Mechanical Hazards

TOPIC 7a MECHANICAL HAZARDS
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TOPIC 7a : MECHANICAL HAZARDS

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OBJECTIVES: MECHANICAL HAZARDS

By the end of this topic, you should be able to:

1. Describe common of injuries resulting from mechanical hazards;

2. Explain the main requirements for safeguards

3. Apply the precautions to mechanical hazards.
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7.1 Definition of Pressure Hazards
7.1.1 Wound and Tearing
7.1.2 Shearing
7.1.3 Crushing
7.1.4 Fractured
7.1.5 Straining and Spraining
7.1.6 Puncturing
7.2 Safeguards
7.2.1 Point-of-operation Guards
7.2.2 Point-of-operation Devices
7.2.3 Feeding and Ejection System
7.2.4 Lockout/Tagout Systems
7.3 Mechanical Hazard Prevention
Summary

TABLE OF CONTENT : MECHANICAL HAZARDS
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INTRODUCTION
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As the term suggests, mechanical hazards are associated with
power-driven machines, whether automated or manually
operated.

Concerns about mechanical hazards date back to the Industrial
Revolution and the earliest days of mechanization.

Machines whether driven by steam, hydraulic, or electric power
has introduced new hazards into the workplace.

In spite of advances in safeguarding technologies and techniques,
mechanical hazards are still major concerns today.

In addition, the advent of automated machines has also fresh
concerns about workplace safety.
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7a.1 COMMON MECHANICAL INJURIES
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In an industrial setting, people operate machines that are
designed to drill, cut, shear, punch, chip, staple, stitch, abrade,
shape, stamp, and slit materials such as metals, composites,
and plastics.

These processes are purely mechanical; they cause material
to be deformed or broken into smaller pieces.

If appropriate safeguards are not in place or if the operators
themselves fail to follow safety precautions, they may be hurt
by these machines.
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7a.1 COMMON MECHANICAL INJURIES
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COMMON
MECHANICAL
INJURIES
shearing
crushing
fractured
Straining &
Spraining
Puncturing
Wound
&
Tearing
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7a.1.1 WOUND AND TEARING
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A cut occurs when our skin suddenly comes into contact with a
sharp edge.

Tearing implies further opening of a cut through strong forces.

The human body's outer layer or skin consists of the epidermis
which is the tough outer covering;
- the dermis which is the thick part beneath the epidermis;
- the capillaries which are the tiny blood vessels that branch off
from small arteries and veins in the dermis;

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7a.1.1 WOUND AND TEARING
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- the veins which are the blood vessels that collect blood from the
capillaries and return it to the heart;
- the arteries which are the larger vessels that carry blood from
the heart to the capillaries in the skin.

Deeper down below the skin are the muscle tissues which in turn
wrap around the bones.

How serious is a cut or tear depends on how much damage is
done to the skin, veins, arteries, muscles, and even bones.
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7a.1.2 Shearing
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To understand what shearing means, imagine using a paper
cutter. Power-driven shears for cutting paper, metal, plastic, and
composite materials are dangerous because of their extreme
cutting properties.

However, they are widely used in manufacturing for cutting
various materials to different sizes.
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7a.1.2 Shearing
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You must have heard of, or read news reports about, how such
machines often amputated fingers and hands of careless
workers.

Such tragedies typically occurred when the operators
reached under the shearing blade to make an

adjustment or placed materials there and accidentally activated
the blade before fully removing their hands.
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7a.1.3 Crushing
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Injuries from crushing can be particularly debilitating,
painful, and difficult to heal.

They occur when a part of the body is caught between two
hard surfaces that progressively move together, thereby
crushing anything between them.

