions are taken.


Nominated Person Competence
A competent Nominated Person should:

• Have a sound technical foundation
• Understand the requirements of the Saint-
Gobain Machinery Safety Risk Assessment
Standard
• Understand all applicable national and
international regulations and norms relating to
Machinery Safety.
• Have a working knowledge of the machinery
present on their site


The Team
Risk Assessments are more complete and of better

quality if conducted by a team.
When launching a Machinery Risk Assessment, it is
important for the Nominate Person to ensure that
the team has the correct:
• Technical & operational competences
• Practical experience with the machine
• Knowledge of the Machinery Safety Standard
and assessment tools

Machinery Risk Assessment Identify

the
Hazards
and Risks
Assess the
Recognise Risk &
all changes Identify
controls
All machines should undergo a risk assessment. This
assessment should be reviewed regularly and Is Risk
Reduction
updated whenever the machine is modified. achievable?
Any plan to modify a machine or its safety

features should trigger the site Management of Conduct
Pre-Start-
Change process. up Safety
Review
Implement
Change
if safe
Train
affected
workers
Monitor
and Adjust


Triggers for Assessment
An assessment should be conducted on any
machine (or combination of machines) that:
• Is in the process of being designed
• Will be or has just been installed or moved to
a new location (including within a workshop)
• Has its existing safeguarding devices (including
programming) modified in any way
• Will be used in a new or modified way (including
using new types of materials)
• Will have additional elements, tools, modules or
functions added
• Has anything installed, modified or removal
nearby that impacts its functioning or the
functioning of its safeguards.

Machinery Risk Assessment
The Saint-Gobain Machinery Safety Risk

Assessment Standard requires that the
assessment should start by assuming no
safeguard or other controls are present.
This requires the assessment team to identify
and examine all hazards. They cannot dismiss a
hazard as under control without first examining
it, assessing the risk and deciding the
appropriate control measures.
They can then compare their defined controls
with the existing ones. If the existing controls are
adequate then no additional measures are
needed.


Process Overview
START
Machinery Risk Assessment should follow 3 key Define/Understand the LIMITS of the machine
steps:
1. Define the LIMITS of the machine
Identify the HAZARDS on the machine
2. Identify the HAZARDS on the machine RISK REDUCTION by
3. Assess the RISK for each HAZARD selecting suitable
protective measures
While the logical flow is to define limits then ASSESS the RISK for each HAZARD & EVALUATE
identify hazards these two activities are most
efficiently conducted concurrently.
NO Is the
RISK adequately
reduced?
YES
END


Process Overview
START
Once the risk has been assessed the team Define/Understand the LIMITS of the machine
should decide if it is adequately controlled. If it
is not additional actions should be taken to
reduce the risk to a reasonable level. Identify the HAZARDS on the machine
RISK REDUCTION by
Once these additional measures have been selecting suitable
protective measures
defined the risk assessment should be repeated ASSESS the RISK for each HAZARD & EVALUATE
to ensure that the final Risk level will be
acceptable.
NO Is the
RISK adequately
reduced?
YES
END

1. Define the LIMITS &

2. Identify the Hazards of the Machine
The assessment team should define the LIFE CYCLE

phases that will be included in the risk assessment.
The key phases for most machines already installed
and operating are:
• Setting Up
• Process Changeover
• Operation
• Maintenance
• Cleaning
• Troubleshooting


The team should then gather the necessary

information about the machine during the relevant
phases by:
• Reviewing the manufacturer’s instructions
• Reviewing the operating procedures involving the
machine
• Conducting a physical examination of the machine
• Talking to machine users
• Talking to maintenance engineers
• Reviewing experience gained from this or other
similar machinery (eg accident and maintenance
records)


In order to identify all hazards the different

exposure scenarios identified within the machine
across its relevant LIFE CYCLE phases should be
considered.
This includes all modes of operation, including
breakdown and misuse.
For example, there may be no hazards for an
operator when performing simple tasks from the
machine control panel but they may quickly
appear when the operator needs to clear a
blockage from the machine.


It is important to take a structured approach to

ensure all the different possible interactions with
the machine are considered.
Whenever possible this should be done through
direct examination of the machine and
observation of it in use.
REMINDER: This step should assume there are no
safeguarding or other controls implemented

Example Risk Matrix

3. RISK ASSESS & EVALUATE
PROBABILITY
Each identified hazard should be ASSESSED. Very High High Medium Low Very Low
10 8 6 4 1
Saint-Gobain recommends using a simple
Very High 100 1000 800 600 400 100
calculation to assess risk:
RISK RATING = SEVERITY x PROBABILITY High 40 400 320 240 160 40
SEVERITY
In order for meaningful estimates of SEVERITY Medium 21 210 168 126 84 21
and PROBABILITY additional information
should be gathered. Low 8 80 64 48 32 8
Very Low 2 20 16 12 8 2

Machinery Risk Assessment: Example Severity Scoring

Severity Description Score
To better estimate SEVERITY assessors should try to
determine the most likely level of harm that would be Very High May cause death 100
suffered if the risk was realised. To help them estimate this
they can examine: May cause a permanent impairment or a high
High
consequence injury
40
• Accident records involving the same or similar machines
• The machine’s operating characteristics (eg speed, May cause a lost-time accident (LTA) which
torque, temperature) Medium makes the resumption of usual work temporarily 21
• The possibility to limit contact with the hazard impossible
(eg an operator may be able to remove their hand from
a hot surface in a second, limiting the likely harm Low May cause a non-lost-time accident (NLTA) 8
suffered or an operator’s hand may become bound to
a rotating shaft increasing the likely harm)
• The likely extent of the harm caused
Very Low May cause a slight injury that requires first aid 2
(will it result it a slight burn, a cut, a bruise, an
amputation of a finger, or an arm)

