.

� Before beginning machine adjustment, maintenance,

or servicing work, do the following [NIOSH 1999]:

1. De-energize all sources of hazardous energy:

— Disconnect or shut down engines or motors.

— De-energize electrical circuits.

— Block fluid (gas or liquid) flow in hydraulic

or pneumatic systems.
— Block machine parts against motion.

2. Lockout and tagout all forms of hazardous ener­

gy, including electrical breaker panels and con­
trol valves. [†]

3. Block or dissipate stored energy:

— Discharge capacitors.

— Release or block springs that are under com­

pression or tension.
— Vent fluids from pressure vessels, tanks, or

accumulators, but never vent toxic, flamma­
ble, or explosive substances directly into the
atmosphere.

� Make sure that only one key exists for each of your as­

signed locks and that only you hold that key. [‡]

� Verify by test and/or observation that all energy

sources are de-energized.

- OSHA standards require the use of either lockout or tagout. However,

NIOSH [1999] recommends that any hazardous control program include
both to ensure maximum protection. Also note that some State plans may
have more stringent requirements than those found in 29 CFR 1910.147.

- Use of master keys should be reserved for unusual circumstances when the

worker is absent from the workplace. However, if master keys are necessary,
keep them under supervisory control. List the proper procedures for using
them in the written program for controlling hazardous energy.

� Inspect repair work before removing your lock and

activating the equipment.

� Make sure that only you remove your assigned lock.

� Make sure that you and your coworkers are clear of

danger points before re-energizing the system (see 29

CFR 1910.147(e) and 29 CFR 1910.117(f).

### Manufacturers

 Consider designing equipment that requires fewer and

more easily accessible disconnect points to facilitate the
use of safe lockout/tagout procedures for maintenance
and repair [NIOSH 2006].

## OSHA Information

For information about energy control procedures, protec­

 tive equipment, inspection, and training, see (http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_

table=STANDARDS&p_id=9804). OSHA has a Lock­
out-Tagout Interactive Training Program that can be
useful in better understanding the requirements of the
OSHA hazardous energy control standard (http://www.
osha.gov/dts/osta/lototraining/index.html ).

## Acknowledgments

This document was developed by Susan Afanuh, Educa­
tion and Information Division (NIOSH); and Paul Moore
and Tim Pizatella, Division of Safety Research (NIOSH).

## References

Bulzacchelli MT, Vernick JS, Sorock GS, Webster, DW, Lees

PSJ [2008]. Circumstances of fatal lockout/tagout-related
injuries in manufacturing. Am J Ind Med 51:728–734.
CFR. Code of Federal regulations. Washington, DC: U.S.

Government Printing Office, Office of the Federal Register.
Jarrell JL, Washam J [2009]. Lockout/tagout: controlling haz­

ardous energy to prevent workplace injury. Washington,

DC: OSHA Training and Education Directorate, OSHA
Course No. 7115.

 Michalscheck J [2008]. Lockout/tagout: are the hazards misun­derstood? EHS Today Dec: 38–43. http://ehstoday.com/safe­

ty/best-practices/lockouttagout_hazards_misunderstood/
NIOSH [1999]. NIOSH Alert: preventing worker deaths from

uncontrolled release of electrical, mechanical, and other
types of hazardous energy. Cincinnati, OH: U.S. Department
of Health and Human Services, Centers for Disease Control
and Prevention, National Institute for Occupational Safe­
ty and Health, DHHS (NIOSH) Publication No. 99−110.
http://www.cdc.gov/niosh/docs/99-110/

_DEPARTMENT OF HEALTH AND HUMAN SERVICES_

_Centers for Disease Control and Prevention_

_National Institute for Occupational Safety and Health_
_4676 Columbia Parkway_
_Cincinnati, OH 45226–1998_

_Official Business_
_Penalty for Private Use $300_

NIOSH [2006]. Millwright killed when pinned between the

feed rolls of a debarker during machine maintenance—
South Carolina. Morgantown, WV: U.S. Department of
Health and Human Services, Centers for Disease Control
and Prevention, National Institute for Occupational Safety

## For More Information

and Health, DHHS (NIOSH) FACE Report 2006−02. http://
www.cdc.gov/niosh/face/In-house/full200602.html
OSHA [2002]. Control of hazardous energy: lockout/tagout

(2002 Revised). Washington, DC: U.S. Department of Labor,
Occupational Safety and Health Administration.

**Safer • Healthier • People** **[TM]** April 2011

**29 CFR 1910.147 (up to date as of 7/23/2025)**
**29 CFR 1910.147 (July 23, 2025)**
**The control of hazardous energy (lockout/tagout).**

This content is from the eCFR and is authoritative but unofficial.

**Title 29 —Labor**

**Subtitle B —Regulations Relating to Labor**
**Chapter XVII —Occupational Safety and Health Administration, Department of Labor**
**Part 1910 —Occupational Safety and Health Standards**
**Subpart J —General Environmental Controls**

**Authority:** [29 U.S.C. 653, 655, 657; Secretary of Labor's Order No. 12-71 (36 FR 8754), 8-76 (41 FR 25059), 9-83 (48 FR 35736),](https://www.govinfo.gov/link/uscode/29/653)

[1-90 (55 FR 9033), 6-96 (62 FR 111), 3-2000 (65 FR 50017), 5-2007 (72 FR 31159), 4-2010 (75 FR 55355), or 1-2012 (77 FR](https://www.federalregister.gov/citation/55-FR-9033)
[3912), as applic](https://www.federalregister.gov/citation/77-FR-3912) ~~a~~ ble. Sections 191 ~~0~~ .141, 1910.142, 1910. ~~1~~ 45, 1910.146, and 19 ~~1~~ 0.147 also issued und ~~e~~ r 29 CFR part 191 ~~1~~ .
**Authority:** [33 U.S.C. 941; 29 U.S.C. 653, 655, 657; Secretary of Labor's Order No. 12-71 (36 FR 8754); 8-76 (41 FR 25059), 9-83](https://www.govinfo.gov/link/uscode/33/941)

[(48 FR 35736), 1-90 (55 FR 9033), 6-96 (62 FR 111), 3-2000 (65 FR 50017), 5-2002 (67 FR 65008), 5-2007 (72 FR 31160),](https://www.federalregister.gov/citation/48-FR-35736)
4-2010 (75 F ~~R~~ [55355), 1-2012 (](https://www.federalregister.gov/citation/75-FR-55355) ~~7~~ [7 FR 3912), or 08](https://www.federalregister.gov/citation/77-FR-3912) ~~-~~ [2020 (85 FR 58393); 2](https://www.federalregister.gov/citation/85-FR-58393) ~~9~~ CFR part 1911; and 5 [U.S.C. 553, as applica](https://www.govinfo.gov/link/uscode/5/553) ~~b~~ le.
**Source:** [39 FR 23502, June 27, 1974, unless otherwise noted.](https://www.federalregister.gov/citation/39-FR-23502)

**§ 1910.147 The control of hazardous energy (lockout/tagout).**

(a) _Scope, application, and purpose_ —

(1) _Scope._

(i) This standard covers the servicing and maintenance of machines and equipment in which the

_unexpected_ energization or start up of the machines or equipment, or release of stored energy
could cause injury to employees. This standard establishes minimum performance
requirements for the control of such hazardous energy.

(ii) This standard does not cover the following:

(A) Construction and agriculture employment;

(B) [Employment covered by parts 1915, 1917, and 1918 of this title;](https://www.ecfr.gov/on/2025-07-23/title-29/part-1915/)

(C) Installations under the exclusive control of electric utilities for the purpose of power

generation, transmission and distribution, including related equipment for communication
or metering;

(D) Exposure to electrical hazards from work on, near, or with conductors or equipment in

[electric-utilization installations, which is covered by subpart S of this part; and](https://www.ecfr.gov/on/2025-07-23/title-29/part-1910/subpart-S/)

(E) Oil and gas well drilling and servicing.

(2) _Application._

(i) This standard applies to the control of energy during servicing and/or maintenance of

machines and equipment.

(ii) [Normal production operations are not covered by this standard (See subpart O of this part).](https://www.ecfr.gov/on/2025-07-23/title-29/part-1910/subpart-O/)

Servicing and/or maintenance which takes place during normal production operations is
covered by this standard only if;:

(A) An employee is required to remove or bypass a guard or other safety device; or

**29 CFR 1910.147(a)(2)(ii)(A) (enhanced display)** **page 1 of 13**

**29 CFR 1910.147(a)(2)(ii)(B)**

(B) An employee is required to place any part of his or her body into an area on a machine or

piece of equipment where work is actually performed upon the material being processed
(point of operation) or where an associated danger zone exists during a machine
operating cycle.

Note: _Exception to paragraph (a)(2)(ii):_ Minor tool changes and adjustments, and

other minor servicing activities, which take place during normal production

operations, are not covered by this standard if they are routine, repetitive, and

integral to the use of the equipment for production, provided that the work is

performed using alternative measures which provide effective protection (See

[subpart O of this part).](https://www.ecfr.gov/on/2025-07-23/title-29/part-1910/subpart-O/)

(iii) This standard does not apply to the following.

(A) Work on cord and plug connected electric equipment for which exposure to the hazards of

unexpected energization or start up of the equipment is controlled by the unplugging of
the equipment from the energy source and by the plug being under the exclusive control of
the employee performing the servicing or maintenance.

(B) Hot tap operations involving transmission and distribution systems for substances such

as gas, steam, water or petroleum products when they are performed on pressurized
pipelines, provided that the employer demonstrates that

( _1_ ) continuity of service is essential;

( _2_ ) shutdown of the system is impractical; and

( _3_ ) documented procedures are followed, and special equipment is used which will

provide proven effective protection for employees.

(3) _Purpose._

(i) This section requires employers to establish a program and utilize procedures for affixing

appropriate lockout devices or tagout devices to energy isolating devices, and to otherwise
disable machines or equipment to prevent unexpected energization, start-up or release of
stored energy in order to prevent injury to employees.

(ii) When other standards in this part require the use of lockout or tagout, they shall be used and

supplemented by the procedural and training requirements of this section.

(b) _Definitions applicable to this section._

_Affected employee._ An employee whose job requires him/her to operate or use a machine or equipment on

which servicing or maintenance is being performed under lockout or tagout, or whose job requires
him/her to work in an area in which such servicing or maintenance is being performed.

_Authorized employee._ A person who locks out or tags out machines or equipment in order to perform

servicing or maintenance on that machine or equipment. An affected employee becomes an
authorized employee when that employee's duties include performing servicing or maintenance

covered under this section.

**29 CFR 1910.147(b) “Authorized employee” (enhanced display)** **page 2 of 13**

**29 CFR 1910.147(b) “Capable of being locked out”**

_Capable of being locked out._ An energy isolating device is capable of being locked out if it has a hasp or

other means of attachment to which, or through which, a lock can be affixed, or it has a locking
mechanism built into it. Other energy isolating devices are capable of being locked out, if lockout
can be achieved without the need to dismantle, rebuild, or replace the energy isolating device or
permanently alter its energy control capability.

_Energized._ Connected to an energy source or containing residual or stored energy.

_Energy isolating device._ A mechanical device that physically prevents the transmission or release of energy,

including but not limited to the following: A manually operated electrical circuit breaker; a disconnect
switch; a manually operated switch by which the conductors of a circuit can

C:\Users\megahefm\Dropbox\SIGHT Project\sight\app\data\29 CFR 1910.147 (up to date as of 7-23-2025).pdf

1910.147(b) “Capable of being locked out”**

switch; a manually operated switch by which the conductors of a circuit can be disconnected from
all ungrounded supply conductors, and, in addition, no pole can be operated independently; a line
valve; a block; and any similar device used to block or isolate energy. Push buttons, selector
switches and other control circuit type devices are not energy isolating devices.

_Energy source._ Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other

energy.

_Hot tap._ A procedure used in the repair, maintenance and services activities which involves welding on a

piece of equipment (pipelines, vessels or tanks) under pressure, in order to install connections or
appurtenances. It is commonly used to replace or add sections of pipeline without the interruption of
service for air, gas, water, steam, and petrochemical distribution systems.

_Lockout._ The placement of a lockout device on an energy isolating device, in accordance with an

established procedure, ensuring that the energy isolating device and the equipment being controlled
cannot be operated until the lockout device is removed.

_Lockout device._ A device that utilizes a positive means such as a lock, either key or combination type, to

hold an energy isolating device in a safe position and prevent the energizing of a machine or
equipment. Included are blank flanges and bolted slip blinds.

_Normal production operations._ The utilization of a machine or equipment to perform its intended

production function.

_Servicing and/or maintenance._ Workplace activities such as constructing, installing, setting up, adjusting,

inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities
include lubrication, cleaning or unjamming of machines or equipment and making adjustments or
tool changes, where the employee may be exposed to the _unexpected_ energization or startup of the
equipment or release of hazardous energy.

_Setting up._ Any work performed to prepare a machine or equipment to perform its normal production

operation.

_Tagout._ The placement of a tagout device on an energy isolating device, in accordance with an established

procedure, to indicate that the energy isolating device and the equipment being controlled may not
be operated until the tagout device is removed.

_Tagout device._ A prominent warning device, such as a tag and a means of attachment, which can be

securely fastened to an energy isolating device in accordance with an established procedure, to
indicate that the energy isolating device and the equipment being controlled may not be operated
until the tagout device is removed.

(c) _General_ —

**29 CFR 1910.147(c) (enhanced display)** **page 3 of 13**

**29 CFR 1910.147(c)(1)**

(1) _Energy control program._ The employer shall establish a program consisting of energy control

procedures, employee training and periodic inspections to ensure that before any employee
performs any servicing or maintenance on a machine or equipment where the unexpected
energizing, start up or release of stored energy could occur and cause injury, the machine or
equipment shall be isolated from the energy source, and rendered inoperative.

(2) _Lockout/tagout._

(i) If an energy isolating device is not capable of being locked out, the employer's energy control

program under paragraph (c)(1) of this section shall utilize a tagout system.

(ii) If an energy isolating device is capable of being locked out, the employer's energy control

program under paragraph (c)(1) of this section shall utilize lockout, unless the employer can
demonstrate that the utilization of a tagout system will provide full employee protection as set
forth in paragraph (c)(3) of this section.

(iii) After January 2, 1990, whenever replacement or major repair, renovation or modification of a

machine or equipment is performed, and whenever new machines or equipment are installed,
energy isolating devices for such machine or equipment shall be designed to accept a lockout

device.

(3) _Full employee protection._

(i) When a tagout device is used on an energy isolating device which is capable of being locked

out, the tagout device shall be attached at the same location that the lockout device would
have been attached, and the employer shall demonstrate that the tagout program will provide a
level of safety equivalent to that obtained by using a lockout program.

(ii) In demonstrating that a level of safety is achieved in the tagout program which is equivalent to

the level of safety obtained by using a lockout program, the employer shall demonstrate full
compliance with all tagout-related provisions of this standard together with such additional
elements as are necessary to provide the equivalent safety available from the use of a lockout
device. Additional means to be considered as part of the demonstration of full employee
protection shall include the implementation of additional safety measures such as the removal
of an isolating circuit element, blocking of a controlling switch, opening of an extra
disconnecting device, or the removal of a valve handle to reduce the likelihood of inadvertent
energization.

(4) _Energy control procedure._

(i) Procedures shall be developed, documented and utilized for the control of potentially

hazardous energy when employees are engaged in the activities covered by this section.