Crushing hazards can be divided into 2 categories:
i. squeeze-point types
ii. run-in points.
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7a.1.3 Crushing
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1. Squeeze-point
hazards
Squeeze-point hazards exist where two
hard surfaces, at least one of which must
be in motion, close in together to crush
any object that may be between them
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7a.1.3 Crushing
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2. Run-in point
hazards
Run-in point hazards exist where two objects, at least
one of which is rotating, come progressively closer
together. Any gap between them need not become
completely closed. It needs only to be smaller than
the width of the object or body part to be lodged in it.
Meshing gears and belt pulleys are examples of run-
in point hazards.
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7a.1.4 Fractured
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Machines used to deform raw materials such as wood and steel
in factories can easily break human bones. A break in the bone is
known as a fracture. Fractures are classified as:
(a) Simple;
(b) Compound;
(c) Complete; and
(d) Incomplete.
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7a.1.4 Fractured
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Type of Fracture Injuries
1. Simple fracture A break in a bone that does not pierce the
skin.
2. Compound fracture A break that has broken through the
surrounding tissue and skin.
3. Complete fracture Divides the affected bone into two or more
separate pieces
4. Incomplete fracture Leaves the affected bone in one piece but
cracked.
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7a.1.4 Fractured
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Other types of fractures include transverse fracture, oblique
fracture and comminute fracture.

A transverse fracture is a break at right angles to the axis of the
bone, while an oblique fracture is diagonal.

Comminute fracture on the other hand occurs when the bone is
broken into a number of small pieces at the point of fracture.
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7a.1.5 Straining and Spraining
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There are numerous situations in an industrial setting when
straining of muscles or spraining of ligaments is possible.

A strain results when muscles are overstretched or torn.

A sprain is the result of torn ligaments in a joint.

Strains and sprains can cause swelling and intense pain.
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7a.1.6 Puncturing
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Punching machines that have sharp tools can puncture a body part
if safety precautions are not observed or if appropriate
safeguards are not in place.

Puncturing results when an object penetrates straight into the
body and pulls straight out, creating a wound in the shape of the
piercing object.

The greatest risk with puncture wounds is causing damage to
internal organs.
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7a.2 SAFEGUARDS
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Modern machinery has various mechanisms that can rotate,
reciprocate, or do both.

You can find many types of tools, bits, chucks, blades, spokes,
screws, gears, shafts, belts, and a huge variety of other
equipment for manufacturing products.

Certainly, safeguards have to be devised to protect workers
from coming into contact with such mechanisms while at the
same time allowing work to progress at a productive rate.
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7a.2 SAFEGUARDS
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7a.2 SAFEGUARDS
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(a) Prevent Contact
Safeguards would prevent human contact with any potentially
harmful machine part.

The prevention extends to machine operators and any other
person who may need to do so, e.g. the technician or service
engineer.
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7a.2 SAFEGUARDS
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(b) Secure and Durable
Safeguards should be firmly attached so that they are secure. This
means that workers cannot render them ineffective by tampering
with or disabling them.

This is critical because removing safeguards in an attempt to speed
up production is common practice.

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7a.2 SAFEGUARDS
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(b) Secure and Durable

This should not be encouraged at the expense of work safety.

Safeguards must also be durable enough to withstand the
rigors of the workplace.

Worn-out safeguards will become less effective over time, in
protecting workers properly.
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7a.2 SAFEGUARDS
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(c) Protect against Falling Objects
Objects falling onto moving machine mechanisms increase
the risk of accidents, property damage, and injury.

Objects that fall on a moving part can be quickly hurled out,
creating a dangerous projectile.

Therefore, safeguards must do more than just prevent human
contact.

They must also shield the moving parts of machines from falling
objects.
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7a.2 SAFEGUARDS
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(d) Create No New Hazard
Safeguards should overcome the hazards in question without
creating new ones.

For example, a safeguard with a sharp edge, unfinished surface,
or protruding bolts introduces new hazards while protecting
against the old.
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7a.2 SAFEGUARDS
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(e) Create No Interference

Safeguards can interfere with the progress of work if they are not
properly designed.

Such safeguards are likely to be disregarded or disabled by
workers who find such safeguards a nuisance rather than a safety
feature.
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7a.2 SAFEGUARDS
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(f) Allow Safe Maintenance
Safeguards should be designed to allow frequently performed
maintenance tasks (e.g., lubrication) to be accomplished
without removing them.
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7a.2 SAFEGUARDS
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(g) Construction of Safeguards
Design and construction of safeguards are highly specialized
activities requiring a strong working knowledge of machines,
production techniques, and safety.

However, it is critical that all of the factors explained in this
section be considered and accommodated during the design
process.
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7a.2.1 Point-of-Operation Guards
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Safeguards are most effective when used at the point of
operation, which is where hazards to humans exist.