Machinery Risk Assessment: Example Probability Scoring

Probability Description Score
An accident will almost certainly happen

To better estimate PROBABILITY assessors can Very High
An accident is expected (>50%)
10
examine:
• The need for access into the hazard zone An accident is likely
• The nature of that access High
An accident is expected occasionally (>10%)
8
• The number of people requiring access
• The duration of the access An accident is possible
Medium 6
• The frequency of the access (see next page) An accident is expected infrequently (>1%)
• The possible occurrence of a hazardous event

An accident is rare
(eg from accident data) Low An accident is expected very infrequently 4
• The possibility of avoiding the hazard (eg speed (>0.1%)
of moving parts, escape routes) An accident is very rare
• Human factors (ergonomics, stress, interaction Very Low An accident is expected in extreme 1
with the machine) circumstances (>0.01%)


When using the recommended Saint-Gobain
calculation (RISK RATING = SEVERITY x PROBABILITY)
it is necessary to estimate the FREQUENCY of
exposure as part of the estimation of PROBABILITY.
The Saint-Gobain Machinery Risk Assessment
Standard requires that estimations of frequency be
based on the FREQUENCY OF EXPOSURE DURING A
TASK – not the frequency of the task.
For example, if a task takes place once per year but
during its execution there is a continuous exposure
to the hazard zone then the frequency should be
considered “continuous” – not once per year.


When estimating PROBABILITY & SEVERITY it is also

necessary to take account of the possibility that
users may try to defeat or avoid existing
protective measures. The defeating of control
measures is much more likely if they:
• Slow down production
• Interfere with another activity or preferred
action of the user
• Are difficult to use
• Are easy to defeat
• Are only used by one person
• Have not been accepted by users as
appropriate and/or suitable.


Once all risks have been assessed they should be

organised into their appropriate Risk Level. Score Risk Level
The Saint-Gobain Health & Safety Risk Assessment and ≥ 600 Score ≤ 1000 Very Critical
Control Standard requires, as a minimum, the use of 4
risk level bands (see opposite). ≥ 210 Score < 600 Critical
The Saint-Gobain Machinery Risk Assessment
Standard goes on to stipulate the type of controls that ≥ 20 Score < 210 Medium
must or should be implemented depending on the risk
< 20 Low
level.


For risks classed as VERY CRITICAL or CRITICAL RECOMMENDED MINIMUM

Technical Control
control measures must include reliable technical Risk Level
Measure Required? Safety Circuit
Design Architecture
& Performance
controls (i.e. physical guards or other protective Performance
Level
devices) that prevent access to the hazard zone Control
Very Critical MANDATORY Cat 3, PL-d
and/or remove the hazard before allowing Reliable
access. Critical MANDATORY
Control Cat 3, PL-d
Reliable
When the implementation of such technical
Single Channel Cat 2, PL-c
controls is not practicable (e.g. access into a Medium RECOMMENDED
with monitoring
hazard zone is required for the task) other controls Cat 1, PL-b
can be considered. This scenario is covered by Low OPTIONAL Simple
the Control of Hazardous Energy (LOTO) Standard
and Implementation Guide.


This approach is also RECOMMENDED for hazards RECOMMENDED MINIMUM

Technical Control
assessed to be MEDIUM risk. Risk Level
Measure Required? Safety Circuit
Design Architecture
& Performance
Performance
The process of selecting the most effective Level
protective measure follows the principles of the Control

Very Critical MANDATORY Cat 3, PL-d
Reliable
HIERARCHY OF CONTROL and is covered in
Control Cat 3, PL-d
Section 4 (Risk Control Strategies). Critical MANDATORY
Reliable
Single Channel Cat 2, PL-c
Medium RECOMMENDED
with monitoring
Cat 1, PL-b
Low OPTIONAL Simple


Once control measure have been identified it is

necessary to REASSESS the risk to understand the
impact they have on the Risk level and to ensure that
the remaining risk level is acceptable.
If the risk level remains high additional controls should
be identified and implemented.


All operating conditions and interventions
have been considered
Once the Risk Rating has been reassessed the Hazards have been eliminated or risks
next step is to implement the necessary reduced to their lowest practicable level
changes.
Any New Hazards that have been introduced
A risk can be said to be adequately have been addressed
controlled when:
Users are informed about remaining risks
Protective measures are compatible with
each other
Reasonably foreseeable misuse has been
considered
Protective measures do not adversely affect
working conditions or usability of the machine

Risk Assessment Process
Saint-Gobain Risk Assessment Tool

Saint-Gobain Machinery
Risk Assessment Template
Saint-Gobain has created a tool to assist in the
assessment of Machinery Safety.
As usual it's up to individual sites to decide if they
wish to use it.
The template complies with the requirements of
the standard.

Risk Assessment Tool
The tool is organised into life cycle phases.
Each phase has its own section. The same
hazard can appear multiple times in different
phases as its level of risk may vary depending
on the life cycle phase (eg a hazard can
have a higher risk during cleaning than
during normal operations).
The Assessment team should select the
phases relevant to their assessment and
complete the assessment for each.
The view shown opposite will display which
phases have been assessed and the highest
risk found in each phase.