Note: _Exception:_ The employer need not document the required procedure for a

particular machine or equipment, when all of the following elements exist: (1) The

machine or equipment has no potential for stored or residual energy or reaccumulation

of stored energy after shut down which could endanger employees; (2) the machine or

equipment has a single energy source which can be readily identified and isolated; (3)

the isolation and locking out of that energy source will completely deenergize and

deactivate the machine or equipment; (4) the machine or equipment is isolated from that

**29 CFR 1910.147(c)(4)(i) (enhanced display)** **page 4 of 13**

**29 CFR 1910.147(c)(4)(ii)**

energy source and locked out during servicing or maintenance; (5) a single lockout

device will achieve a locked-out condition; (6) the lockout device is under the exclusive

control of the authorized employee performing the servicing or maintenance; (7) the

servicing or maintenance does not create hazards for other employees; and (8) the

employer, in utilizing this exception, has had no accidents involving the unexpected

activation or reenergization of the machine or equipment during servicing or

maintenance.

(ii) The procedures shall clearly and specifically outline the scope, purpose, authorization, rules,

and techniques to be utilized for the control of hazardous energy, and the means to enforce
compliance including, but not limited to, the following:

(A) A specific statement of the intended use of the procedure;

(B) Specific procedural steps for shutting down, isolating, blocking and securing machines or

equipment to control hazardous energy;

(C) Specific procedural steps for the placement, removal and transfer of lockout devices or

tagout devices and the responsibility for them; and

(D) Specific requirements for testing a machine or equipment to determine and verify the

effectiveness of lockout devices, tagout devices, and other energy control measures.

(5) _Protective materials and hardware._

(i) Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware

shall be provided by the employer for isolating, securing or blocking of machines or equipment
from energy sources.

(ii) Lockout devices and tagout devices shall be singularly identified; shall be the only devices(s)

used for controlling energy; shall not be used for other purposes; and shall meet the following
requirements:

(A) _Durable._

( _1_ ) Lockout and tagout devices shall be capable of withstanding the environment to

which they are exposed for the maximum period of time that exposure is expected.

( _2_ ) Tagout devices shall be constructed and printed so that exposure to weather

conditions or wet and damp locations will not cause the tag to deteriorate or the
message on the tag to become illegible.

( _3_ ) Tags shall not deteriorate when used in corrosive environments such as areas

( _3_ ) Tags shall not deteriorate when used in corrosive environments such as areas where

acid and alkali chemicals are handled and stored.

(B) _Standardized._ Lockout and tagout devices shall be standardized within the facility in at

least one of the following criteria: Color; shape; or size; and additionally, in the case of
tagout devices, print and format shall be standardized.

(C) _Substantial_ —

**29 CFR 1910.147(c)(5)(ii)(C) (enhanced display)** **page 5 of 13**

**29 CFR 1910.147(c)(5)(ii)(C)(1)**

( _1_ ) _Lockout devices._ Lockout devices shall be substantial enough to prevent removal

without the use of excessive force or unusual techniques, such as with the use of
bolt cutters or other metal cutting tools.

( _2_ ) _Tagout devices._ Tagout devices, including and their means of attachment, shall be

substantial enough to prevent inadvertent or accidental removal. Tagout device
attachment means shall be of a non-reusable type, attachable by hand, self-locking,
and non-releasable with a minimum unlocking strength of no less than 50 pounds
and having the general design and basic characteristics of being at least equivalent
to a one-piece, all-environment-tolerant nylon cable tie.

(D) _Identifiable._ Lockout devices and tagout devices shall indicate the identity of the employee

applying the device(s).

(iii) Tagout devices shall warn against hazardous conditions if the machine or equipment is

energized and shall include a legend such as the following: _Do Not Start, Do Not Open, Do Not_
_Close, Do Not Energize, Do Not Operate._

(6) _Periodic inspection._

(i) The employer shall conduct a periodic inspection of the energy control procedure at least

annually to ensure that the procedure and the requirements of this standard are being followed.

(A) The periodic inspection shall be perfomed by an authorized employee other than the

ones(s) utilizing the energy control procedure being inspected.

(B) The periodic inspection shall be conducted to correct any deviations or inadequacies

identified.

(C) Where lockout is used for energy control, the periodic inspection shall include a review,

between the inspector and each authorized employee, of that employee's responsibilities
under the energy control procedure being inspected.

(D) Where tagout is used for energy control, the periodic inspection shall include a review,

between the inspector and each authorized and affected employee, of that employee's
responsibilities under the energy control procedure being inspected, and the elements set
forth in paragraph (c)(7)(ii) of this section.

(ii) The employer shall certify that the periodic inspections have been performed. The certification

shall identify the machine or equipment on which the energy control procedure was being
utilized, the date of the inspection, the employees included in the inspection, and the person
performing the inspection.

(7) _Training and communication._

(i) The employer shall provide training to ensure that the purpose and function of the energy

control program are understood by employees and that the knowledge and skills required for
the safe application, usage, and removal of the energy controls are acquired by employees. The
training shall include the following:

(A) Each authorized employee shall receive training in the recognition of applicable hazardous

energy sources, the type and magnitude of the energy available in the workplace, and the
methods and means necessary for energy isolation and control.

**29 CFR 1910.147(c)(7)(i)(A) (enhanced display)** **page 6 of 13**

**29 CFR 1910.147(c)(7)(i)(B)**

(B) Each affected employee shall be instructed in the purpose and use of the energy control

procedure.

(C) All other employees whose work operations are or may be in an area where energy control

procedures may be utilized, shall be instructed about the procedure, and about the
prohibition relating to attempts to restart or reenergize machines or equipment which are
locked out or tagged out.

(ii) When tagout systems are used, employees shall also be trained in the following limitations of

tags:

(A) Tags are essentially warning devices affixed to energy isolating devices, and do not

provide the physical restraint on those devices that is provided by a lock.

(B) When a tag is attached to an energy isolating means, it is not to be removed without

authorization of the authorized person responsible for it, and it is never to be bypassed,
ignored, or otherwise defeated.

(C) Tags must be legible and understandable by all authorized employees, affected

employees, and all other employees whose work operations are or may be in the area, in
order to be effective.

(D) Tags and their means of attachment must be made of materials which will withstand the

environmental conditions encountered in the workplace.

(E) Tags may evoke a false sense of security, and their meaning needs to be understood as

part of the overall energy control program.

(F) Tags must be securely attached to energy isolating devices so that they cannot be

inadvertently or accidentally detached during use.

(iii) Employee retraining.

(A) Retraining shall be provided for all authorized and affected employees whenever there is a

change in their job assignments, a change in machines, equipment or processes that
present a new hazard, or when there is a change in the energy control procedures.

(B) Additional retraining shall also be conducted whenever a periodic inspection under

paragraph (c)(6) of this section reveals, or whenever the employer has reason to believe,
that there are deviations from or inadequacies in the employee's knowledge or use of the
energy control procedures.

(C) The retraining shall reestablish employee proficiency and introduce new or revised control

methods and procedures, as necessary.

(iv) The employer shall certify that employee training has been accomplished and is being kept up

to date. The certification shall contain each employee's name and dates of training.

(8) _Energy isolation._ Lockout or tagout shall be performed only by the authorized employees who are

performing the servicing or maintenance.

(9) _Notification of employees._ Affected employees shall be notified by the employer or authorized

employee of the application and removal of lockout devices or tagout devices. Notification shall be
given before the controls are applied, and after they are removed from the machine or equipment.

**29 CFR 1910.147(c)(9) (enhanced display)** **page 7 of 13**

**29 CFR 1910.147(d)**

(d) _Application of control._ The established procedures for the application of energy control (the lockout or

tagout procedures) shall cover the following elements and actions and shall be done in the following

sequence:

(1) _Preparation for shutdown._ Before an authorized or affected employee turns off a machine or

equipment, the authorized employee shall have knowledge of the type and magnitude of the energy,
the hazards of the energy to be controlled, and the method or means to control the energy.

(2) _Machine or equipment shutdown._ The machine or equipment shall be turned off or shut down using

the procedures established for the machine or equipment. An orderly shutdown must be utilized to
avoid any additional or increased hazard(s) to employees as a result of the equipment stoppage.

(3) _Machine or equipment isolation._ All energy isolating devices that are needed to control the energy to

the machine or equipment shall be physically located and operated in such a manner as to isolate
the machine or equipment from the energy source(s).

(4) _Lockout or tagout device application._

(i) Lockout or tagout devices shall be affixed to each energy isolating device by authorized

employees.

(ii) Lockout devices, where used, shall be affixed in a manner to that will hold the energy isolating

devices in a “safe” or “off” position.

(iii) Tagout devices, where used, shall be affixed in such a manner as will clearly indicate that the

operation or movement of energy isolating devices from the “safe”

 using

operation or movement of energy isolating devices from the “safe” or “off” position is
prohibited.

(A) Where tagout devices are used with energy isolating devices designed with the capability

of being locked, the tag attachment shall be fastened at the same point at which the lock

would have been attached.

(B) Where a tag cannot be affixed directly to the energy isolating device, the tag shall be

located as close as safely possible to the device, in a position that will be immediately
obvious to anyone attempting to operate the device.

(5) _Stored energy._

(i) Following the application of lockout or tagout devices to energy isolating devices, all potentially

hazardous stored or residual energy shall be relieved, disconnected, restrained, and otherwise
rendered safe.

(ii) If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of

isolation shall be continued until the servicing or maintenance is completed, or until the
possibility of such accumulation no longer exists.

(6) _Verification of isolation._ Prior to starting work on machines or equipment that have been locked out

or tagged out, the authorized employee shall verify that isolation and deenergization of the machine
or equipment have been accomplished.

(e) _Release from lockout or tagout._ Before lockout or tagout devices are removed and energy is restored to the

machine or equipment, procedures shall be followed and actions taken by the authorized employee(s) to
ensure the following:

**29 CFR 1910.147(e) (enhanced display)** **page 8 of 13**

**29 CFR 1910.147(e)(1)**

(1) _The machine or equipment._ The work area shall be inspected to ensure that nonessential items have

been removed and to ensure that machine or equipment components are operationally intact.

(2) _Employees._

(i) The work area shall be checked to ensure that all employees have been safely positioned or

removed.

(ii) After lockout or tagout devices have been removed and before a machine or equipment is

started, affected employees shall be notified that the lockout or tagout device(s) have been
removed.

(3) _Lockout or tagout devices removal._ Each lockout or tagout device shall be removed from each energy

isolating device by the employee who applied the device. _Exception to paragraph (e)(3):_ When the
authorized employee who applied the lockout or tagout device is not available to remove it, that
device may be removed under the direction of the employer, provided that specific procedures and
training for such removal have been developed, documented and incorporated into the employer's
energy control program. The employer shall demonstrate that the specific procedure provides
equivalent safety to the removal of the device by the authorized employee who applied it. The
specific procedure shall include at least the following elements:

(i) Verfication by the employer that the authorized employee who applied the device is not at the

facility;

(ii) Making all reasonable efforts to contact the authorized employee to inform him/her that his/her

lockout or tagout device has been removed; and

(iii) Ensuring that the authorized employee has this knowledge before he/she resumes work at that

facility.

(f) _Additional requirements_ —

(1) _Testing or positioning of machines, equipment or components thereof._ In situations in which lockout

or tagout devices must be temporarily removed from the energy isolating device and the machine or
equipment energized to test or position the machine, equipment or component thereof, the following
sequence of actions shall be followed:

(i) Clear the machine or equipment of tools and materials in accordance with paragraph (e)(1) of

this section;

(ii) Remove employees from the machine or equipment area in accordance with paragraph (e)(2) of

(iii) Remove the lockout or tagout devices as specified in paragraph (e)(3) of this section;

(iv) Energize and proceed with testing or positioning;

(v) Deenergize all systems and reapply energy control measures in accordance with paragraph (d)

of this section to continue the servicing and/or maintenance.

(2) _Outside personnel (contractors, etc.)._

(i) Whenever outside servicing personnel are to be engaged in activities covered by the scope and

application of this standard, the on-site employer and the outside employer shall inform each
other of their respective lockout or tagout procedures.

**29 CFR 1910.147(f)(2)(i) (enhanced display)** **page 9 of 13**

**29 CFR 1910.147(f)(2)(ii)**

(ii) The on-site employer shall ensure that his/her employees understand and comply with the

restrictions and prohibitions of the outside employer's energy control program.

(3) _Group lockout or tagout._

(i) When servicing and/or maintenance is performed by a crew, craft, department or other group,

they shall utilize a procedure which affords the employees a level of protection equivalent to
that provided by the implementation of a personal lockout or tagout device.

(ii) Group lockout or tagout devices shall be used in accordance with the procedures required by

paragraph (c)(4) of this section including, but not necessarily limited to, the following specific

(A) Primary responsibility is vested in an authorized employee for a set number of employees

working under the protection of a group lockout or tagout device (such as an operations
lock);

(B) Provision for the authorized employee to ascertain the exposure status of individual group

members with regard to the lockout or tagout of the machine or equipment and

(C) When more than one crew, craft, department, etc. is involved, assignment of overall job
associated lockout or tagout control responsibility to an authorized employee designated
to coordinate affected work forces and ensure continuity of protection; and

(D) Each authorized employee shall affix a personal lockout or tagout device to the group

lockout device, group lockbox, or comparable mechanism when he or she begins work,
and shall remove those devices when he or she stops working on the machine or
equipment being serviced or maintained.

(4) _Shift or personnel changes._ Specific procedures shall be utilized during shift or personnel changes to

ensure the continuity of lockout or tagout protection, including provision for the orderly transfer of
lockout or tagout device protection between off-going and oncoming employees, to minimize
exposure to hazards from the unexpected energization or start-up of the machine or equipment, or
the release of stored energy.

Note: The following appendix to § 1910.147 services as a non-mandatory guideline to assist

employers and employees in complying with the requirements of this section, as well as to provide

other helpful information. Nothing in the appendix adds to or detracts from any of the

requirements of this section.

# Appendix A to § 1910.147—Typical Minimal Lockout Procedure

## General

The following simple lockout procedure is provided to assist employers in developing their procedures so they
meet the requirements of this standard. When the energy isolating devices are not lockable, tagout may be
used, provided the employer complies with the provisions of the standard which require additional training and
more rigorous periodic inspections. When tagout is used and the energy isolating devices are lockable, the

**29 CFR 1910.147(f)(4) (enhanced display)** **page 10 of 13**

**29 CFR 1910.147(f)(4)**

employer must provide full employee protection ( _see_ paragraph (c)(3)) and additional training and more
rigorous periodic inspections are required. For more complex systems, more comprehensive procedures may
need to be developed, documented and utilized.

L OCKOUT P ROCEDURE

Lockout procedure for

(Name of Company for single procedure or identification of equipment if multiple procedures are used)

## Purpose

This procedure establishes the minimum requirements for the lockout of energy isolating devices whenever
maintenance or servicing is done on machines or equipment. It shall be used to ensure that the machine or
equipment is

able, the

## Purpose

equipment is stopped, isolated from all potentially hazardous energy sources and locked out before employees
perform any servicing or maintenance where the unexpected energization or start-up of the machine or
equipment or release of stored energy could cause injury.

## Compliance With This Program

All employees are required to comply with the restrictions and limitations imposed upon them during the use of
lockout. The authorized employees are required to perform the lockout in accordance with this procedure. All
employees, upon observing a machine or piece of equipment which is locked out to perform servicing or
maintenance shall not attempt to start, energize or use that machine or equipment.

Type of compliance enforcement to be taken for violation of the above.

## Sequence of Lockout

(1) Notify all affected employees that servicing or maintenance is required on a machine or equipment and that
the machine or equipment must be shut down and locked out to perform the servicing or maintenance.

Name(s)/Job Title(s) of affected employees and how to notify.