Point-of-operation hazards are those caused by the shearing,
cutting, or bending motions of a machine.

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Pinch-point hazards result from guiding material into a machine
or transferring motion (e.g., from gears, pressure rollers, or
chains and sprockets).

Single-purpose safeguards, because they guard against only one
hazard, typically are permanently fixed and non-adjustable.

Multiple-purpose safeguards, which guard against more than
one hazard, typically are adjustable.
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There are 3 types of point-of-operation guards:
i. Fixed
ii. Interlocked
iii. Adjustable

Each has its own advantages and limitations.
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Type of Guard Explanation
1. Fixed guards Fixed guards provide a permanent barrier between
workers and the point of operation. They offer the
following advantages:

They are suitable for many specific applications, can
be constructed in-plant, require little maintenance
and are suitable for high-production, repetitive
operations.

Limitations include the following:
They sometimes limit visibility, are often limited to
specific operations, and sometimes inhibit normal
cleaning and maintenance.
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2. Interlocked guards Interlocked guards shut down the machine when the
guard is not securely in place or is disengaged.

The main advantage of this type of guard is that it
allows safe access to the machine for removing jams
or conducting routine maintenance without the need
for taking off the guard.

There are also limitations. Interlocked guards
require careful adjustment and maintenance and, in
some cases, can be easily disengaged.
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3. Adjustable guards Adjustable guards provide a barrier against a variety
of different hazards associated with different
production operations.

They have the advantage of flexibility.

However, they do not provide as dependable a barrier
as other guards do, and they require frequent
maintenance and careful adjustment.
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7a.2.2 Point-of-Operation Devices
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A number of different point-of-operation devices can be used to
protect workers. The six most widely used are explained below:
(a) Photoelectric devices
(b) Radio-frequency devices
(c) Electromechanical devices
(d) Pullback devices
(e) Restraint devices
(f) Two-hand controls.
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The 6 Point-of-Operation Devices
Point-of- Operation
Devices
Explanation
1. Photoelectric
devices
Photoelectric devices are optical devices that shut down
the machine whenever the light beam is broken.

These devices allow operators relatively free movement.
They do have limitations, including the following:

They do not protect against mechanical failure, they
require frequent calibration, and they can be used
only with machines that can be stopped.
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Point-of- Operation
Devices
Explanation
2. Radio-frequency
devices
Radio-frequency devices are capacitance devices that
brake or quickly slow down the machine if the
capacitance field is interrupted by a worker's body or
another object.

These devices have the same limitations as photoelectric
devices.
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Point-of- Operation
Devices
Explanation
3. Electromechanical
devices
Electromechanical devices are contact bars that allow
only a specified amount of movement between the
worker and the machine.

If the worker moves the contact bar beyond a
specified point, the machine will not work.

These devices have the limitation of requiring
frequent maintenance and careful adjustment.
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Point-of- Operation
Devices
Explanation
4. Pullback devices Pullback devices pull the operator's hands out of the
danger zone when the machine starts to operate.

These devices eliminate the need for auxiliary barriers.
However they also have limitations.

They limit operator movement, must be adjusted for
each individual operator, and require close supervision
to ensure proper use.
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Point-of- Operation
Devices
Explanation
5. Restraint devices Restraint devices hold the operator back from the
danger zone.

They work well, with little risk of mechanical failure.

However, they do limit the operator's movement,
must be adjusted for each individual operator, and
require close supervision to ensure proper use.
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Point-of- Operation
Devices
Explanation
6. Two-hand controls Two-hand controls require the operator to use both
hands concurrently to activate the machine (e.g., a
paper cutter or metal-shearing machine).

This ensures that his hands cannot stray into the
danger zone.

Although these controls do an excellent job of
protecting the operator, they do not protect onlookers
or passers-by.

In addition, some two-hand controls can be
tampered with and foolishly made operable using
only one hand to save time.
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Point-of- Operation
Devices
Explanation
6. Two-hand controls Two-hand controls require the operator to use both
hands concurrently to activate the machine (e.g., a
paper cutter or metal-shearing machine).

This ensures that his hands cannot stray into the
danger zone.

Although these controls do an excellent job of
protecting the operator, they do not protect onlookers
or passers-by.