Each phase should be populated with a list of all

the tasks, interactions, activities and other types of
intervention that may take place during that
phase.
There are some generic tasks already defined
(taken from ISO12100) and accessible using drop
down lists but users are able to enter their own free
text if they prefer. This can allow for more precise
and meaningful descriptions.

After defining all tasks the team should list all

machinery hazards associated with each one.
This is done by completing the columns
“Hazard Group” (which is taken from a
predefined list and cannot be modified) and
“Hazard Source” (which has default values but
can be modified).
Each task may require multiple lines to define
all the hazards present.

Once the hazard has been clearly defined

the template asks for a description of
potential accident scenarios
(consequences/exposures).
The drop down list provides some common
consequences from exposure to each
hazard group however, it is recommend to
be as descriptive as possible at this stage.
The assessment team are able to enter free
text in this field to proved additional details.

The next 4 columns are where each risk is
assessed, given a numerical value and risk
rating.
The tool uses SEVERITY x PROBABILITY
calculation as recommended by the Risk
Assessment and Control standard.
The team select their estimated level for both
SEVERITY and PROBABILITY using the drop
down lists (Very Low, Low, Medium, High, Very
High).
Once done the tool will automatically
generate a Risk score (between 2 and 1000)
and identify its risk rating (Low, Medium,
Critical, Very Critical)

The tool includes additional columns to help
guide the team with the necessary corrective
actions.
The tool tells the team if Engineering Controls
are MANDATORY or RECOMMENDED based on
the Machinery Safety Risk Assessment
Standard requirements and depending on the
risk rating for the hazard.
If the team choose to implement “Engineering
controls stopping the hazard” such as
presence sensing or interlocks then the tool
also identifies the minimum level of
performance necessary for these system.

Saint-Gobain Machinery Risk

Assessment: EXAMPLE ASSESSMENT
A site uses a screw conveyor to transport raw materials
into its mixing process.
A team is assembled by the site nominated person to
perform a Machinery Risk Assessment on the screw
feeder and other equipment in the area.
The team consists of:
• The maintenance engineer responsible for the area
• An operator
• A contractor who often works in the area
As the machinery is already installed and there is no
plan to decommission it the team agree that their
assessment should cover the life cycle phases of Set-up,
Operation, Maintenance, Cleaning and Trouble
shooting.


The team start to define the screw feeder LIMITS:
USE LIMITS Raw materials to be fed manually by an
operators by opening paper bags and pouring
raw material into a funnel.
Foreseeable intervention: if material gets stuck
due to humidity, it may need to be pushed into
the screw
Foreseeable misuse: Bag dropped into funnel
and operator may try to recover it immediately
SPACE LIMITS Operating position on a safe platform with the
funnel located at waist height.
TIME LIMIT Continuously running batch process.
5 bags to be fed into the mixer every 30-45
minutes
Periodic maintenance of the machine every 6
months
OTHER LIMITS Material is fine granules, some exposure to dust
is expected.


They then start to compile the different activities and ACCESS POINT
interactions that taken place in and around the screw feeder.
For this example we will examine one of these in more detail:
TASK / INTERACTION Feeding, filling, loading or raw materials

HAZARD GROUP Mechanical
HAZARD ORIGIN Rotating elements
ACCIDENT SCENARIO 1 Shearing between rotating blades of a
screw and stationary frame of conveyor
body, resulting in limb amputation HAZARD ZONE
ACCIDENT SCENARIO 2 Entanglement around the center shaft of
a screw, pulling-in and entrapping
worker


The team discovered access to two hazard points

on the screw: Factor Probability
• entanglement around the centre shaft and
• shearing by the rotating blade against a Safe work platform
stationary frame. Height of funnel
Severity was judged to be: 25KG bags
Entanglement: VERY HIGH High frequency of exposure
Amputation of arm
Need to manually clear “bridging”
Pulling in of body
material from funnel
Shearing: HIGH
Amputation of fingers or fingertips Need to clear jammed screw caused by
dropped bag
Probability was determined to be HIGH for both
based on the table opposite.


The following details were entered into the Machinery
Safety Risk Assessment Tool:


They examine the operational, set-up and maintenance
requirements to access the screw and conclude the best
solution is the installation of a fixed guard.
ACCIDENT SCENARIO 1 Shearing between rotating and

stationary parts of the screw
ACCIDENT SCENARIO 2 Entanglement around the center shaft
RISK RATING VERY CRITICAL

TECHNICAL MEASURES MANDATORY
PROPOSED TECHNICAL Install fixed guard preventing access
MEASURES through it to the hazard zone


The design and construction of the fixed guard following
the requirements of the relevant ISO standards and safe
distances are respected.
Following the installation of the fixed guard the machine
is reassessed by the team:
LIFE CYCLE: OPERATION
TECHNICAL MEASURES Fixed guard preventing access through
it to the hazard zone
RISK SCORE & RATING ELIMINATED (no access to hazard zone)


However, the same risks are present during MAINTENANCE
when access to the screw is required for certain tasks.
The team decide to control these risks through the
implementation of LOTO procedures and Permit to Work.
LIFE CYCLE: MAINTENANCE

ORGANISATIONAL MEASURES Require a PTW and LOTO for all
maintenance tasks on the screw
RISK RATING Medium


Selecting The Most Appropriate

Risk Control Strategy
When selecting a SAFEGUARDING solution for a

machine it is necessary to take more than just
safety related factors into account.
Other factors include its location, the practical
aspects of productively using the machine, and
the technical limits of its operation.
WARNING: The design of safeguarding can be a
very technical process. It is STRONGLY
RECOMMENDED that sites engage outside
experts to design, install or modify guards and
other protective devices.