(2) The authorized employee shall refer to the company procedure to identify the type and magnitude of the
energy that the machine or equipment utilizes, shall understand the hazards of the energy, and shall know the
methods to control the energy.

Type(s) and magnitude(s) of energy, its hazards and the methods to control the energy.

(3) If the machine or equipment is operating, shut it down by the normal stopping procedure (depress stop
button, open switch, close valve, etc.).

**29 CFR 1910.147(f)(4) (enhanced display)** **page 11 of 13**

Type(s) and location(s) of machine or equipment operating controls.

(4) De-activate the energy isolating device(s) so that the machine or equipment is isolated from the energy
source(s).

Type(s) and location(s) of energy isolating devices.

(5) Lock out the energy isolating device(s) with assigned individual lock(s).

(6) Stored or residual energy (such as that in capacitors, springs, elevated machine members, rotating
flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or restrained by
methods such as grounding, repositioning, blocking, bleeding down, etc.

Type(s) of stored energy—methods to dissipate or restrain.

(7) Ensure that the equipment is disconnected from the energy source(s) by first checking that no personnel
are exposed, then verify the isolation of the equipment by operating the push button or other normal operating
control(s) or by testing to make certain the equipment will not operate.

C AUTION : Return operating control(s) to neutral or “off” position after verifying the isolation of the equipment.

Method of verifying the isolation of the equipment.

(8) The machine or equipment is now locked out.

_Restoring Equipment to Service._ When the servicing or maintenance is completed and the machine or
equipment is ready to return to normal operating condition, the following steps shall be taken.

(1) Check the machine or equipment and the immediate area around the machine or equipment to ensure that
nonessential items have been removed and that the machine or equipment components are operationally

intact.

(2) Check the work area to ensure that all employees have been safely positioned or removed from the area.

(3) Verify that the controls are in neutral.

(4) Remove the lockout devices and reenergize the machine or equipment.

Note: The removal of some forms of blocking may require reenergization of the machine

before safe removal.

**29 CFR 1910.147(f)(4) (enhanced display)** **page 12 of 13**

(5) Notify affected employees that the servicing or maintenance is completed and the machine or equipment is
ready for use.

_[[54 FR 36687, Sept. 1, 1989, as amended at 54 FR 42498, Oct. 17, 1989; 55 FR 38685, 38686, Sept. 20, 1990; 76 FR 24698, May 2,](https://www.federalregister.gov/citation/54-FR-36687)_
_[2011; 76 FR 44265, July 25, 2011]](https://www.federalregister.gov/citation/76-FR-44265)_

**29 CFR 1910.147(f)(4) (enhanced display)** **page 13 of 13**

**29 CFR 1910.178 (up to date as of 7/23/2025)**
**29 CFR 1910.178 (July 23, 2025)**
**Powered industrial trucks.**

**Subpart N —Materials Handling and Storage**

[1-90 (55 FR 9033), 6-96 (62 FR 111), 3-2000 (65 FR 50017), 5-2002 (67 FR 65008), 5-2007 (72 FR 31159), 4-2010 (75 FR](https://www.federalregister.gov/citation/55-FR-9033)
[55355), or 1-201](https://www.federalregister.gov/citation/75-FR-55355) ~~2~~ [(77 FR 3912), as](https://www.federalregister.gov/citation/77-FR-3912) applicable; and 29 CF ~~R~~ part 1911.

**§ 1910.178 Powered industrial trucks.**

(a) _General requirements._

(1) This section contains safety requirements relating to fire protection, design, maintenance, and use of

fork trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial
trucks powered by electric motors or internal combustion engines. This section does not apply to
compressed air or nonflammable compressed gas-operated industrial trucks, nor to farm vehicles,
nor to vehicles intended primarily for earth moving or over-the-road hauling.

(2) All new powered industrial trucks acquired and used by an employer shall meet the design and

construction requirements for powered industrial trucks established in the “American National
Standard for Powered Industrial Trucks, Part II, ANSI B56.1-1969”, which is incorporated by reference
[as specified in § 1910.6, except for vehicles intended primarily for earth moving or over-the-road](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.6/)
hauling.

(3) Approved trucks shall bear a label or some other identifying mark indicating approval by the testing

laboratory. See paragraph (a)(7) of this section and paragraph 405 of “American National Standard
for Powered Industrial Trucks, Part II, ANSI B56.1-1969”, which is incorporated by reference in
paragraph (a)(2) of this section and which provides that if the powered industrial truck is accepted
by a nationally recognized testing laboratory it should be so marked.

(4) Modifications and additions which affect capacity and safe operation shall not be performed by the

customer or user without manufacturers prior written approval. Capacity, operation, and
maintenance instruction plates, tags, or decals shall be changed accordingly.

(5) If the truck is equipped with front-end attachments other than factory installed attachments, the user

shall request that the truck be marked to identify the attachments and show the approximate weight
of the truck and attachment combination at maximum elevation with load laterally centered.

(6) The user shall see that all nameplates and markings are in place and are maintained in a legible

condition.

(7) As used in this section, the term, _approved truck_ or _approved industrial truck_ means a truck that is

listed or approved for fire safety purposes for the intended use by a nationally recognized testing
[laboratory, using nationally recognized testing standards. Refer to § 1910.155(c)(3)(iv)(A) for](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.155/?#p-1910.155(c)(3)(iv)(A))
[definition of listed, and to § 1910.7 for definition of nationally recognized testing laboratory.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.7/)

**29 CFR 1910.178(a)(7) (enhanced display)** **page 1 of 21**

**29 CFR 1910.178(b)**

(b) _Designations._ For the purpose of this standard there are eleven different designations of industrial trucks

or tractors as follows: D, DS, DY, E, ES, EE, EX, G, GS, LP, and LPS.

(1) The D designated units are units similar to the G units except that they are diesel engine powered

instead of gasoline engine powered.

(2) The DS designated units are diesel powered units that are provided with additional safeguards to the

exhaust, fuel and electrical systems. They may be used in some locations where a D unit may not be

considered suitable.

(3) The DY designated units are diesel powered units that have all the safeguards of the DS units and in

addition do not have any electrical equipment including the ignition and are equipped with
temperature limitation features.

(4) The E designated units are electrically powered units that have minimum acceptable safeguards

against inherent fire hazards.

(5) The ES designated units are electrically powered units that, in addition to all of the requirements for

the E units, are provided with additional safeguards to the electrical system to prevent emission of
hazardous sparks and to limit surface temperatures. They may be used in some locations where the
use of an E unit may not be considered suitable.

(6) The EE designated units are electrically powered units that have, in addition to all of the requirements

for the E and ES units, the electric motors and all other electrical equipment completely enclosed. In
certain locations the EE unit may be used where the use of an E and ES unit may not be considered

suitable.

(7) The EX designated units are electrically powered units that differ from the E, ES, or EE units in that

the electrical fittings and equipment are so designed, constructed and assembled that the units may
be used in certain atmospheres containing flammable vapors or dusts.

(8) The G designated units are gasoline powered units having minimum acceptable safeguards against

inherent fire hazards.

(9) The GS designated units are gasoline powered units that are provided with additional safeguards to

the exhaust, fuel, and electrical systems. They may be used in some locations where the use of a G
unit may not be considered suitable.

(10) The LP designated unit is similar to the G unit except that liquefied petroleum gas is used for fuel

instead of gasoline.

(11) The LPS designated units are liquefied petroleum gas powered units that are provided with additional

safeguards to the exhaust, fuel, and electrical systems. They may be used in some locations where
the use of an LP unit may not be considered suitable.

(12) The atmosphere or location shall have been classified as to whether it is hazardous or nonhazardous

prior to the consideration of industrial trucks being used therein and the type of industrial truck
required shall be as provided in paragraph (d) of this section for such location.

(c) _Designated locations._

(1) The industrial trucks specified under subparagraph (2) of this paragraph are the minimum types

required but industrial trucks

C:\Users\megahefm\Dropbox\SIGHT Project\sight\app\data\29 CFR 1910.178 (up to date as of 7-23-2025).pdf

 and electrical systems. They may be used in some locations where the use of a G

required but industrial trucks having greater safeguards may be used if desired.

**29 CFR 1910.178(c)(1) (enhanced display)** **page 2 of 21**

**29 CFR 1910.178(c)(2)**

(2) For specific areas of use, see Table N-1 which tabulates the information contained in this section.

[References are to the corresponding classification as used in subpart S of this part.](https://www.ecfr.gov/on/2025-07-23/title-29/part-1910/subpart-S/)

(i) Power-operated industrial trucks shall not be used in atmospheres containing hazardous

concentration of acetylene, butadiene, ethylene oxide, hydrogen (or gases or vapors equivalent
in hazard to hydrogen, such as manufactured gas), propylene oxide, acetaldehyde,
cyclopropane, diethyl ether, ethylene, isoprene, or unsymmetrical dimethyl hydrazine (UDMH).

(ii) ( _a_ ) Power-operated industrial trucks shall not be used in atmospheres containing hazardous

concentrations of metal dust, including aluminum, magnesium, and their commercial alloys,
other metals of similarly hazardous characteristics, or in atmospheres containing carbon black,
coal or coke dust except approved power-operated industrial trucks designated as EX may be
used in such atmospheres.

( _b_ ) In atmospheres where dust of magnesium, aluminum or aluminum bronze may be present,
fuses, switches, motor controllers, and circuit breakers of trucks shall have enclosures
specifically approved for such locations.

(iii) Only approved power-operated industrial trucks designated as EX may be used in atmospheres

containing acetone, acrylonitrile, alcohol, ammonia, benzine, benzol, butane, ethylene dichloride,
gasoline, hexane, lacquer solvent vapors, naphtha, natural gas, propane, propylene, styrene,
vinyl acetate, vinyl chloride, or xylenes in quantities sufficient to produce explosive or ignitable
mixtures and where such concentrations of these gases or vapors exist continuously,
intermittently or periodically under normal operating conditions or may exist frequently because
of repair, maintenance operations, leakage, breakdown or faulty operation of equipment.

(iv) Power-operated industrial trucks designated as DY, EE, or EX may be used in locations where

volatile flammable liquids or flammable gases are handled, processed or used, but in which the
hazardous liquids, vapors or gases will normally be confined within closed containers or closed
systems from which they can escape only in case of accidental rupture or breakdown of such
containers or systems, or in the case of abnormal operation of equipment; also in locations in
which hazardous concentrations of gases or vapors are normally prevented by positive
mechanical ventilation but which might become hazardous through failure or abnormal
operation of the ventilating equipment; or in locations which are adjacent to Class I, Division 1
locations, and to which hazardous concentrations of gases or vapors might occasionally be
communicated unless such communication is prevented by adequate positive-pressure
ventilation from a source of clear air, and effective safeguards against ventilation failure are
provided.

## **T ABLE N-1—S UMMARY T ABLE ON U SE OF I NDUSTRIAL T RUCKS IN V ARIOUS** **L OCATIONS**

**Class II**
**Classes** **Unclassified** **Class I locations** **Class III locations**
**locations**

Description

of classes

Locations

not

Locations in which
flammable gases or

Locations

which are

Locations where easily
ignitible fibers or flyings

**29 CFR 1910.178(c)(2)(iv) (enhanced display)** **page 3 of 21**

**29 CFR 1910.178(c)(2)(iv)**

hazardous

because of

the presence

of

combustible

dust

are present but not likely to
be in suspension in
quantities sufficient to
produce ignitible mixtures.

possessing
atmospheres

as described

in other

columns

vapors are, or may be,
present in the air in
produce explosive or
ignitible mixtures

**29 CFR 1910.178(c)(2)(iv) (enhanced display)** **page 4 of 21**

**Groups in classes** **None** **A** **B** **C** **D** **E** **F** **G** **None**

Baled waste, cocoa fiber, cotton, excelsior,
hemp, istle, jute, kapok, oakum, sisal,
Spanish moss, synthetic fibers, tow.

Examples of

locations or

atmospheres in
classes and groups

Piers and wharves inside and

outside general storage, general
industrial or commercial properties

Acetylene Hydrogen Ethyl

ether

Gasoline

Naphtha

Alcohols

Acetone

Lacquer

solvent

Benzene

Metal

dust

Carbon

black coal

dust, coke

dust

Grain dust, flour
dust, starch

dust, organic

dust

**29 CFR 1910.178(c)(2)(iv) (enhanced display)** **page 5 of 21**

**T** **ABLE** **N-1—S** **UMMARY** **T** **ABLE** **ON** **U** **SE** **OF** **I** **NDUSTRIAL** **T** **RUCKS** **IN** **V** **ARIOUS** **L** **OCATIONS** **—C** **ONTINUED**

**1** **2** **1** **2** **1** **2**

Above

condition

may occur
accidentally

as due to a

puncture of a
storage drum

Explosive mixture may be present under normal
operating conditions, or where failure of
equipment may cause the condition to exist
simultaneously with arcing or sparking of
electrical equipment, or where dusts of an
electrically conducting nature may be present

Explosive mixture not normally
present, but where deposits of
dust may cause heat rise in
electrical equipment, or where
such deposits may be ignited by
arcs or sparks from electrical

equipment

easily ignitible fibers

or materials

producing
combustible flyings
are handled,

manufactured, or

used

Locations in

which easily
ignitible fibers

are stored or

handled (except
in the process of
manufacture).

Divisions

(nature of

hazardous

conditions)

None Above condition

exists

continuously,
intermittently, or
periodically

under normal

operating

conditions

**29 CFR 1910.178(c)(2)(iv) (enhanced display)** **page 6 of 21**

**Authorized uses of trucks by types in groups of classes and divisions**

**Groups in classes** **None** **A** **B** **C** **D** **A** **B** **C** **D** **E** **F** **G** **E** **F** **G** **None** **None**

Type of truck authorized:

Diesel:

Type D D**

Type DS DS DS DS

Type

ature of

hazardous

exists

operating

Diesel:

Type D D**

Type DY DY DY DY DY

Electric:

Type E E** E

Type ES ES ES ES

Type EE EE EE EE EE

Type EX EX EX EX EX EX EX EX

Gasoline:

Type G G**

Type GS GS GS GS

LP-Gas:

Type LP LP**

Type LPS LPS LPS LPS

Paragraph Ref. in No. 505 210.211 201
(a)

203

(a)

209

(a)

204

(a),
(b)

202

(a)

205

(a)

209

(a)

206

(a),
(b)

207(a) 208 (a)

_**Trucks conforming to these types may also be used—see subdivision (c)(2)(x) and (c)(2)(xii) of this section._

**29 CFR 1910.178(c)(2)(iv) (enhanced display)** **page 7 of 21**

**29 CFR 1910.178(c)(2)(v)**

(v) In locations used for the storage of hazardous liquids in sealed containers or liquefied or

compressed gases in containers, approved power-operated industrial trucks designated as DS,
ES, GS, or LPS may be used. This classification includes locations where volatile flammable
liquids or flammable gases or vapors are used, but which, would become hazardous only in
case of an accident or of some unusual operating condition. The quantity of hazardous
material that might escape in case of accident, the adequacy of ventilating equipment, the total
area involved, and the record of the industry or business with respect to explosions or fires are
all factors that should receive consideration in determining whether or not the DS or DY, ES, EE,
GS, LPS designated truck possesses sufficient safeguards for the location. Piping without
valves, checks, meters and similar devices would not ordinarily be deemed to introduce a
hazardous condition even though used for hazardous liquids or gases. Locations used for the
storage of hazardous liquids or of liquified or compressed gases in sealed containers would
not normally be considered hazardous unless subject to other hazardous conditions also.