In addition, some two-hand controls can be
tampered with and foolishly made operable using
only one hand to save time.
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7a.2.3 Feeding and Ejection System
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Feeding and ejection systems can be effective safeguards if
properly designed and used.

There are 4 types of feeding and ejection systems available for
use with modern industrial machines, as below:
(a) Automatic feed systems;
(b) Semi-automatic feed systems;
(c) Automatic ejection systems; and
(d) Semi-automatic ejection systems.
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Feeding and Ejection
Systems
Explanation
1. Automatic Feed
Systems
Automatic feed systems feed stock to the machine
from rolls.

Automatic feeds eliminate the need for operators to
enter the danger zone.

Such systems are limited in the types and variations
of stock that they can feed.

They also typically require an auxiliary barrier guard
and frequent maintenance
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Systems
Explanation
2. Semi-automatic
Feed Systems
Semi-automatic feed systems use a variety of
approaches for feeding stock to the machine.

Prominent among these are chutes, moveable dies,
dial feeds, plungers, and sliding bolsters.

They have the same advantages and limitations as
automatic feed systems.
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Systems
Explanation
3. Automatic Ejection
Systems
Automatic ejection systems eject the work
pneumatically or mechanically.

The advantage of either approach is that operators do
not have to reach into the danger zone to retrieve work
pieces.

However, these systems are restricted to use with
relatively small stock. Potential hazards include blown
chips or debris and noise.

Automatic ejectors can be noisy.
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Systems
Explanation
4. Semi-automatic
Ejection Systems
Semi-automatic ejection systems eject the work using
mechanisms that are activated by the operator.

Consequently, the operator does not have to reach into
the danger zone to retrieve work pieces.

These systems do require auxiliary barriers and can be
used with a limited variety of stock.
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7a.2.4 Lockout/Tagout Systems
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One of the most effective systems to control hazardous energy
today is the tagout system.

This method is created to protect people from accidental
activation of a machine when it is suppose to be shut.

This is very important because OSHAs statistics shows that six
percent of workplace deaths are caused by accidental or
inadvertent activation of a machine while it is being serviced or
repaired.
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In the lockout system, a lockout device such as a padlock is
placed on an energy- isolating device to prevent the accidental
or inadvertent energizing of a machine until the padlock is
unlocked.

The padlock will normally bear the name, department and
phone extension of the person in-charge.
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The tagout system is similar to the lockout system except that a
tag is used instead of a padlock.

The tag must only be used when the lockout system cannot be
implemented.

Sometimes a tag and a padlock are used together.
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7a.3 MECHANICAL HAZARD PREVENTION

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No General Precautions
1 All operators should be trained in the safe operation and
maintenance of their machines.

2 All machine operators should be trained in the emergency
procedures to take when accidents occur.

3 All employees should know how to activate emergency
shutdown controls.
This means knowing where the controls are and how to
activate them.

The following are general precautions that apply across the
board where machines are used:
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4 Inspection, maintenance, adjustment, repair, and calibration
of safeguards should be carried out regularly.

5 Supervisors should ensure that safeguards are properly in
place when machines are in use.

Employees who disable or remove safeguards should be
disciplined appropriately.

6 Operator teams (two or more operators) of the same system
should be trained in coordination techniques and proper use
of devices that prevent premature activation by a team
member.
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7 Operators should be trained and supervised to ensure
that they dress properly for the job.

Long hair, loose clothing, neckties, rings, watches, necklaces,
chains, and earrings can become caught in equipment and, in
turn, pull the employee into the hazard zone.

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8 Shortcuts that violate safety principles and practices should be
avoided.

Deadline pressures should never be the reason for unsafe
work practices.

9 Other employees who work around machines but do not
operate them should be made aware of the emergency
procedures to take when an accident occurs.
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SUMMARY

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1. Mechanical safety is important and must be addressed
consistently with the development of technology worldwide.

2. Management must conduct a safety risk analysis on all
mechanical equipment installed at their facilities.

3. From this analysis a safety procedure to handle each
machine must be developed and made known to all workers.
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SUMMARY

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3. This will enable workers to understand how to use the
machines safely, hence, reducing the numbers of mechanical-
related accidents.

4. Workers must also be exposed to periodical mechanical safety
training to ensure that they are able to use mechanical
equipment at their workplace safely and correctly.
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