Machinery Safety &

The Hierarchy of Control
Process design, redesign or modification including elimination
ELIMINATE
When considering PROTECTIVE MEASURES of the hazard or exposure to it
to ensure the safety of our machinery the SUBSTITUTE OR Inherently Safe Design such as intrinsically safe equipment,
REDUCE reduced energy (lower speed, force, pressure, temperature etc)
HIERARCHY OF CONTROL should be
applied in the normal way. Prevent
Access
Guarding Fixed, Mobile, Interlocking or adjustable
However, within each control strategy TECHNICAL

CONTROLS Other
Sensitive Protective Equipment including trip devices, hold to
Prevent run devices, Two handed controls, Limiting devices, mechanical
there is a range of measures that can be Motion
Protective
Devices
constraints
taken based on the nature of the hazard
Recoverability Lights, beacons, strobes, alarms, beepers, horns, Human-
that have varying levels of effectiveness. & Awareness machine interface, computer warnings etc
ORGANISATIONAL
We will look at each level of the hierarchy CONTROLS Training in safe procedures including operating procedures,
Lock Out Tag Out, inspection, risk assessment, preventative
in turn. maintenance)
PPE Protective clothing, headwear and eyewear

Eliminate & Reduce:

Inherently Safe Design
ELIMINATE
These measures are not easily available to of the hazard or exposure to it
the user and are normally applied by the SUBSTITUTE OR Inherently Safe Design such as intrinsically safe equipment,
designer.
Prevent
Inherently safe design is created through Access
an in depth assessment of the different TECHNICAL

CONTROLS Other
Prevent run devices, Two handed controls, Limiting devices, mechanical
hazards presented by the machine within Motion
Protective
Devices
constraints
its LIMITS.
Control measures are then built into the & Awareness machine interface, computer warnings etc
ORGANISATIONAL
design of machinery to eliminate or CONTROLS Training in safe procedures including operating procedures,
Substitute/Reduce these risks. maintenance)

Eliminate & Reduce:

Inherently Safe Design
“INHERENTLY SAFE DESIGN” includes: ELIMINATE
of the hazard or exposure to it
• Mechanisation/automation SUBSTITUTE OR Inherently Safe Design such as intrinsically safe equipment,

• Reducing the speed or force applied
Prevent
during the machine operation Access
TECHNICAL
While ELIMINATION is possible the result is CONTROLS Prevent
Other
run devices, Two handed controls, Limiting devices, mechanical
Protective
most often a reduction in the exposure to Motion
Devices
constraints
the risks in specific modes of operation. Recoverability Lights, beacons, strobes, alarms, beepers, horns, Human-
& Awareness machine interface, computer warnings etc
The risk may still exist in other modes such as ORGANISATIONAL
maintenance or cleaning. Addressing these CONTROLS Training in safe procedures including operating procedures,
risks involves applying additional technical maintenance)
or organisational measures. PPE Protective clothing, headwear and eyewear

Technical Controls:
Safeguarding & Other Measures
When a hazard has not been eliminated or ELIMINATE
reduced sufficiently, additional safeguards SUBSTITUTE OR Inherently Safe Design such as intrinsically safe equipment,
will be required. REDUCE reduced energy (lower speed, force, pressure, temperature etc)
Prevent
Completely or partially enclosing the hazard Access
or hazard zone by using an appropriately TECHNICAL

Other
CONTROLS Prevent run devices, Two handed controls, Limiting devices, mechanical
constructed fixed guard is a simple and Motion
Protective
constraints
Devices
effective solution but it may not be practical
if access is required. & Awareness machine interface, computer warnings etc
ORGANISATIONAL
Other guard designs can be considered CONTROLS Training in safe procedures including operating procedures,
that have mobile, interlocking and maintenance)
adjustable elements to enable controlled PPE Protective clothing, headwear and eyewear
access.

Technical Controls:
Safeguarding Options
Here is a simple representation of Safeguarding
the different families of
SAFEGUARDING methods.
These methods can be used in Guarding Protective Devices
(Prevent Access) (Prevent Motion)
combination with other methods to
achieve safety. Including:
Fixed
The selection of SAFEGUARDING
Interlocking
method should follow the Movable/Adjustable Presence Sensing Devices Control Devices
HIERARCHY OF CONTROL. The
priority should be: Including: Including:
Trip switches Two handed controls
1. Guarding Optical (eg light curtain) Hold to run devices
2. Presence Sensing Devices Pressure (eg pressure mat) Limiting Devices
3. Control Devices

Technical Controls:
Selection of Guarding
When deciding which type of guarding to apply the

following priority should be respected:
• Fixed guard
• Interlocking guard
• Movable or removable guards
REMEMBER: The selection of safeguarding method
should take more than just safety factors into
account.
Selecting a fully enclosed fixed guard to eliminate a
hazard may be technically possible but if it renders
the desired function of the machine unusable then
other methods of achieving safety should be found.

Guarding:
Fixed Enclosed Guards
This is a guard that is fixed in a position that prevents

access to a hazard or hazard zone.
There may be openings in this guard but they should
be sized to only allow the safe introduction work
pieces into the hazard zone or facilitate observations
of the process.
There should be no way to remove the guard
without the use of a tool or destruction of the fixings.