(vi) ( _a_ ) Only approved power operated industrial trucks designated as EX shall be used in

atmospheres in which combustible dust is or may be in suspension continuously, intermittently,
or periodically under normal operating conditions, in quantities sufficient to produce explosive
or ignitable mixtures, or where mechanical failure or abnormal operation of machinery or
equipment might cause such mixtures to be produced.

( _b_ ) The EX classification usually includes the working areas of grain handling and storage
plants, room containing grinders or pulverizers, cleaners, graders, scalpers, open conveyors or
spouts, open bins or hoppers, mixers, or blenders, automatic or hopper scales, packing
machinery, elevator heads and boots, stock distributors, dust and stock collectors (except allmetal collectors vented to the outside), and all similar dust producing machinery and
equipment in grain processing plants, starch plants, sugar pulverizing plants, malting plants,
hay grinding plants, and other occupancies of similar nature; coal pulverizing plants (except
where the pulverizing equipment is essentially dust tight); all working areas where metal dusts
and powders are produced, processed, handled, packed, or stored (except in tight containers);
and other similar locations where combustible dust may, under normal operating conditions, be
present in the air in quantities sufficient to produce explosive or ignitable mixtures.

(vii) Only approved power-operated industrial trucks designated as DY, EE, or EX shall be used in

atmospheres in which combustible dust will not normally be in suspension in the air or will not
be likely to be thrown into suspension by the normal operation of equipment or apparatus in
quantities sufficient to produce explosive or ignitable mixtures but where deposits or
accumulations of such dust may be ignited by arcs or sparks originating in the truck.

(viii) Only approved power-operated industrial trucks designated as DY, EE, or EX shall be used in

locations which are hazardous because of the presence of easily ignitable fibers or flyings but
in which such fibers or flyings are not likely to be in suspension in the air in quantities sufficient
to produce ignitable mixtures.

(ix) Only approved power-operated industrial trucks designated as DS, DY, ES, EE, EX, GS, or LPS

shall be used in locations where easily ignitable fibers are stored or handled, including outside
storage, but are not being processed or manufactured. Industrial trucks designated as E, which
have been previously used in these locations may be continued in use.

(x) On piers and wharves handling general cargo, any approved power-operated industrial truck

designated as Type D, E, G, or LP may be used, or trucks which conform to the requirements for
these types may be used.

**29 CFR 1910.178(c)(2)(x) (enhanced display)** **page 8 of 21**

**29 CFR 1910.178(c)(2)(xi)**

(xi) If storage warehouses and outside storage locations are hazardous only the approved power
operated industrial truck specified for such locations in this paragraph (c)(2) shall be used. If
not classified as hazardous, any approved power-operated industrial truck designated as Type
D, E, G, or LP may be used, or trucks which conform to the requirements for these types may be

used.

(xii) If general industrial or commercial properties are hazardous, only approved power-operated

industrial trucks specified for such locations in this paragraph (c)(2) shall be used. If not
classified as hazardous, any approved power-operated industrial truck designated as Type D, E,
G, or LP may be used, or trucks which conform to the requirements of these types may be used.

(d) _Converted industrial trucks._ Power-operated industrial trucks that have been originally approved for the

use of gasoline for fuel, when converted to the use of liquefied petroleum gas fuel in accordance with
paragraph (q) of this section, may be used in those locations where G, GS or LP, and LPS designated
trucks have been specified in the preceding paragraphs.

(e) _Safety guards._

(1) High Lift Rider trucks shall be fitted with an overhead guard manufactured in accordance with

paragraph (a)(2) of this section, unless operating conditions do not permit.

(2) If the type of load presents a hazard, the user shall equip fork trucks with a vertical load backrest

extension manufactured in accordance with paragraph (a)(2) of this section.

(f) _Fuel handling and storage._

(1) The storage and handling of liquid fuels such as gasoline and diesel fuel shall be in accordance with

NFPA Flammable and Combustible Liquids Code (NFPA No. 30-1969), which is incorporated by
[reference as specified in § 1910.6.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.6/)

(2) The storage and handling of liquefied petroleum gas fuel shall be in accordance with NFPA Storage

and Handling of Liquefied Petroleum Gases (NFPA No. 58-1969), which is incorporated by reference
[as specified in § 1910.6.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.6/)

(g) _Changing and charging storage batteries._

(1) Battery charging installations shall be located in areas designated for that purpose.

(2) Facilities shall be provided for flushing and neutralizing spilled electrolyte, for fire protection, for

protecting charging apparatus from damage by trucks, and for adequate ventilation for dispersal of
fumes from gassing batteries.

(3) [Reserved]

(4) A conveyor, overhead hoist, or equivalent material handling equipment shall be provided for handling

batteries.

(5) Reinstalled batteries shall be properly positioned and secured in the truck.

(6) A carboy tilter or siphon shall be provided for handling electrolyte.

(7) When charging batteries, acid shall be poured into water; water shall not be poured into acid.

(8) Trucks shall be properly

0.6.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.6/)

(8) Trucks shall be properly positioned and brake applied before attempting to change or charge

**29 CFR 1910.178(g)(8) (enhanced display)** **page 9 of 21**

**29 CFR 1910.178(g)(9)**

(9) Care shall be taken to assure that vent caps are functioning. The battery (or compartment) cover(s)

shall be open to dissipate heat.

(10) Smoking shall be prohibited in the charging area.

(11) Precautions shall be taken to prevent open flames, sparks, or electric arcs in battery charging areas.

(12) Tools and other metallic objects shall be kept away from the top of uncovered batteries.

(h) _Lighting for operating areas._

(1) [Reserved]

(2) Where general lighting is less than 2 lumens per square foot, auxiliary directional lighting shall be

provided on the truck.

(i) _Control of noxious gases and fumes._

(1) Concentration levels of carbon monoxide gas created by powered industrial truck operations shall

[not exceed the levels specified in § 1910.1000.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.1000/)

(j) _Dockboards (bridge plates)._ [See subpart D of this part.](https://www.ecfr.gov/on/2025-07-23/title-29/part-1910/subpart-D/)

(k) _Trucks and railroad cars._

(1) The brakes of highway trucks shall be set and wheel chocks placed under the rear wheels to prevent

the trucks from rolling while they are boarded with powered industrial trucks.

(2) Wheel stops or other recognized positive protection shall be provided to prevent railroad cars from

moving during loading or unloading operations.

(3) Fixed jacks may be necessary to support a semitrailer and prevent upending during the loading or

unloading when the trailer is not coupled to a tractor.

(4) Positive protection shall be provided to prevent railroad cars from being moved while dockboards or

bridge plates are in position.

(l) Operator training.

(1) _Safe operation._

(i) The employer shall ensure that each powered industrial truck operator is competent to operate

a powered industrial truck safely, as demonstrated by the successful completion of the training
and evaluation specified in this paragraph (l).

(ii) Prior to permitting an employee to operate a powered industrial truck (except for training

purposes), the employer shall ensure that each operator has successfully completed the
training required by this paragraph (l), except as permitted by paragraph (l)(5).

(2) _Training program implementation._

(i) Trainees may operate a powered industrial truck only:

(A) Under the direct supervision of persons who have the knowledge, training, and experience

to train operators and evaluate their competence; and

(B) Where such operation does not endanger the trainee or other employees.

**29 CFR 1910.178(l)(2)(i)(B) (enhanced display)** **page 10 of 21**

**29 CFR 1910.178(l)(2)(ii)**

(ii) Training shall consist of a combination of formal instruction (e.g., lecture, discussion,

interactive computer learning, video tape, written material), practical training (demonstrations
performed by the trainer and practical exercises performed by the trainee), and evaluation of
the operator's performance in the workplace.

(iii) All operator training and evaluation shall be conducted by persons who have the knowledge,

training, and experience to train powered industrial truck operators and evaluate their

competence.

(3) _Training program content._ Powered industrial truck operators shall receive initial training in the

following topics, except in topics which the employer can demonstrate are not applicable to safe
operation of the truck in the employer's workplace.

(i) Truck-related topics:

(A) Operating instructions, warnings, and precautions for the types of truck the operator will

be authorized to operate;

(B) Differences between the truck and the automobile;

(C) Truck controls and instrumentation: where they are located, what they do, and how they

work;

(D) Engine or motor operation;

(E) Steering and maneuvering;

(F) Visibility (including restrictions due to loading);

(G) Fork and attachment adaptation, operation, and use limitations;

(H) Vehicle capacity;

(I) Vehicle stability;

(J) Any vehicle inspection and maintenance that the operator will be required to perform;

(K) Refueling and/or charging and recharging of batteries;

(L) Operating limitations;

(M) Any other operating instructions, warnings, or precautions listed in the operator's manual

for the types of vehicle that the employee is being trained to operate.

(ii) Workplace-related topics:

(A) Surface conditions where the vehicle will be operated;

(B) Composition of loads to be carried and load stability;

(C) Load manipulation, stacking, and unstacking;

(D) Pedestrian traffic in areas where the vehicle will be operated;

(E) Narrow aisles and other restricted places where the vehicle will be operated;

(F) Hazardous (classified) locations where the vehicle will be operated;

(G) Ramps and other sloped surfaces that could affect the vehicle's stability;

**29 CFR 1910.178(l)(3)(ii)(G) (enhanced display)** **page 11 of 21**

**29 CFR 1910.178(l)(3)(ii)(H)**

(H) Closed environments and other areas where insufficient ventilation or poor vehicle

maintenance could cause a buildup of carbon monoxide or diesel exhaust;

(I) Other unique or potentially hazardous environmental conditions in the workplace that

could affect safe operation.

(iii) The requirements of this section.

(4) _Refresher training and evaluation._

(i) Refresher training, including an evaluation of the effectiveness of that training, shall be

conducted as required by paragraph (l)(4)(ii) to ensure that the operator has the knowledge and
skills needed to operate the powered industrial truck safely.

(ii) Refresher training in relevant topics shall be provided to the operator when:

(A) The operator has been observed to operate the vehicle in an unsafe manner;

(B) The operator has been involved in an accident or near-miss incident;

(C) The operator has received an evaluation that reveals that the operator is not operating the

truck safely;

(D) The operator is assigned to drive a different type of truck; or

(E) A condition in the workplace changes in a manner that could affect safe operation of the

truck.

(iii) An evaluation of each powered industrial truck operator's performance shall be conducted at

least once every three years.

(5) _Avoidance of duplicative training._ If an operator has previously received training in a topic specified in

paragraph (l)(3) of this section, and such training is appropriate to the truck and working conditions
encountered, additional training in that topic is not required if the operator has been evaluated and
found competent to operate the truck safely.

(6) _Certification._ The employer shall certify that each operator has been trained and evaluated as

required by this paragraph (l). The certification shall include the name of the operator, the date of the
training, the date of the evaluation, and the identity of the person(s) performing the training or
evaluation.

(7) _Dates._ The employer shall ensure that operators of powered industrial trucks are trained, as

appropriate, by the dates shown in the following table.

(8) Appendix A to this section provides non-mandatory guidance to assist employers in implementing

this paragraph (l). This appendix does not add to, alter, or reduce the requirements of this section.

**29 CFR 1910.178(l)(8) (enhanced display)** **page 12 of 21**

**29 CFR 1910.178(m)**

(m) _Truck operations._

(1) Trucks shall not be driven up to anyone standing in front of a bench or other fixed object.

(2) No person shall be allowed to stand or pass under the elevated portion of any truck, whether loaded

or empty.

(3

or empty.

(3) Unauthorized personnel shall not be permitted to ride on powered industrial trucks. A safe place to

ride shall be provided where riding of trucks is authorized.

(4) The employer shall prohibit arms or legs from being placed between the uprights of the mast or

outside the running lines of the truck.

(5)

(i) When a powered industrial truck is left unattended, load engaging means shall be fully lowered,

controls shall be neutralized, power shall be shut off, and brakes set. Wheels shall be blocked if
the truck is parked on an incline.

(ii) A powered industrial truck is unattended when the operator is 25 ft. or more away from the

vehicle which remains in his view, or whenever the operator leaves the vehicle and it is not in his

view.

(iii) When the operator of an industrial truck is dismounted and within 25 ft. of the truck still in his

view, the load engaging means shall be fully lowered, controls neutralized, and the brakes set to

prevent movement.

(6) A safe distance shall be maintained from the edge of ramps or platforms while on any elevated dock,

or platform or freight car. Trucks shall not be used for opening or closing freight doors.

(7) Brakes shall be set and wheel blocks shall be in place to prevent movement of trucks, trailers, or

railroad cars while loading or unloading. Fixed jacks may be necessary to support a semitrailer
during loading or unloading when the trailer is not coupled to a tractor. The flooring of trucks, trailers,
and railroad cars shall be checked for breaks and weakness before they are driven onto.

(8) There shall be sufficient headroom under overhead installations, lights, pipes, sprinkler system, etc.

(9) An overhead guard shall be used as protection against falling objects. It should be noted that an

overhead guard is intended to offer protection from the impact of small packages, boxes, bagged
material, etc., representative of the job application, but not to withstand the impact of a falling
capacity load.

(10) A load backrest extension shall be used whenever necessary to minimize the possibility of the load

or part of it from falling rearward.

(11) Only approved industrial trucks shall be used in hazardous locations.

(12)-(13) [Reserved]

(14) Fire aisles, access to stairways, and fire equipment shall be kept clear.

(n) _Traveling._

(1) All traffic regulations shall be observed, including authorized plant speed limits. A safe distance shall

be maintained approximately three truck lengths from the truck ahead, and the truck shall be kept

under control at all times.

**29 CFR 1910.178(n)(1) (enhanced display)** **page 13 of 21**

**29 CFR 1910.178(n)(2)**

(2) The right of way shall be yielded to ambulances, fire trucks, or other vehicles in emergency

situations.

(3) Other trucks traveling in the same direction at intersections, blind spots, or other dangerous

locations shall not be passed.

(4) The driver shall be required to slow down and sound the horn at cross aisles and other locations

where vision is obstructed. If the load being carried obstructs forward view, the driver shall be
required to travel with the load trailing.

(5) Railroad tracks shall be crossed diagonally wherever possible. Parking closer than 8 feet from the

center of railroad tracks is prohibited.

(6) The driver shall be required to look in the direction of, and keep a clear view of the path of travel.

(7) Grades shall be ascended or descended slowly.

(i) When ascending or descending grades in excess of 10 percent, loaded trucks shall be driven

with the load upgrade.

(ii) [Reserved]

(iii) On all grades the load and load engaging means shall be tilted back if applicable, and raised

only as far as necessary to clear the road surface.

(8) Under all travel conditions the truck shall be operated at a speed that will permit it to be brought to a

stop in a safe manner.

(9) Stunt driving and horseplay shall not be permitted.

(10) The driver shall be required to slow down for wet and slippery floors.

(11) Dockboard or bridgeplates, shall be properly secured before they are driven over. Dockboard or

bridgeplates shall be driven over carefully and slowly and their rated capacity never exceeded.

(12) Elevators shall be approached slowly, and then entered squarely after the elevator car is properly

leveled. Once on the elevator, the controls shall be neutralized, power shut off, and the brakes set.

(13) Motorized hand trucks must enter elevator or other confined areas with load end forward.

(14) Running over loose objects on the roadway surface shall be avoided.

(15) While negotiating turns, speed shall be reduced to a safe level by means of turning the hand steering

wheel in a smooth, sweeping motion. Except when maneuvering at a very low speed, the hand
steering wheel shall be turned at a moderate, even rate.

(o) _Loading._

(1) Only stable or safely arranged loads shall be handled. Caution shall be exercised when handling off
center loads which cannot be centered.

(2) Only loads within the rated capacity of the truck shall be handled.