Guarding:
Fixed Distance Guards
A fixed distance guard is a type of fixed guard that

does not completely enclose the hazard or hazard
zone but reduces access to it due to its physical
dimensions.
The most common type of guard in this category are
“perimeter fence guards”.
When designing, selecting or installing these guards
defined “safety distances” must be respected.
See the REFERENCE section of this document for
more details.

Guarding:
Interlocking Guards
An interlocking guard is a movable guard or a guard
with movable parts that is connected to the power
or control system of the machine through an
interlocking device. Many varieties exist.
The interlocking guard should be designed to ensure
that:
• The functions covered by the interlock cannot
operate unless the guard is in its closed position
effectively enclosing or preventing access to the
hazard or hazard zone
• The guard remains locked in place whenever the
hazard is present or
• Opening the guard causes the hazard to be
eliminated before access is possible

Guarding:
Adjustable Guards
An adjustable guard is either entirely or partially

adjusted to accommodate the passage of material.
This type of guard is most often used to prevent any
access to the hazard until a workpiece is present.
This is often achieved using gravity, springs or
external power.
There are automatic (self adjustable) and manually
adjustable solutions available.
These guards are normally used in conjunction with
additional feeding and take off devices.

Protective Devices:
Protective devices cover a wide range of devices

including:
• Presence Sensing devices (Trip devices)
• Hold to Run/Limiting devices
• Enabling devices
• Position fixing devices (eg Two handed controls)
• Mechanical restraints
• Emergency operation devices

Protective Devices:
Presence Sensing (Trip) Devices
A Presence Sensing (trip) device causes a machine to
stop or return to a safe position when a person
approaches a hazard or a hazard zone and keeps the
machine in that state while the person remains in the
area.
It is critical when using these devices that the stopping
characteristics of the machine are fully understood
and taken into account in their design and installation.
Trip devices include:
• Mechanical Trip Devices such as barriers that
causes a trip when a force is applied to them.
• Electro sensitive Devices that detect the approach
or presence of a person (eg optical, IR, radar, laser,
ultrasonic, pressure sensitive etc)
Protective Devices :
Hold to Run/Enabling Devices
A “hold to run” device should only allow a machine to
operate in a limited mode while the device is being held
in a defined position. If the device is released the
machine should automatically return to its “Stop”
position.
An “Enabling” device is one that is used in conjunction
with a start control. It allows the function of the machine
for as long as it is actuated.
These devices should only be considered for machines
which require intervention when their guarding is in its
open position or when there is a requirement to access
into the hazard zone.

Position Fixing Devices
Position fixing devices such as “two handed controls”
require the operator to remain in a safe position away
from any Hazard Zone.
Two handed controls achieve this by requiring the
operator to use at least both hands to simultaneously
actuate the controls in order to initiate and maintain
the hazardous function of a machine.
This solution only provides protection to the operator of
the position fixing device.
This type of device should almost always be
implemented alongside other complimentary controls
to ensure it’s effectiveness.

Mechanical Restrain Devices
A mechanical restrain device applies
mechanical restraint to a hazardous part of a
machine which is set in motion due to a failure
of the machinery or its controls in order to
prevent a hazardous situation.
For example a mechanical restraint (or
“scotch”) may be required to be introduced to
prevent the fall of a hydraulic ram if pressure is
lost in the system and the fall of the ram would
occur in such a way as to be hazardous to
operators or those nearby.

Emergency Operation Devices
Emergency operation devices are complimentary

safety devices such as Emergency Stop buttons and
pull cords. They are not designed primarily as a
method of risk reduction.
They are initiated by a single human action when an
existing impending hazard is recognised.
Actuating this device switches off all power to the
machine. The machine should then remain in this
state until the emergency operation device is reset.

Organisational Controls:
Recoverability & Awareness
The next level of the hierarchy is ELIMINATE
“Recoverability and Awareness”. SUBSTITUTE OR Inherently Safe Design such as intrinsically safe equipment,
This refers to the implementation of built in
Prevent
information systems that make users aware Access
of hazards around them giving them the TECHNICAL

Other
CONTROLS Prevent run devices, Two handed controls, Limiting devices, mechanical
possibility to react and restore safe Motion
Protective
constraints
Devices
conditions or move to a place of safety.
ORGANISATIONAL
CONTROLS Training in safe procedures including operating procedures,
maintenance)

Organisational Controls:
Recoverability & Awareness
This category includes the provision of

automatic warnings, beacons alarms,
klaxons etc.
These systems should always be used in
conjunction with other technical controls.

Organisational Measures:
Safe Use Information & Work Practices
Provision of information on safe use to the ELIMINATE
user. This information should describe the
SUBSTITUTE OR Inherently Safe Design such as intrinsically safe equipment,
LIMITS of use of the machine and it’s built in REDUCE reduced energy (lower speed, force, pressure, temperature etc)
safety devices. It can take the form of: Prevent
Access
• User manuals TECHNICAL Sensitive Protective Equipment including trip devices, hold to
• Operating Instructions CONTROLS Prevent
Other
Protective
run devices, Two handed controls, Limiting devices, mechanical
Motion constraints
• Technical description of operating Devices
parameters Recoverability Lights, beacons, strobes, alarms, beepers, horns, Human-

• Warning signage ORGANISATIONAL
CONTROLS Training in safe procedures including operating procedures,
Additional organisational measures should Lock Out Tag Out, inspection, risk assessment, preventative
maintenance)
be implemented to ensure safety. They
should reflect how the machine is used. PPE Protective clothing, headwear and eyewear
These include creating safe work instructions,

LOTO and Permit to Work procedures.