(3) The long or high (including multiple-tiered) loads which may affect capacity shall be adjusted.

(4) Trucks equipped with attachments shall be operated as partially loaded trucks when not handling a

load.

**29 CFR 1910.178(o)(4) (enhanced display)** **page 14 of 21**

**29 CFR 1910.178(o)(5)**

(5) A load engaging means shall be placed under the load as far as possible; the mast shall be carefully

tilted backward to stabilize the load.

(6) Extreme care shall be used when tilting the load forward or backward, particularly when high tiering.

Tilting forward with load engaging means elevated shall be prohibited except to pick up a load. An
elevated load shall not be tilted forward except when the load is in a deposit position over a rack or
stack. When stacking or tiering, only enough backward tilt to stabilize the load shall be used.

(p) _Operation of the truck._

(1) If at any time a powered industrial truck is found to be in need of repair, defective, or in any way

unsafe, the truck shall be taken out of service until it has been restored to safe operating condition.

(2) Fuel tanks shall not be filled while the engine is running. Spillage shall be avoided.

(3) Spillage of oil or fuel shall be carefully washed away or completely evaporated and the fuel tank cap

replaced before restarting engine.

(4) No truck shall be operated with a leak in the fuel system until the leak has been corrected.

(5) Open flames shall not be used for checking electrolyte level in storage batteries or gasoline level in

fuel tanks.

(q) _Maintenance of industrial trucks._

(1) Any power-operated industrial truck not in safe operating condition shall be removed from service.

All repairs shall be made by authorized personnel.

(2) No repairs shall be made in Class I, II, and III locations.

(3) Those repairs to the fuel and ignition systems of industrial trucks which involve fire hazards shall be

conducted only in locations designated for such repairs.

(4) Trucks in need of repairs to the electrical system shall have the battery disconnected prior to such

repairs.

(5) All parts of any such industrial truck requiring replacement shall be replaced only by parts equivalent

as to safety with those used in the original design.

(6) Industrial trucks shall not be altered so that the relative positions of the various parts are different

from what they were when originally received from the manufacturer, nor shall they be altered either
by the addition of extra parts not provided by the manufacturer or by the elimination of any parts,
except as provided in paragraph (q)(12) of this section. Additional counterweighting of fork trucks
shall not be done unless approved by the truck manufacturer.

(7) Industrial trucks shall be examined before being placed in service, and shall not be placed in service

if the examination shows any condition adversely affecting the safety of the vehicle. Such
examination shall be

 be

repairs.

examination shall be made at least daily.

Where industrial trucks are used on a round-the-clock basis, they shall be examined after each shift.
Defects when found shall be immediately reported and corrected.

(8) Water mufflers shall be filled daily or as frequently as is necessary to prevent depletion of the supply

of water below 75 percent of the filled capacity. Vehicles with mufflers having screens or other parts
that may become clogged shall not be operated while such screens or parts are clogged. Any vehicle

**29 CFR 1910.178(q)(8) (enhanced display)** **page 15 of 21**

**29 CFR 1910.178(q)(9)**

that emits hazardous sparks or flames from the exhaust system shall immediately be removed from
service, and not returned to service until the cause for the emission of such sparks and flames has
been eliminated.

(9) When the temperature of any part of any truck is found to be in excess of its normal operating

temperature, thus creating a hazardous condition, the vehicle shall be removed from service and not
returned to service until the cause for such overheating has been eliminated.

(10) Industrial trucks shall be kept in a clean condition, free of lint, excess oil, and grease.

Noncombustible agents should be used for cleaning trucks. Low flash point (below 100 °F.) solvents
shall not be used. High flash point (at or above 100 °F.) solvents may be used. Precautions regarding
toxicity, ventilation, and fire hazard shall be consonant with the agent or solvent used.

(11) [Reserved]

(12) Industrial trucks originally approved for the use of gasoline for fuel may be converted to liquefied

petroleum gas fuel provided the complete conversion results in a truck which embodies the features
specified for LP or LPS designated trucks. Such conversion equipment shall be approved. The
description of the component parts of this conversion system and the recommended method of
installation on specific trucks are contained in the “Listed by Report.”

# Appendix A to § 1910.178—Stability of Powered Industrial Trucks (Non- mandatory Appendix to Paragraph (l) of This Section)

_A-1. Definitions._ The following definitions help to explain the principle of stability:

_Center of gravity_ is the point on an object at which all of the object's weight is concentrated. For symmetrical
loads, the center of gravity is at the middle of the load.

_Counterweight_ is the weight that is built into the truck's basic structure and is used to offset the load's weight
and to maximize the vehicle's resistance to tipping over.

_Fulcrum_ is the truck's axis of rotation when it tips over.

_Grade_ is the slope of a surface, which is usually measured as the number of feet of rise or fall over a hundred
foot horizontal distance (the slope is expressed as a percent).

_Lateral stability_ is a truck's resistance to overturning sideways.

_Line of action_ is an imaginary vertical line through an object's center of gravity.

_Load center_ is the horizontal distance from the load's edge (or the fork's or other attachment's vertical face) to
the line of action through the load's center of gravity.

_Longitudinal stability_ is the truck's resistance to overturning forward or rearward.

_Moment_ is the product of the object's weight times the distance from a fixed point (usually the fulcrum). In the
case of a powered industrial truck, the distance is measured from the point at which the truck will tip over to
the object's line of action. The distance is always measured perpendicular to the line of action.

**29 CFR 1910.178(q)(12) (enhanced display)** **page 16 of 21**

**29 CFR 1910.178(q)(12)**

_Track_ is the distance between the wheels on the same axle of the truck.

_Wheelbase_ is the distance between the centerline of the vehicle's front and rear wheels.

A-2. _General._

A-2.1. Determining the stability of a powered industrial truck is simple once a few basic principles are
understood. There are many factors that contribute to a vehicle's stability: the vehicle's wheelbase, track, and
height; the load's weight distribution; and the vehicle's counterweight location (if the vehicle is so equipped).

A-2.2. The “stability triangle,” used in most stability discussions, demonstrates stability simply.

A-3. _Basic Principles._

A-3.1. Whether an object is stable depends on the object's moment at one end of a system being greater than,
equal to, or smaller than the object's moment at the system's other end. This principle can be seen in the way a
see-saw or teeter-totter works: that is, if the product of the load and distance from the fulcrum (moment) is
equal to the moment at the device's other end, the device is balanced and it will not move. However, if there is a
greater moment at one end of the device, the device will try to move downward at the end with the greater

moment.

A-3.2. The longitudinal stability of a counterbalanced powered industrial truck depends on the vehicle's
moment and the load's moment. In other words, if the mathematic product of the load moment (the distance
from the front wheels, the approximate point at which the vehicle would tip forward) to the load's center of
gravity times the load's weight is less than the vehicle's moment, the system is balanced and will not tip
forward. However, if the load's moment is greater than the vehicle's moment, the greater load-moment will
force the truck to tip forward.

A-4. _The Stability Triangle._

A-4.1. Almost all counterbalanced powered industrial trucks have a three-point suspension system, that is, the
vehicle is supported at three points. This is true even if the vehicle has four wheels. The truck's steer axle is
attached to the truck by a pivot pin in the axle's center. When the points are connected with imaginary lines, this
three-point support forms a triangle called the stability triangle. Figure 1 depicts the stability triangle.

**29 CFR 1910.178(q)(12) (enhanced display)** **page 17 of 21**

A-4.2. When the vehicle's line of action, or load center, falls within the stability triangle, the vehicle is stable and
will not tip over. However, when the vehicle's line of action or the vehicle/load combination falls outside the
stability triangle, the vehicle is unstable and may tip over. (See Figure 2.)

**29 CFR 1910.178(q)(12) (enhanced display)** **page 18 of 21**

A-5. _Longitudinal Stability._

A-5.1. The axis of rotation when a truck tips forward is the front wheels' points of contact with the pavement.
When a powered industrial truck tips forward, the truck will rotate about this line. When a truck is stable, the
vehicle-moment must exceed the load-moment. As long as the vehicle-moment is equal to or exceeds the loadmoment, the vehicle will not tip over. On the other hand, if the load moment slightly exceeds the vehicle

**29 CFR 1910.178(q)(12) (enhanced display)** **page 19 of 21**

moment, the truck will begin to tip forward, thereby causing the rear to lose contact with the floor or ground
and resulting in loss of steering control. If the load-moment greatly exceeds

. The axis of rotation when a truck tips forward is the front wheels' points of contact with the pavement.

and resulting in loss of steering control. If the load-moment greatly exceeds the vehicle moment, the truck will
tip forward.

A-5.2. To determine the maximum safe load-moment, the truck manufacturer normally rates the truck at a
maximum load at a given distance from the front face of the forks. The specified distance from the front face
of the forks to the line of action of the load is commonly called the load center. Because larger trucks normally
handle loads that are physically larger, these vehicles have greater load centers. Trucks with a capacity of
30,000 pounds or less are normally rated at a given load weight at a 24-inch load center. Trucks with a capacity
greater than 30,000 pounds are normally rated at a given load weight at a 36- or 48-inch load center. To safely
operate the vehicle, the operator should always check the data plate to determine the maximum allowable
weight at the rated load center.

A-5.3. Although the true load-moment distance is measured from the front wheels, this distance is greater than
the distance from the front face of the forks. Calculating the maximum allowable load-moment using the loadcenter distance always provides a lower load-moment than the truck was designed to handle. When handling
unusual loads, such as those that are larger than 48 inches long (the center of gravity is greater than 24 inches)
or that have an offset center of gravity, etc., a maximum allowable load-moment should be calculated and used
to determine whether a load can be safely handled. For example, if an operator is operating a 3000 pound
capacity truck (with a 24-inch load center), the maximum allowable load-moment is 72,000 inch-pounds (3,000
times 24). If a load is 60 inches long (30-inch load center), then the maximum that this load can weigh is 2,400
pounds (72,000 divided by 30).

A-6. _Lateral Stability._

A-6.1. The vehicle's lateral stability is determined by the line of action's position (a vertical line that passes
through the combined vehicle's and load's center of gravity) relative to the stability triangle. When the vehicle is
not loaded, the truck's center of gravity location is the only factor to be considered in determining the truck's
stability. As long as the line of action of the combined vehicle's and load's center of gravity falls within the
stability triangle, the truck is stable and will not tip over. However, if the line of action falls outside the stability
triangle, the truck is not stable and may tip over. Refer to Figure 2.

A-6.2. Factors that affect the vehicle's lateral stability include the load's placement on the truck, the height of
the load above the surface on which the vehicle is operating, and the vehicle's degree of lean.

A-7. _Dynamic Stability._

A-7.1. Up to this point, the stability of a powered industrial truck has been discussed without considering the
dynamic forces that result when the vehicle and load are put into motion. The weight's transfer and the
resultant shift in the center of gravity due to the dynamic forces created when the machine is moving, braking,
cornering, lifting, tilting, and lowering loads, etc., are important stability considerations.

A-7.2. When determining whether a load can be safely handled, the operator should exercise extra caution
when handling loads that cause the vehicle to approach its maximum design characteristics. For example, if an
operator must handle a maximum load, the load should be carried at the lowest position possible, the truck
should be accelerated slowly and evenly, and the forks should be tilted forward cautiously. However, no precise
rules can be formulated to cover all of these eventualities.

**29 CFR 1910.178(q)(12) (enhanced display)** **page 20 of 21**

_[[39 FR 23502, June 27, 1974, as amended at 40 FR 23073, May 28, 1975; 43 FR 49749, Oct. 24, 1978; 49 FR 5322, Feb. 10, 1984;](https://www.federalregister.gov/citation/39-FR-23502)_
_[53 FR 12122, Apr. 12, 1988; 55 FR 32015, Aug. 6, 1990; 61 FR 9239, Mar. 7, 1996; 63 FR 66270, Dec. 1, 1998; 68 FR 32638, June 2,](https://www.federalregister.gov/citation/53-FR-12122)_
_[2003; 71 FR 16672, Apr. 3, 2006; 81 FR 83005, Nov. 18, 2016]](https://www.federalregister.gov/citation/71-FR-16672)_

**29 CFR 1910.178(q)(12) (enhanced display)** **page 21 of 21**

**29 CFR 1910.211 (up to date as of 7/23/2025)**
**29 CFR 1910.211 (July 23, 2025)**
**Definitions.**

**Subpart O —Machinery and Machine Guarding**

[1-90 (55 FR 9033), 5-2002 (67 FR 65008), or 1-2012 (77 FR 3912), as applicable; 20 CFR part 1911. Sections 1910.217 and](https://www.federalregister.gov/citation/55-FR-9033)
1910.219 also is ~~s~~ [ued under 5 U.S.C. 55](https://www.govinfo.gov/link/uscode/5/553) ~~3~~ .

**§ 1910.211 Definitions.**

(a) [As used in §§ 1910.213 and 1910.214 unless the context clearly requires otherwise, the following](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.213/)

woodworking machinery terms shall have the meaning prescribed in this paragraph.

(1) _Point of operations_ means that point at which cutting, shaping, boring, or forming is accomplished

upon the stock.

(2) _Push stick_ means a narrow strip of wood or other soft material with a notch cut into one end and

which is used to push short pieces of material through saws.

(3) _Block_ means a short block of wood, provided with a handle similar to that of a plane and a shoulder

at the rear end, which is used for pushing short stock over revolving cutters.

(b) [As used in § 1910.215 unless the context clearly requires otherwise, the following abrasive wheel](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.215/)

machinery terms shall have the meanings prescribed in this paragraph.

(1) _Type 1 straight wheels_ means wheels having diameter, thickness, and hole size dimensions, and they

should be used only on the periphery. Type 1 wheels shall be mounted between flanges.

L IMITATION : Hole dimension (H) should not be greater than two-thirds of wheel diameter dimension (D) for
precision, cylindrical, centerless, or surface grinding applications. Maximum hole size for all other
applications should not exceed one-half wheel diameter.

F IGURE N O . 0-1—T YPE 1 S TRAIGHT W HEELS

T YPE 1—S TRAIGHT W HEEL

**29 CFR 1910.211(b)(1) (enhanced display)** **page 1 of 11**

**29 CFR 1910.211(b)(2)**

# Peripheral grinding wheel having a diameter, thickness and hole.

(2) _Type 2 cylinder wheels_ means wheels having diameter, wheel thickness, and rim thickness

dimensions. Grinding is performed on the rim face only, dimension W. Cylinder wheels may be plain,
plate mounted, inserted nut, or of the projecting stud type.

L IMITATION : Rim height, T dimension, is generally equal to or greater than rim thickness, W dimension.

F IGURE N O . 0-2—T YPE 2 C YLINDER W HEELS

T YPE 2—C YLINDER W HEEL

_Side grinding wheel having a diameter, thickness and wall—wheel is mounted on the diameter._

(3) _Type 6 straight cup wheels_ means wheels having diameter, thickness, hole size, rim thickness, and

back thickness dimensions. Grinding is always performed on rim face, W dimension.

L IMITATION : Minimum back thickness, E dimension, should not be less than one-fourth T dimension. In
addition, when unthreaded hole wheels are specified, the inside flat, K dimension, must be large enough to
accommodate a suitable flange.