5 Useful References

Safeguarding Design
What follows is a selection of reference tables

to assist sites to ensure new or existing
SAFEGUARDING is effective and meets
international standards.
It is not meant to be a complete guide nor
does it replace expert advice.
When designing, installing or modifying
SAFEGUARDING it is recommended to seek
expert assistance.
Reference to the source International or
National standards are given when relevant.

Simple Safeguard Selection Flowchart*

HAZARD generated by moving parts at the point of operation
HAZARD generated by moving transmission parts OR (directly involved in the process of machining, handling, securing etc)
Can these elements

YES be made completely NO
inaccessible while
working?
FIXED (BARRIER) GUARDS FIXED (BARRIER) GUARDS FIXED (BARRIER) GUARDS OR

OR OR INTERLOCKING MOVABLE GUARDS
That prevent access to the moving
INTERLOCKING MOVABLE GUARDS INTERLOCKING MOVABLE GUARDS
parts within the zone where
With or without guard locking With or without guard locking
access is not required
With automatic monitoring With automatic monitoring
AND
OR
ADJUSTABLE GUARDS
PROTECTIVE DEVICES
Restricting access to the moving
Chosen based on the need for
parts within the zones where
access into the “point of
access is necessary for the process
operation” and characteristics of
the hazard
*following Z432-16

Fixed Guard Design

When designing and installing fixed guards the guards
must:
• Not allow access to the hazard zone from any direction
(check AUTO: Around, Under, Through or Over)
• Not create additional pinch points or other hazards
• Be capable of containing any broken parts (eg chains,
belts, ejected material being processed)
• Be secured by fasteners that require a tool for removal
unless suitably interlocked with the machine control
system
• Allow safe access for lubrication and minor adjustments
• Offer good visibility for feed points, stand points,
• Be robust enough to stand up to normal wear and tear
• Be difficult to modify or defeat

Combining Protective Devices

It is possible to combine different types of guard and
protective devices to achieve safety.
This can sometimes be necessary when the required
safety distances cannot be respected (eg due to space
limits or other existing machine elements or structures).
For example:
If large openings are required in a fixed guard for
operational purposes that would allow contact with the
hazard zone then presence sensing devices could be
installed that ensure the hazard is removed if a person is
detected.
It is important to ensure that when combining guards and
devices that they are compatible with each other and
do not create additional hazards.

Reaching Over a Guard – HIGH RISK*

Height “a” of the
The height required for fixed distance hazard zone (mm)
Horizontal safety distance to hazard zone “c” (mm)
guard to prevent access to a HIGH RISK 2700 0 0 0 0 0 0 0 0 0 0
hazard zone can be found by referring to 2600 900 800 700 600 600 500 400 300 100 0
2400 1100 1000 900 800 700 600 400 300 100 0
the table opposite where: 2200 1300 1200 1000 900 800 600 400 300 0 0
2000 1400 1300 1100 900 800 600 400 0 0 0
a is the height of the hazard zone 1800 1500 1400 1100 900 800 600 0 0 0 0
b is the required height of the guard 1600 1500 1400 1100 900 800 500 0 0 0 0
1400 1500 1400 1100 900 800 0 0 0 0 0
c is the horizontal distance to the hazard
1200 1500 1400 1100 900 700 0 0 0 0 0
zone 1000 1500 1400 1000 800 0 0 0 0 0 0
800 1500 1300 900 600 0 0 0 0 0 0
600 1400 1300 800 0 0 0 0 0 0 0
400 1400 1200 400 0 0 0 0 0 0 0
200 1200 900 0 0 0 0 0 0 0 0
0 1100 500 0 0 0 0 0 0 0 0
Height of the guard “b” (mm)
1000 1200 1400 1600 1800 2000 2200 2400 2500 2700
*Following ISO 13857

Reaching Over a Guard – HIGH RISK*

hazard zone (mm)
2700 0 0 0 0 0 0 0 0 0 0
2600 900 800 700 600 600 500 400 300 100 0
2400 1100 1000 900 800 700 600 400 300 100 0
2200 1300 1200 1000 900 800 600 400 300 0 0
2000 1400 1300 1100 900 800 600 400 0 0 0
1800 1500 1400 1100 900 800 600 0 0 0 0
1600 1500 1400 1100 900 800 500 0 0 0 0
1400 1500 1400 1100 900 800 0 0 0 0 0
1200 1500 1400 1100 900 700 0 0 0 0 0
EXAMPLE: 1000 1500 1400 1000 800 0 0 0 0 0 0
We have a HIGH RISK hazard zone at 800mm and we
800 1500 1300 900 600 0 0 0 0 0 0
want to install a safety barrier.
600 1400 1300 800 0 0 0 0 0 0 0
• If we want to install the fence with a safety 400 1400 1200 400 0 0 0 0 0 0 0
distance (c) of less than 600mm the fence should 200 1200 900 0 0 0 0 0 0 0 0
be at least 1800m high. 0 1100 500 0 0 0 0 0 0 0 0
• If we can install the fence at 600mm then the Height of the guard “b” (mm)
fence should be at least 1600mm high. 1000 1200 1400 1600 1800 2000 2200 2400 2500 2700
If the hazard zone height is not listed ROUND UP to the
next value (eg 650mm should refer to the 800mm row) *Following ISO 13857