F IGURE N O . 0-3—T YPE 6 S TRAIGHT C UP W HEELS

              T YPE 6—S TRAIGHT CUP W HEEL

**29 CFR 1910.211(b)(3) (enhanced display)** **page 2 of 11**

**29 CFR 1910.211(b)(4)**

_Side grinding wheel having a diameter, thickness and hole with one side straight or flat and the opposite side_
_recessed. This type, however, differs from Type 5 in that the grinding is performed on the wall of the abrasive_
_created by the difference between the diameter of the recess and the outside diameter of the wheel. Therefore, the_
_wall dimension “W” takes precedence over the diameter of the recess as an essential intermediate dimension to_
_describe this shape type._

(4) _Type 11 flaring cup wheels_ mean wheels having double diameter dimensions D and J, and in addition

have thickness, hole size, rim and back thickness dimensions. Grinding is always performed on rim
face, W dimension. Type 11 wheels are subject to all limitations of use and mounting listed for type
6 straight sided cup wheels definition.

addition when unthreaded hole wheels are specified the inside flat, K dimension, shall be large enough to

F IGURE N O . 0-4—T YPE 11 F LARING C UP W HEELS

              T YPE 11—F LARING CUP W HEEL

_Side grinding wheel having a wall flared or tapered outward from the back. Wall thickness at the back is normally_
_greater than at the grinding face (W)._

(5) _Modified types 6 and 11 wheels (terrazzo)_ mean some type 6 and 11 cup wheels used in the terrazzo

trade having tapered K dimensions to match a special tapered flange furnished by the machine
builder.

L IMITATION : These wheels shall be mounted only with a special tapered flange.

F IGURE N O . 0-5

**29 CFR 1910.211(b)(5) (enhanced display)** **page 3 of 11**

**29 CFR 1910.211(b)(6)**

T YPICAL EXAMPLES OF MODIFIED TYPES 6 AND 11 WHEELS ( TERRAZZO ) SHOWING TAPERED K DIMENSIONS .

(6) _Types 27 and 28 depressed center wheels_ mean wheels having diameter, thickness, and hole size

dimensions. Both types are reinforced, organic bonded wheels having offset hubs which permit side
and peripheral grinding operations without interference with the mounting. Type 27 wheels are
manufact

C:\Users\megahefm\Dropbox\SIGHT Project\sight\app\data\29 CFR 1910.211 (up to date as of 7-23-2025).pdf

 a special tapered flange furnished by the machine
builder.

manufactured with flat grinding rims permitting notching and cutting operations. Type 28 wheels
have saucer shaped grinding rims.

(i) Limitations: Special supporting, back adapter and inside flange nuts are required for the proper

[mounting of these types of wheels subject to limitations of § 1910.215(c)(4) (i) and (ii).](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.215/?#p-1910.215(c)(4)(i))

(ii) Mounts which are affixed to the wheel by the manufacturer may not require an inside nut and

shall not be reused.

(7) _Type 27A depressed center, cutting-off wheels_ mean wheels having diameter, thickness, and hole size

dimensions. They are reinforced, organic bonded, offset hub type wheels, usually 16 inches diameter
and larger, specially designed for use on cutting-off machines where mounting nut or outer flange
interference cannot be tolerated.

L IMITATIONS [: See § 1910.215(c)(1).](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.215/?#p-1910.215(c)(1))

(8) _Surface feet per minute_ (s.f.p.m.) means the distance in feet any one abrasive grain on the peripheral

surface of a grinding wheel travels in 1 minute.

Surface Feet Per Minute = 3.1416 × diameter in inches × r.p.m. ÷ 12 or .262 × diameter in inches × r.p.m.

_Examples:_ (a) 24-inch diameter wheel, 1,000 revolutions per minute. Surface Feet per minute .262 × 24 ×

1,000 = 6,288 s.f.p.m.
(b) 12-inch diameter wheel, 1,000 revolutions per minute. Surface Feet per minute .262 × 12 × 1,000 =

3,144 s.f.p.m.

(9) _Flanges_ means collars, discs or plates between which wheels are mounted and are referred to as

[adaptor, sleeve, or back up type. See paragraph (c) of § 1910.215 for full description.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.215/?#p-1910.215(c))

(10) _Snagging_ means grinding which removes relatively large amounts of material without regard to close

tolerances or surface finish requirements.

(11) _Off-hand grinding_ means the grinding of any material or part which is held in the operator's hand.

(12) _Safety guard_ means an enclosure designed to restrain the pieces of the grinding wheel and furnish all

[possible protection in the event that the wheel is broken in operation. See paragraph (b) of §](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.215/?#p-1910.215(b))

[1910.215.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.215/?#p-1910.215(b))

**29 CFR 1910.211(b)(12) (enhanced display)** **page 4 of 11**

**29 CFR 1910.211(b)(13)**

(13) _Cutting off wheels_ means wheels having diameter thickness and hole size dimensions and are

subject to all limitations of mounting and use listed for type 1 wheels, the definition in subparagraph
[(1) of this paragraph and paragraph (d) of § 1910.215. They may be steel centered, diamond](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.215/?#p-1910.215(d))
abrasive or organic bonded abrasive of the plain or reinforced type.

(i) Limitation: Cutting off wheels are recommended only for use on specially designed and fully

guarded machines and are subject to the following maximum thickness and hole size

limitations.

(ii) Maximum hole size for cutting-off wheels should not be larger than [1] ⁄4 -wheel diameter.

(14) _Abrasive wheel_ means a cutting tool consisting of abrasive grains held together by organic or

inorganic bonds. Diamond and reinforced wheels are included.

(15) _Organic wheels_ means wheels which are bonded by means of an organic material such as resin,

rubber, shellac, or other similar bonding agent.

(16) _Inorganic wheels_ means wheels which are bonded by means of inorganic material such as clay,

glass, porcelain, sodium silicate, magnesium oxychloride, or metal. Wheels bonded with clay, glass,
porcelain or related ceramic materials are characterized as _vitrified bonded wheels._

(c) [As used in § 1910.216, unless the context clearly requires otherwise, the following mills and calenders in](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.216/)

the rubber and plastic industries terms shall have the meanings prescribed in this paragraph.

(1) _Bite_ means the nip point between any two inrunning rolls.

(2) _Calender_ means a machine equipped with two or more metal rolls revolving in opposite directions

and used for continuously sheeting or plying up rubber and plastics compounds and for frictioning
or coating materials with rubber and plastics compounds.

(3) _Mill_ means a machine consisting of two adjacent metal rolls, set horizontally, which revolve in

opposite directions (i.e., toward each other as viewed from above) used for the mechanical working
of rubber and plastics compounds.

(d) [As used in § 1910.217, unless the context clearly requires otherwise, the following power press terms](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/)

shall have the meaning prescribed in this paragraph.

(1) _Antirepeat_ means the part of the clutch/brake control system designed to limit the press to a single

stroke if the tripping means is held operated. Antirepeat requires release of all tripping mechanisms
before another stroke can be initiated. _Antirepeat_ is also called single stroke reset or reset circuit.

(2) _Brake_ means the mechanism used on a mechanical power press to stop and/or hold the crankshaft,

either directly or through a gear train, when the clutch is disengaged.

**29 CFR 1910.211(d)(2) (enhanced display)** **page 5 of 11**

**29 CFR 1910.211(d)(3)**

(3) _Bolster plate_ means the plate attached to the top of the bed of the press having drilled holes or T
slots for attaching the lower die or die shoe.

(4) _Clutch_ means the coupling mechanism used on a mechanical power press to couple the flywheel to

the crankshaft, either directly or through a gear train.

(5) _Full revolution clutch_ means a type of clutch that, when tripped, cannot be disengaged until the

crankshaft has completed a full revolution and the press slide a full stroke.

(6) _Part revolution clutch_ means a type of clutch that can be disengaged at any point before the

(7) _Direct drive_ means the type of driving arrangement wherein no clutch is used; coupling and

decoupling of the driving torque is accomplished by energization and deenergization of a motor.
Even though not employing a clutch, direct drives match the operational characteristics of “part
revolution clutches” because the driving power may be disengaged during the stroke of the press.

(8) _Concurrent_ means acting in conjunction, and is used to describe a situation wherein two or more

controls exist in an operated condition at the same time.

(9) _Continuous_ means uninterrupted multiple strokes of the slide without intervening stops (or other

clutch control action) at the end of individual strokes.

(10) _Counterbalance_ means the mechanism that

.

(10) _Counterbalance_ means the mechanism that is used to balance or support the weight of the

connecting rods, slide, and slide attachments.

(11) _Device_ means a press control or attachment that:

(i) Restrains the operator from inadvertently reaching into the point of operation, or

(ii) Prevents normal press operation if the operator's hands are inadvertently within the point of

operation, or

(iii) Automatically withdraws the operator's hands if the operator's hands are inadvertently within

the point of operation as the dies close, or

(iv) Prevents the initiation of a stroke, or stops of stroke in progress, when there is an intrusion

through the sensing field by any part of the operator's body or by any other object.

(12) _Presence sensing device_ means a device designed, constructed and arranged to create a sensing

field or area that signals the clutch/brake control to deactivate the clutch and activate the brake of
the press when any part of the operator's body or a hand tool is within such field or area.

(13) _Gate or movable barrier device_ means a movable barrier arranged to enclose the point of operation

before the press stroke can be started.

(14) _Holdout or restraint device_ means a mechanism, including attachments for operator's hands, that

when anchored and adjusted prevent the operator's hands from entering the point of operation.

(15) _Pull-out device_ means a mechanism attached to the operator's hands and connected to the upper die

or slide of the press, that is designed, when properly adjusted, to withdraw the operator's hands as
the dies close, if the operator's hands are inadvertently within the point of operation.

(16) _Sweep device_ means a single or double arm (rod) attached to the upper die or slide of the press and

designed to move the operator's hands to a safe position as the dies close, if the operator's hands
are inadvertently within the point of operation.

**29 CFR 1910.211(d)(16) (enhanced display)** **page 6 of 11**

**29 CFR 1910.211(d)(17)**

(17) _Two hand control device_ means a two hand trip that further requires concurrent pressure from both

hands of the operator during a substantial part of the die-closing portion of the stroke of the press.

(18) _Die_ means the tooling used in a press for cutting or forming material. An upper and a lower die make

a complete set.

(19) _Die builder_ means any person who builds dies for power presses.

(20) _Die set_ means a tool holder held in alignment by guide posts and bushings and consisting of a lower

shoe, an upper shoe or punch holder, and guide posts and bushings.

(21) _Die setter_ means an individual who places or removes dies in or from mechanical power presses,

and who, as a part of his duties, makes the necessary adjustments to cause the tooling to function
properly and safely.

(22) _Die setting_ means the process of placing or removing dies in or from a mechanical power press, and

the process of adjusting the dies, other tooling and safeguarding means to cause them to function

(23) _Die shoe_ means a plate or block upon which a die holder is mounted. A die shoe functions primarily

as a base for the complete die assembly, and, when used, is bolted or clamped to the bolster plate or
the face of slide.

(24) _Ejector_ means a mechanism for removing work or material from between the dies.

(25) _Face of slide_ means the bottom surface of the slide to which the punch or upper die is generally

attached.

(26) _Feeding_ means the process of placing or removing material within or from the point of operation.

(27) _Automatic feeding_ means feeding wherein the material or part being processed is placed within or

removed from the point of operation by a method or means not requiring action by an operator on
each stroke of the press.

(28) _Semiautomatic feeding_ means feeding wherein the material or part being processed is placed within

or removed from the point of operation by an auxiliary means controlled by operator on each stroke
of the press.

(29) _Manual feeding_ means feeding wherein the material or part being processed is handled by the

operator on each stroke of the press.

(30) _Foot control_ means the foot operated control mechanism designed to be used with a clutch or

clutch/brake control system.

(31) _Foot pedal_ means the foot operated lever designed to operate the mechanical linkage that trips a full

revolution clutch.

(32) _Guard_ means a barrier that prevents entry of the operator's hands or fingers into the point of

(33) _Die enclosure guard_ means an enclosure attached to the die shoe or stripper, or both, in a fixed

position.

(34) _Fixed barrier guard_ means a die space barrier attached to the press frame.

**29 CFR 1910.211(d)(34) (enhanced display)** **page 7 of 11**

**29 CFR 1910.211(d)(35)**

(35) _Interlocked press barrier guard_ means a barrier attached to the press frame and interlocked so that

the press stroke cannot be started normally unless the guard itself, or its hinged or movable
sections, enclose the point of operation.

(36) _Adjustable barrier guard_ means a barrier requiring adjustment for each job or die setup.

(37) _Guide post_ means the pin attached to the upper or lower die shoe operating within the bushing on the

opposing die shoe, to maintain the alignment of the upper and lower dies.

(38) _Hand feeding tool_ means any hand held tool designed for placing or removing material or parts to be

processed within or from the point of operation.

(39) _Inch_ means an intermittent motion imparted to the slide (on machines using part revolution

clutches) by momentary operation of the _Inch_ operating means. Operation of the _Inch_ operating
means engages the driving clutch so that a small portion of one stroke or indefinite stroking can
occur, depending upon the length of time the _Inch_ operating means is held operated. _Inch_ is a
function used by the die setter for setup of dies and tooling, but is not intended for use during
production operations by the operator.

(40) _Jog_ means an intermittent motion imparted to the slide by momentary operation of the drive motor,

after the clutch is engaged with the flywheel at rest.

(41) _Knockout_ means a mechanism for releasing material from either die.

(42) _Liftout_ means the mechanism also known as knockout.

(43) _Operator's station_ means the complete complement of controls used by or available to an operator

on a given operation for stroking the press.

(44) _Pinch point_ means any point other than the point of operation at which it is possible for a part of the

body to be caught between the moving parts of a press or auxiliary equipment, or between moving
and stationary parts of a press or auxiliary equipment or between the material and moving part or
parts of the press or auxiliary equipment.

(45) _Point of operation_ means the area of the press where material is actually positioned and work is

being performed during any process such as shearing, punching, forming, or assembling.

(46) _Press_ means a mechanically powered machine that shears, punches, forms or assembles metal or

other material by means of cutting, shaping, or combination dies attached to slides. A press consists
of a stationary bed or anvil, and a slide (or slides) having a controlled reciprocating motion toward
and away from the bed surface, the slide being guided in a definite path by the frame of the press.

(47) _Repeat_ means an unintended or unexpected successive stroke of the press resulting from a

malfunction.

(48) _Safety block_ means a prop that, when inserted between the upper and lower dies or between the

bolster plate and the face of the slide, prevents the slide from falling of its own deadweight.

(49) _Single stroke_ means one complete

 means the area of the press where material is actually positioned and work is

(49) _Single stroke_ means one complete stroke of the slide, usually initiated from a full open (or up)

position, followed by closing (or down), and then a return to the full open position.

(50) _Single stroke mechanism_ means an arrangement used on a full revolution clutch to limit the travel of

the slide to one complete stroke at each engagement of the clutch.

(51) _Slide_ means the main reciprocating press member. A slide is also called a ram, plunger, or platen.

**29 CFR 1910.211(d)(51) (enhanced display)** **page 8 of 11**

**29 CFR 1910.211(d)(52)**

(52) _Stop control_ means an operator control designed to immediately deactivate the clutch control and

activate the brake to stop slide motion.

(53) _Stripper_ means a mechanism or die part for removing the parts or material from the punch.

(54) _Stroking selector_ means the part of the clutch/brake control that determines the type of stroking

when the operating means is actuated. The stroking selector generally includes positions for “Off”
(Clutch Control), “Inch,” “Single Stroke,” and “Continuous” (when Continuous is furnished).

(55) _Trip or (tripping)_ means activation of the clutch to “run” the press.

(56) _Turnover bar_ means a bar used in die setting to manually turn the crankshaft of the press.

(57) _Two-hand trip_ means a clutch actuating means requiring the concurrent use of both hands of the

operator to trip the press.

(58) _Unitized tooling_ means a type of die in which the upper and lower members are incorporated into a

selfcontained unit so arranged as to hold the die members in alignment.