Reaching Over a Guard – LOW RISK*

The height required for fixed distance hazard zone (mm)
guard to prevent access to a LOW RISK 2500 0 0 0 0 0 0 0 0 0
hazard zone can be found by referring to 2400 100 100 100 100 100 100 100 100 0
2200 600 600 500 500 400 350 250 0 0
the table opposite where: 2000 1100 900 700 600 500 350 0 0 0
1800 1100 1000 900 900 600 0 0 0 0
a is the height of the hazard zone 1600 1300 1000 900 900 500 0 0 0 0
b is the required height of the guard 1400 1300 1000 900 800 100 0 0 0 0
1200 1400 1000 900 500 0 0 0 0 0
c is the horizontal distance to the hazard
1000 1400 1000 900 300 0 0 0 0 0
zone 800 1300 900 600 0 0 0 0 0 0
600 1200 500 0 0 0 0 0 0 0
400 1200 300 0 0 0 0 0 0 0
200 1100 200 0 0 0 0 0 0 0
0 1100 200 0 0 0 0 0 0 0
Height of the guard “b” (mm)
1000 1200 1400 1600 1800 2000 2200 2400 2500
* Following ISO 13857

Prevent Access through Guards

This section explains how to calculate the permissible size
of openings in fixed guards. This could be to allow
specific operations (eg introducing work pieces) or to
ensure that access to a hazard is not possible through a
mesh guard.
This is determined by two variables:
“e” The smallest dimension of the opening
“sd” Safety distance or the distance between the
guard and the hazard zone
The table on the next slide gives reference values for
different body parts to assist deciding the correct values
for e and sd.

Prevent Access through Guards:

Upper Limbs*
Dimensions in Millimeters
Minimum (safe) distance, sd
Part of Body Illustration Opening (e)
Slot Square Round
Example: ℯ≤4 ≥2 ≥2 ≥2
A safety fence is made up of square Fingertip

4<ℯ≤6 ≥ 10 ≥5 ≥5
mesh. The opening is 25mm by 25mm.
6<ℯ≤8 ≥ 20 ≥ 15 ≥5
In order to ensure that a person Finger up to knuckle joint
8 < ℯ ≤ 10 ≥ 80 ≥ 25 ≥ 20
cannot reach through the mesh and
contact a hazard zone the fence 10 < ℯ ≤ 12 ≥ 100 ≥ 80 ≥ 80
must be positioned at least 120mm

Hand 12 < ℯ ≤ 20 ≥ 120 ≥ 120 ≥ 120
from the hazard zone.
20 < ℯ ≤ 30 ≥ 850 ≥ 120 ≥ 120
30 < ℯ ≤ 40 ≥ 850 ≥ 200 ≥ 120

Arm up to junction with
shoulder
40 < ℯ ≤ 120 ≥ 850 ≥ 850 ≥ 850


Lower Limbs*
Dimensions in Millimeters
Minimum (safe) distance, sd
Part of Body Illustration Opening
Slot Square or Round
ℯ≤5 0 0
Toe tip
5 < ℯ ≤ 15 ≥ 10 0
Toe 15 < ℯ ≤ 35 ≥ 80 ≥ 25
35 < ℯ ≤ 60 ≥ 180 ≥ 80
Foot
60 < ℯ ≤ 80 ≥ 650 ≥ 180
Leg (Toe tip to knee) 80 < ℯ ≤ 95 ≥ 1100 ≥ 650
Leg (Toe tip to crotch) 95 < ℯ ≤ 180 ≥ 1100 ≥ 1100
180 < ℯ ≤ 240 NOT ALLOWED ≥ 1100


Whole Body*
To prevent whole body access through an opening in
a guard:
• 180 mm is the maximum size of a vertical or
horizontal slot capable of preventing whole body
access to the hazard zone;
• 240 mm is the maximum size of a square or circular
opening, capable of preventing whole body
access to the hazard zone.
If guards have openings larger than these dimensions
additional protective measures must be used to Max 180mm
prevent whole body access.
Barriers 1400mm or higher are considered adequate
to protect against climbing. At this height climbing is
considered incorrect behavior and not reasonably
foreseeable. *Following ISO 13857


Irregular Openings*
In the case of irregular openings:

1. Determine:
• the diameter of the smallest round opening,
• the side of the smallest square opening, and
• the width of the narrowest slot opening into which
the irregular opening can be completely inserted
2. Using these three measurements refer to the relevant
corresponding table from the previous slides.
3. Select the shortest safety distance of the three values
found in step 2.


Tunnel Guards*
When implementing a tunnel guard to allow safe access
into the hazard zone safety distance is calculated a little
differently.
In this case it is necessary to add a second safety
distance which is the length of the tunnel guard.
So in these cases the safety distance (sd) is equal to the
distance from the guard to the hazard zone PLUS the
distance from the opening of the tunnel guard to the
guard.
*Following CSA Z432

Safety Distances for Interlocking Guards*
The minimum safe distance to be used for

interlocking guards is calculated using:
S = (K x T) + C
Where:
S = minimum distance in mm between the nearest
hazard zone and the nearest opening point.
K = speed of approach of a body part in mm/s
(usually 1600mm/s)
T = time in seconds it takes the overall system to run
down or stop
C = the safety distance required based on the size
of openings in the guard (see Prevent Access
through Guards, above).