(59) _Control system_ means sensors, manual input and mode selection elements, interlocking and

decision-making circuitry, and output elements to the press operating mechanism.

(60) _Brake monitor_ means a sensor designed, constructed, and arranged to monitor the effectiveness of

the press braking system.

(61) _Presence sensing device initiation_ means an operating mode of indirect manual initiation of a single

stroke by a presence sensing device when it senses that work motions of the operator, related to
feeding and/or removing parts, are completed and all parts of the operator's body or hand tools are
safely clear of the point of operation.

(62) _Safety system_ means the integrated total system, including the pertinent elements of the press, the

controls, the safeguarding and any required supplemental safeguarding, and their interfaces with the
operator, and the environment, designed, constructed and arranged to operate together as a unit,
such that a single failure or single operating error will not cause injury to personnel due to point of
operation hazards.

(63) _Authorized person_ means one to whom the authority and responsibility to perform a specific

assignment has been given by the employer.

(64) _Certification_ or _certify_ means, in the case of design certification/validation, that the manufacturer

has reviewed and tested the design and manufacture, and in the case of installation certification/
validation and annual recertification/revalidation, that the employer has reviewed and tested the
[installation, and concludes in both cases that the requirements of § 1910.217 (a) through (h) and](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/?#p-1910.217(a))
appendix A have been met. The certifications are made to the validation organization.

(65) _Validation_ or _validate_ means for PSDI safety systems that an OSHA recognized third-party validation

organization:

(i) For design certification/validation has reviewed the manufacturer's certification that the PSDI

[safety system meets the requirements of § 1910.217 (a) through (h) and appendix A and the](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/?#p-1910.217(a))
underlying tests and analyses performed by the manufacturer, has performed additional tests
[and analyses which may be required by § 1910.217 (a) through (h) and appendix A, and](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/?#p-1910.217(a))
[concludes that the requirements of § 1910.217 (a) through (h) and appendix A have been met;](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/?#p-1910.217(a))
and

**29 CFR 1910.211(d)(65)(i) (enhanced display)** **page 9 of 11**

**29 CFR 1910.211(d)(65)(ii)**

(ii) For installation certification/validation and annual recertification/revalidation has reviewed the

[employer's certification that the PSDI safety system meets the requirements of § 1910.217 (a)](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/?#p-1910.217(a))
[through (h) and appendix A and the underlying tests performed by the employer, has performed](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/?#p-1910.217(h))
[additional tests and analyses which may be required by § 1910.217 (a) through (h) and](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/?#p-1910.217(a))
[appendix A, and concludes that the requirements of § 1910.217 (a) through (h) and appendix A](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/?#p-1910.217(a))
have been met.

(66) _Certification/validation_ and _certify/validate_ means the combined process of certification and

validation.

(e) [As used in § 1910.218, unless the context clearly requires otherwise, the following forging and hot metal](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.218/)

terms shall have the meaning prescribed in this paragraph.

(1) _Forging_ means the product of work on metal formed to a desired shape by impact or pressure in

hammers, forging machines (upsetters), presses, rolls, and related forming equipment. Forging
hammers, counterblow equipment and high-energy-rate forging machines impart impact to the
workpiece, while most other types of forging equipment impart squeeze pressure in shaping the
stock. Some metals can be forged at room temperature, but the majority of metals are made more
plastic for forging by heating.

(2) _Open framehammers (or blacksmith hammers)_ mean hammers used primarily for the shaping of

forgings by means of impact with flat dies. Open frame hammers generally are so constructed that
the anvil assembly is separate from the operating mechanism and machine supports; it rests on its
own independent foundation. Certain exceptions are forging hammers made with frame mounted on
the anvil; e.g., the smaller, single-frame hammers are usually made with the anvil and frame in one
piece.

(3) _Steam hammers_ mean a type of drop hammer where the ram is raised for each stroke by a double
action steam cylinder and the energy delivered to the workpiece is supplied by the velocity and
weight of the ram and attached upper die driven downward by steam pressure. Energy delivered
during each stroke may be varied.

(4) _Gravity hammers_ mean a class of forging hammer wherein energy for forging is obtained by the

mass and velocity of a freely falling ram and the attached upper die. Examples: board hammers and
air-lift hammers.

(5) _Forging presses_ mean a class of forging equipment wherein the shaping of metal between dies is

 is separate from the operating mechanism and machine supports; it rests on its
piece.

performed by mechanical or hydraulic pressure, and usually is accomplished with a single
workstroke of the press for each die station.

(6) _Trimming presses_ mean a class of auxiliary forging equipment which removes flash or excess metal

from a forging. This trimming operation can also be done cold, as can coining, a product sizing

(7) _High-energy-rate forging machines_ mean a class of forging equipment wherein high ram velocities

resulting from the sudden release of a compressed gas against a free piston impart impact to the
workpiece.

(8) _Forging rolls_ mean a class of auxiliary forging equipment wherein stock is shaped between power

driven rolls bearing contoured dies. Usually used for preforming, roll forging is often employed to
reduce thickness and increase length of stock.

**29 CFR 1910.211(e)(8) (enhanced display)** **page 10 of 11**

**29 CFR 1910.211(e)(9)**

(9) _Ring rolls_ mean a class for forging equipment used for shaping weldless rings from pierced discs or

thick-walled, ring-shaped blanks between rolls which control wall thickness, ring diameter, height and

contour.

(10) _Bolt-headers_ mean the same as an upsetter or forging machine except that the diameter of stock fed

into the machine is much smaller, i.e., commonly three-fourths inch or less.

(11) Rivet making machines mean the same as upsetters and boltheaders when producing rivets with

stock diameter of 1-inch or more. Rivet making with less than 1-inch diameter is usually a cold
forging operation, and therefore not included in this subpart.

(12) Upsetters (or forging machines, or headers) type of forging equipment, related to the mechanical

press, in which the main forming energy is applied horizontally to the workpiece which is gripped and
held by prior action of the dies.

(f) [As used in § 1910.219, unless the context clearly requires otherwise, the following mechanical power-](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.219/)

transmission guarding terms shall have the meaning prescribed in this paragraph.

(1) _Belts_ include all power transmission belts, such as flat belts, round belts, V-belts, etc., unless

otherwise specified.

(2) _Belt shifter_ means a device for mechanically shifting belts from tight to loose pulleys or vice versa, or

for shifting belts on cones of speed pulleys.

(3) _Belt pole_ (sometimes called a _belt shipper_ or _shipper pole,_ ) means a device used in shifting belts on

and off fixed pulleys on line or countershaft where there are no loose pulleys.

(4) _Exposed to contact_ means that the location of an object is such that a person is likely to come into

contact with it and be injured.

(5) _Flywheels_ include flywheels, balance wheels, and flywheel pulleys mounted and revolving on

crankshaft of engine or other shafting.

(6) _Maintenance runway_ means any permanent runway or platform used for oiling, maintenance, running

adjustment, or repair work, but not for passageway.

(7) _Nip-point belt and pulley guard_ means a device which encloses the pulley and is provided with

rounded or rolled edge slots through which the belt passes.

(8) _Point of operation_ means that point at which cutting, shaping, or forming is accomplished upon the

stock and shall include such other points as may offer a hazard to the operator in inserting or
manipulating the stock in the operation of the machine.

(9) _Prime movers_ include steam, gas, oil, and air engines, motors, steam and hydraulic turbines, and

other equipment used as a source of power.

(10) _Sheaves_ mean grooved pulleys, and shall be so classified unless used as flywheels.

_[[39 FR 23502, June 27, 1974, as amended at 39 FR 41846, Dec. 3, 1974; 53 FR 8353, Mar. 14, 1988]](https://www.federalregister.gov/citation/39-FR-23502)_

**29 CFR 1910.211(f)(10) (enhanced display)** **page 11 of 11**

**29 CFR 1910.212 (up to date as of 7/23/2025)**
**29 CFR 1910.212 (July 23, 2025)**
**General requirements for all machines.**

**§ 1910.212 General requirements for all machines.**

(a) _Machine guarding_ —

(1) _Types of guarding._ One or more methods of machine guarding shall be provided to protect the

operator and other employees in the machine area from hazards such as those created by point of
operation, ingoing nip points, rotating parts, flying chips and sparks. Examples of guarding methods
are—barrier guards, two-hand tripping devices, electronic safety devices, etc.

(2) _General requirements for machine guards._ Guards shall be affixed to the machine where possible and

secured elsewhere if for any reason attachment to the machine is not possible. The guard shall be
such that it does not offer an accident hazard in itself.

(3) _Point of operation guarding._

(i) Point of operation is the area on a machine where work is actually performed upon the material

being processed.

(ii) The point of operation of machines whose operation exposes an employee to injury, shall be

guarded. The guarding device shall be in conformity with any appropriate standards therefor, or,
in the absence of applicable specific standards, shall be so designed and constructed as to
prevent the operator from having any part of his body in the danger zone during the operating
cycle.

(iii) Special handtools for placing and removing material shall be such as to permit easy handling of

material without the operator placing a hand in the danger zone. Such tools shall not be in lieu
of other guarding required by this section, but can only be used to supplement protection
provided.

(iv) The following are some of the machines which usually require point of operation guarding:

( _a_ ) Guillotine cutters.

( _b_ ) Shears.

( _c_ ) Alligator shears.

( _d_ ) Power presses.

**29 CFR 1910.212(a)(3)(iv)(d) (enhanced display)** **page 1 of 2**

**29 CFR 1910.212(a)(3)(iv)(e)**

( _e_ ) Milling machines.

( _f_ ) Power saws.

( _g_ ) Jointers.

( _h_ ) Portable power tools.

( _i_ ) Forming rolls and calenders.

(4) _Barrels, containers, and drums._ Revolving drums, barrels, and containers shall be guarded by an

enclosure which is interlocked with the drive mechanism, so that the barrel, drum, or container
cannot revolve unless the guard enclosure is in place.

(5) _Exposure of blades._ When the periphery of the blades of a fan is less than seven (7) feet above the

floor or working level, the blades shall be guarded. The guard shall have openings no larger than onehalf ( [1] ⁄2 ) inch.

(b) _Anchoring fixed machinery._ Machines designed for a fixed location shall be securely anchored to prevent

walking or moving.

**29 CFR 1910.212(b) (enhanced display)** **page 2 of 2**

C:\Users\megahefm\Dropbox\SIGHT Project\sight\app\data\29 CFR 1910.212 (up to date as of 7-23-2025).pdf

**29 CFR 1910.213 (up to date as of 7/23/2025)**
**29 CFR 1910.213 (July 23, 2025)**
**Woodworking machinery requirements.**

**§ 1910.213 Woodworking machinery requirements.**

(a) _Machine construction general._

(1) Each machine shall be so constructed as to be free from sensible vibration when the largest size tool

is mounted and run idle at full speed.

(2) Arbors and mandrels shall be constructed so as to have firm and secure bearing and be free from

play.

(4) Any automatic cutoff saw that strokes continuously without the operator being able to control each

stroke shall not be used.

(5) Saw frames or tables shall be constructed with lugs cast on the frame or with an equivalent means

to limit the size of the saw blade that can be mounted, so as to avoid overspeed caused by mounting
a saw larger than intended.

(6) Circular saw fences shall be so constructed that they can be firmly secured to the table or table

assembly without changing their alignment with the saw. For saws with tilting tables or tilting arbors
the fence shall be so constructed that it will remain in a line parallel with the saw, regardless of the
angle of the saw with the table.

(7) Circular saw gages shall be so constructed as to slide in grooves or tracks that are accurately

machined, to insure exact alignment with the saw for all positions of the guide.

(8) Hinged saw tables shall be so constructed that the table can be firmly secured in any position and in

true alignment with the saw.

(9) All belts, pulleys, gears, shafts, and moving parts shall be guarded in accordance with the specific

[requirements of § 1910.219.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.219/)

(10) It is recommended that each power-driven woodworking machine be provided with a disconnect

switch that can be locked in the off position.

**29 CFR 1910.213(a)(10) (enhanced display)** **page 1 of 9**

**29 CFR 1910.213(a)(11)**

(11) The frames and all exposed, noncurrent-carrying metal parts of portable electric woodworking

machinery operated at more than 90 volts to ground shall be grounded and other portable motors
driving electric tools which are held in the hand while being operated shall be grounded if they
operate at more than 90 volts to ground. The ground shall be provided through use of a separate
ground wire and polarized plug and receptacle.

(12) For all circular saws where conditions are such that there is a possibility of contact with the portion

of the saw either beneath or behind the table, that portion of the saw shall be covered with an
exhaust hood, or, if no exhaust system is required, with a guard that shall be so arranged as to
prevent accidental contact with the saw.

(13) Revolving double arbor saws shall be fully guarded in accordance with all the requirements for

circular crosscut saws or with all the requirements for circular ripsaws, according to the kind of

saws mounted on the arbors.

(14) No saw, cutter head, or tool collar shall be placed or mounted on a machine arbor unless the tool has

been accurately machined to size and shape to fit the arbor.

(15) Combs (featherboards) or suitable jigs shall be provided at the workplace for use when a standard

guard cannot be used, as in dadoing, grooving, jointing, moulding, and rabbeting.

(b) _Machine controls and equipment._

(1) A mechanical or electrical power control shall be provided on each machine to make it possible for

the operator to cut off the power from each machine without leaving his position at the point of

(2) On machines driven by belts and shafting, a locking-type belt shifter or an equivalent positive device

shall be used.

(3) On applications where injury to the operator might result if motors were to restart after power

failures, provision shall be made to prevent machines from automatically restarting upon restoration
of power.

(4) Power controls and operating controls should be located within easy reach of the operator while he

is at his regular work location, making it unnecessary for him to reach over the cutter to make
adjustments. This does not apply to constant pressure controls used only for setup purposes.

(5) On each machine operated by electric motors, positive means shall be provided for rendering such

controls or devices inoperative while repairs or adjustments are being made to the machines they

control.

(6) Each operating treadle shall be protected against unexpected or accidental tripping.

(7) Feeder attachments shall have the feed rolls or other moving parts so covered or guarded as to

protect the operator from hazardous points.

(c) _Hand-fed ripsaws._

(1) Each circular hand-fed ripsaw shall be guarded by a hood which shall completely enclose that

portion of the saw above the table and that portion of the saw above the material being cut. The
hood and mounting shall be arranged so that the hood will automatically adjust itself to the
thickness of and remain in contact with the material being cut but it shall not offer any considerable
resistance to insertion of material to saw or to passage of the material being sawed. The hood shall

**29 CFR 1910.213(c)(1) (enhanced display)** **page 2 of 9**

**29 CFR 1910.213(c)(2)**

be made of adequate strength to resist blows and strains incidental to reasonable operation,
adjusting, and handling, and shall be so designed as to protect the operator from flying splinters and
broken saw teeth. It shall be made of material that is soft enough so that it will be unlikely to cause
tooth breakage. The hood shall be so mounted as to insure that its operation will be positive, reliable,
and in true alignment with the saw; and the mounting shall be adequate in strength to resist any
reasonable side thrust or other force tending to throw it out of line.

(2) Each hand-fed circular ripsaw shall be furnished with a spread

C:\Users\megahefm\Dropbox\SIGHT Project\sight\app\data\29 CFR 1910.213 (up to date as of 7-23-2025).pdf

1910.213(c)(1) (enhanced display)** **page 2 of 9**

(2) Each hand-fed circular ripsaw shall be furnished with a spreader to prevent material from squeezing

the saw or being thrown back on the operator. The spreader shall be made of hard tempered steel, or
its equivalent, and shall be thinner than the saw kerf. It shall be of sufficient width to provide
adequate stiffness or rigidity to resist any reasonable side thrust or blow tending to bend or throw it
out of position. The spreader shall be attached so that it will remain in true alignment with the saw
even when either the saw or table is tilted. The provision of a spreader in connection with grooving,
dadoing, or rabbeting is not required. On the completion of such operations, the spreader shall be
immediately replaced.