Safety Distances for Position Fixing Devices*

The minimum safe distance to be used for Position
Fixing devices is also calculated using:
S = (K x T) + C
Where:
S = minimum distance in mm to the nearest
hazardous point.
K = speed of approach of a body part in mm/s
(usually 1600mm/s)
T = time in seconds it takes the overall system to run
down or stop
C = supplement of 250mm (not always required)
If the device is portable then the maintenance
of the safe distance must be ensured (eg using
fixed cable lengths, spacer bars etc) *Following ISO 13855

Protective Device Safe Distances:

Electro-sensitive Protective Equipment*
Electro-sensitive Protective equipment such as light
curtains or pressure mats need to be installed in a way to
ensure that access to the nearest hazard point is not
possible before the system can remove or neutralise the
hazard.
The safe distance is calculated using the following
formula:
S = (K x T) + C
Where:
S = the minimum safe distance in mm
K = the approach speed of the body part in mm/s
T = the stopping/run down time of the system in seconds
C = the distance of intrusion into the hazard zone before
the protective device is triggered in mm


Once the minimum safe distance has been
established for the field it is necessary to
determine the required field height.
The size and height of a protective field must
ensure that it is only possible to reach the
hazardous area through the field. It should not be
possible to reach the hazardous zone by reaching
over, under or around it.
If it is possible to stand behind the field then
additional measures (such as a restart interlock or
secondary devices) are required.


The height of a protective field can be found in the same
way as for a fixed distance guard by determining:
a = the height of the hazard zone
b = the required height of the protective field
c = the additional horizontal distance to the hazard zone.
This is determined by calculating:
(CRO or CRT) + (K x T)
CRO = reaction time (in seconds) of the protective
device if triggered by reaching over
CRT = reaction time (in seconds) of the protective
device if triggered by reaching through.
The larger value should be selected
K = the approach speed of the body part in mm/s
T = the stopping/run down time of the system in
seconds *Following ISO 13855


Additional horizontal distance to hazard zone “c” (mm)
hazard zone (mm)
After determining a,b and c the required 2600 0 0 0 0 0 0 0 0 0 0 0 0
height can be found by referencing the 2500 400 400 350 300 300 300 300 300 250 150 100 0
table opposite. 2400 550 550 550 500 450 450 400 400 300 250 100 0
2200 800 750 750 700 650 650 600 550 400 250 0 0
2000 950 950 850 850 800 750 700 550 400 0 0 0
1800 1100 1100 950 950 850 800 750 550 0 0 0 0
1600 1150 1150 1100 1000 900 850 750 450 0 0 0 0
1400 1200 1200 1100 1000 900 850 650 0 0 0 0 0
1200 1200 1200 1100 1000 850 800 0 0 0 0 0 0
1000 1200 1150 1050 950 750 700 0 0 0 0 0 0
800 1150 1050 950 800 500 450 0 0 0 0 0 0
600 1050 950 750 550 0 0 0 0 0 0 0 0
400 900 700 0 0 0 0 0 0 0 0 0 0
200 600 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
Height of the top edge of the protective field “b” (mm)
900 1000 1100 1200 1300 1400 1600 1800 2000 2200 2400 2600

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IMPLEMENTATION GUIDE

Machinery Safety (July 2022)

This guide give an overview of a complex

Machinery Safety (July 2022)

3 Machinery Risk Assessment

4 Risk Control Strategies

Machinery Safety (July 2022)

Machinery Life Cycle

Machinery Safety (July 2022)

Machinery Safety (July 2022)

Inherent Safe Design

Protective measures which either eliminate

Machinery Safety (July 2022)

SAFEGUARDS are protective measures such as

Machinery Safety (July 2022)

A physical barrier designed as part of a

Machinery Safety (July 2022)

A PROTECTIVE DEVICE is a SAFEGUARD other than a

Machinery Safety (July 2022)

Hazard or Danger Zone

Any space in, on or around a machine in which

Machinery Safety (July 2022)

Machinery Life Cycle

Machinery Safety (July 2022)

Machine Limits & Life Cycle

It is important to ensure a machines LIMITS and its

Machinery Safety (July 2022)

To assist in the identification of the hazards of a

Machinery Safety (July 2022)

LIMITS of the Machine

A machine’s LIMITS can be broadly split into 4

Machinery Safety (July 2022)

LIMITS of the Machine:

USE LIMITs detail the way the machine is supposed to

Machinery Safety (July 2022)

LIMITS of the Machine:

Machinery Safety (July 2022)

LIMITS of the Machine:

Space LIMITS are:

Machinery Safety (July 2022)

LIMITS of the Machine:

Time LIMITS refer to aspects of the service life of the

Machinery Safety (July 2022)

LIMITS of the Machine:

Other LIMITS include aspects such as:

Machinery Safety (July 2022)

Machinery Life Cycle

Machinery Safety (July 2022)

Machine Life Cycle

A Machine’s LIFE CYCLE consists of the main

Machinery Safety (July 2022)

Phases of a Machine’s Life Cycle

The next section briefly examines the different phases

Machinery Safety (July 2022)

Life Cycle Phases:

Machinery Safety (July 2022)

Life Cycle Phases:

SET UP, TEACHING/PROGRAMMING

Machinery Safety (July 2022)

Life Cycle Phases:

MAINTENACE, CLEANING, & TROUBLESHOOTING

Machinery Safety (July 2022)