(3) Each hand-fed circular ripsaw shall be provided with nonkickback fingers or dogs so located as to

oppose the thrust or tendency of the saw to pick up the material or to throw it back toward the
operator. They shall be designed to provide adequate holding power for all the thicknesses of
materials being cut.

(d) _Hand-fed crosscut table saws._

(1) Each circular crosscut table saw shall be guarded by a hood which shall meet all the requirements of

paragraph (c)(1) of this section for hoods for circular ripsaws.

(2) [Reserved]

(e) _Circular resaws._

(1) Each circular resaw shall be guarded by a hood or shield of metal above the saw. This hood or shield

shall be so designed as to guard against danger from flying splinters or broken saw teeth.

(2) Each circular resaw (other than self-feed saws with a roller or wheel at back of the saw) shall be

provided with a spreader fastened securely behind the saw. The spreader shall be slightly thinner
than the saw kerf and slightly thicker than the saw disk.

(f) _Self-feed circular saws._

(1) Feed rolls and saws shall be protected by a hood or guard to prevent the hands of the operator from

coming in contact with the in-running rolls at any point. The guard shall be constructed of heavy
material, preferably metal, and the bottom of the guard shall come down to within three-eighths inch
of the plane formed by the bottom or working surfaces of the feed rolls. This distance (three-eighths
inch) may be increased to three-fourths inch, provided the lead edge of the hood is extended to be
not less than 5 [1] ⁄2 inches in front of the nip point between the front roll and the work.

(2) Each self-feed circular ripsaw shall be provided with sectional non-kickback fingers for the full width

of the feed rolls. They shall be located in front of the saw and so arranged as to be in continual
contact with the wood being fed.

(g) _Swing cutoff saws._ The requirements of this paragraph are also applicable to sliding cutoff saws mounted

above the table.

**29 CFR 1910.213(g) (enhanced display)** **page 3 of 9**

**29 CFR 1910.213(g)(1)**

(1) Each swing cutoff saw shall be provided with a hood that will completely enclose the upper half of

the saw, the arbor end, and the point of operation at all positions of the saw. The hood shall be
constructed in such a manner and of such material that it will protect the operator from flying
splinters and broken saw teeth. Its hood shall be so designed that it will automatically cover the
lower portion of the blade, so that when the saw is returned to the back of the table the hood will rise
on top of the fence, and when the saw is moved forward the hood will drop on top of and remain in
contact with the table or material being cut.

(2) Each swing cutoff saw shall be provided with an effective device to return the saw automatically to

the back of the table when released at any point of its travel. Such a device shall not depend for its
proper functioning upon any rope, cord, or spring. If there is a counterweight, the bolts supporting
the bar and counterweight shall be provided with cotter pins; and the counterweight shall be
prevented from dropping by either a bolt passing through both the bar and counterweight, or a bolt
put through the extreme end of the bar, or, where the counterweight does not encircle the bar, a
safety chain attached to it.

(3) Limit chains or other equally effective devices shall be provided to prevent the saw from swinging

beyond the front or back edges of the table, or beyond a forward position where the gullets of the
lowest saw teeth will rise above the table top.

(4) Inverted swing cutoff saws shall be provided with a hood that will cover the part of the saw that

protrudes above the top of the table or above the material being cut. It shall automatically adjust
itself to the thickness of and remain in contact with the material being cut.

(h) _Radial saws._

(1) The upper hood shall completely enclose the upper portion of the blade down to a point that will

include the end of the saw arbor. The upper hood shall be constructed in such a manner and of such
material that it will protect the operator from flying splinters, broken saw teeth, etc., and will deflect
sawdust away from the operator. The sides of the lower exposed portion of the blade shall be
guarded to the full diameter of the blade by a device that will automatically adjust itself to the
thickness of the stock and remain in contact with stock being cut to give maximum protection
possible for the operation being performed.

(2) Each radial saw used for ripping shall be provided with nonkickback fingers or dogs located on both

sides of the saw so as to oppose the thrust or tendency of the saw to pick up the material or to
throw it back toward the operator. They shall be designed to provide adequate holding power for all
the thicknesses of material being cut.

(3) An adjustable stop shall be provided to prevent the forward travel of the blade beyond the position

necessary to complete the cut in repetitive operations.

(4) Installation shall be in such a manner that the front end of the unit will be slightly higher than the rear,

so as to cause the cutting head to return gently to the starting position when released by the

operator.

(5) Ripping and ploughing shall be against the direction in which the saw turns. The direction of the saw

rotation shall be conspicuously marked on the hood. In addition, a permanent label not less than 1 [1] ⁄2
inches by [3] ⁄4 inch shall be affixed to the rear of the guard at approximately the level of the arbor,
reading as follows: “Danger: Do Not Rip or Plough From This End”.

(i) _Bandsaws and band resaws._

**29 CFR 1910.213(i) (enhanced display)** **page 4 of 9**

**29 CFR 1910.213(i)(1)**

(1) All portions of the saw blade shall be enclosed or guarded, except for the working portion of the

blade between the bottom of the guide rolls and the table. Bandsaw wheels shall be fully encased.
The outside periphery of the enclosure shall be solid. The front and back of the band wheels shall be
either enclosed by solid material or by wire mesh or perforated metal. Such mesh or perforated
metal shall be not less than 0.037 inch (U.S. Gage No. 20), and the openings shall be not greater
than three-eighths inch. Solid material used for this purpose shall be of an equivalent strength and
firmness. The guard for the portion of the blade between the sliding guide and the upper-saw-wheel
guard shall protect the saw blade at the front and outer side. This portion of the guard shall be selfadjusting to raise and lower with the guide. The upper-wheel guard shall be made to conform to the
travel of the saw on the wheel.

(2) Each bandsaw machine shall be provided with a tension control device to indicate a proper tension

for the standard saws used on the machine, in order

.

for the standard saws used on the machine, in order to assist in the elimination of saw breakage due
to improper tension.

(3) Feed rolls of band resaws shall be protected with a suitable guard to prevent the hands of the

operator from coming in contact with the in-running rolls at any point. The guard shall be
constructed of heavy material, preferably metal, and the edge of the guard shall come to within
three-eighths inch of the plane formed by the inside face of the feed roll in contact with the stock
being cut.

(j) _Jointers._

(1) Each hand-fed planer and jointer with horizontal head shall be equipped with a cylindrical cutting

head, the knife projection of which shall not exceed one-eighth inch beyond the cylindrical body of

the head.

(2) The opening in the table shall be kept as small as possible. The clearance between the edge of the

rear table and the cutter head shall be not more than one-eighth inch. The table throat opening shall
be not more than 2 [1] ⁄2 inches when tables are set or aligned with each other for zero cut.

(3) Each hand-fed jointer with a horizontal cutting head shall have an automatic guard which will cover

all the section of the head on the working side of the fence or gage. The guard shall effectively keep
the operator's hand from coming in contact with the revolving knives. The guard shall automatically
adjust itself to cover the unused portion of the head and shall remain in contact with the material at

all times.

(4) Each hand-fed jointer with horizontal cutting head shall have a guard which will cover the section of

the head back of the gage or fence.

(5) Each wood jointer with vertical head shall have either an exhaust hood or other guard so arranged as

to enclose completely the revolving head, except for a slot of such width as may be necessary and
convenient for the application of the material to be jointed.

(k) _Tenoning machines._

(1) Feed chains and sprockets of all double end tenoning machines shall be completely enclosed,

except for that portion of chain used for conveying the stock.

(2) At the rear ends of frames over which feed conveyors run, sprockets and chains shall be guarded at

the sides by plates projecting beyond the periphery of sprockets and the ends of lugs.

**29 CFR 1910.213(k)(2) (enhanced display)** **page 5 of 9**

**29 CFR 1910.213(k)(3)**

(3) Each tenoning machine shall have all cutting heads, and saws if used, covered by metal guards.

These guards shall cover at least the unused part of the periphery of the cutting head. If such a
guard is constructed of sheet metal, the material used shall be not less than one-sixteenth inch in
thickness, and if cast iron is used, it shall be not less than three-sixteenths inch in thickness.

(4) Where an exhaust system is used, the guard shall form part or all of the exhaust hood and shall be

constructed of metal of a thickness not less than that specified in subparagraph (3) of this
paragraph.

(l) _Boring and mortising machines._

(1) Safety-bit chucks with no projecting set screws shall be used.

(2) Boring bits should be provided with a guard that will enclose all portions of the bit and chuck above

the material being worked.

(3) The top of the cutting chain and driving mechanism shall be enclosed.

(4) If there is a counterweight, one of the following or equivalent means shall be used to prevent its

dropping:

(i) It shall be bolted to the bar by means of a bolt passing through both bar and counterweight;

(ii) A bolt shall be put through the extreme end of the bar;

(iii) Where the counterweight does not encircle the bar, a safety chain shall be attached to it;

(iv) Other types of counterweights shall be suspended by chain or wire rope and shall travel in a

pipe or other suitable enclosure wherever they might fall and cause injury.

(5) Universal joints on spindles of boring machines shall be completely enclosed in such a way as to

prevent accidental contact by the operator.

(6) Each operating treadle shall be covered by an inverted U-shaped metal guard, fastened to the floor,

and of adequate size to prevent accidental tripping.

(m) _Wood shapers and similar equipment._

(1) The cutting heads of each wood shaper, hand-fed panel raiser, or other similar machine not

automatically fed, shall be enclosed with a cage or adjustable guard so designed as to keep the
operator's hand away from the cutting edge. The diameter of circular shaper guards shall be not less
than the greatest diameter of the cutter. In no case shall a warning device of leather or other material
attached to the spindle be acceptable.

(3) All double-spindle shapers shall be provided with a spindle starting and stopping device for each

spindle.

(n) _Planing, molding, sticking, and matching machines._

(1) Each planing, molding, sticking, and matching machine shall have all cutting heads, and saws if used,

covered by a metal guard. If such guard is constructed of sheet metal, the material used shall be not
less than [1] ⁄16 inch in thickness, and if cast iron is used, it shall be not less than three-sixteenths inch

in thickness.

**29 CFR 1910.213(n)(1) (enhanced display)** **page 6 of 9**

**29 CFR 1910.213(n)(2)**

(2) Where an exhaust system is used, the guards shall form part or all of the exhaust hood and shall be

constructed of metal of a thickness not less than that specified in paragraph (h)(1) of this section.

(3) Feed rolls shall be guarded by a hood or suitable guard to prevent the hands of the operator from

coming in contact with the in-running rolls at any point. The guard shall be fastened to the frame
carrying the rolls so as to remain in adjustment for any thickness of stock.

(4) Surfacers or planers used in thicknessing multiple pieces of material simultaneously shall be

provided with sectional infeed rolls having sufficient yield in the construction of the sections to
provide feeding contact pressure on the stock, over the permissible range of variation in stock
thickness specified or for which the machine is designed. In lieu of such yielding sectional rolls,
suitable section kickback finger devices shall be provided at the infeed end.

(o) _Profile and swing-head lathes and wood heel turning machine._

(1) Each profile and swing-head lathe shall have all cutting heads covered by a metal guard. If such a

thickness; and if cast iron is used, it shall not be less than three-sixteenths inch in thickness.

(2) Cutting heads on wood-turning lathes, whether rotating or not, shall be covered as completely as

possible by hoods or shields.

(3) Shoe last and spoke lathes, doweling machines, wood heel turning machines, and other automatic

wood-turning lathes of the rotating knife type shall be equipped with hoods enclosing the cutter
blades completely except at the contact points while the stock is being cut.

(4) Lathes used for turning long pieces of wood stock held only between the two centers shall be

equipped with long curved guards extending over the tops of the lathes in order to prevent the work
pieces from being thrown out of the machines if they should become loose.

(5) Where an exhaust system is used, the guard shall form part or all of the exhaust hood and shall be

constructed of metal of a thickness not less than that specified in subparagraph (1) of this

(p) _Sanding machines._

(1) Feed rolls of self-feed sanding machines shall be protected with a semicylindrical guard to prevent

the hands of the operator from coming in contact with the in-running rolls at any point. The guard
shall be constructed of heavy

shall be constructed of heavy material, preferably metal, and firmly secured to the frame carrying the
rolls so as to remain in adjustment for any thickness of stock. The bottom of the guard should come
down to within three-eighths inch of a plane formed by the bottom or contact face of the feed roll

where it touches the stock.

(2) Each drum sanding machine shall have an exhaust hood, or other guard if no exhaust system is

required, so arranged as to enclose the revolving drum, except for that portion of the drum above the
table, if a table is used, which may be necessary and convenient for the application of the material to
be finished.

(3) Each disk sanding machine shall have the exhaust hood, or other guard if no exhaust system is

required, so arranged as to enclose the revolving disk, except for that portion of the disk above the
table, if a table is used, which may be necessary for the application of the material to be finished.

**29 CFR 1910.213(p)(3) (enhanced display)** **page 7 of 9**

**29 CFR 1910.213(p)(4)**

(4) Belt sanding machines shall be provided with guards at each nip point where the sanding belt runs

on to a pulley. These guards shall effectively prevent the hands or fingers of the operator from
coming in contact with the nip points. The unused run of the sanding belt shall be guarded against

accidental contact.

(q) _Veneer cutters and wringers._

(1) Veneer slicer knives shall be guarded to prevent accidental contact with knife edge, at both front and

rear.

(2) Veneer clippers shall have automatic feed or shall be provided with a guard which will make it

impossible to place a finger or fingers under the knife while feeding or removing the stock.

(3) Sprockets on chain or slat-belt conveyors shall be enclosed.

(4) Where practicable, hand and footpower guillotine veneer cutters shall be provided with rods or plates

or other satisfactory means, so arranged on the feeding side that the hands cannot reach the cutting
edge of the knife while feeding or holding the stock in place.

(5) Power-driven guillotine veneer cutters, except continuous feed trimmers, shall be equipped with:

(i) Starting devices which require the simultaneous action of both hands to start the cutting

motion and of at least one hand on a control during the complete stroke of the knife; or

(ii) An automatic guard which will remove the hands of the operator from the danger zone at every

descent of the blade, used in conjunction with one-hand starting devices which require two
distinct movements of the device to start the cutting motion, and so designed as to return
positively to the nonstarting position after each complete cycle of the knife.

(6) Where two or more workers are employed at the same time on the same power-driven guillotine

veneer cutter equipped with two-hand control, the device shall be so arranged that each worker shall
be required to use both hands simultaneously on the controls to start the cutting motion, and at least
one hand on a control to complete the cut.

(7) Power-driven guillotine veneer cutters, other than continuous trimmers, shall be provided, in addition

to the brake or other stopping mechanism, with an emergency device which will prevent the machine
from operating in the event of failure of the brake when the starting mechanism is in the nonstarting
position.

(r) _Miscellaneous woodworking machines._

(1) The feed rolls of roll type glue spreaders shall be guarded by a semicylindrical guard. The bottom of

the guard shall come to within three-eighths inch of a plane formed by bottom or contact face of the
feed roll where it touches the stock.

(2) Drag saws shall be so located as to give at least a 4-foot clearance for passage when the saw is at

the extreme end of the stroke; or if such clearance is not obtainable, the saw and its driving
mechanism shall be provided with a standard enclosure.

(3) For combination or universal woodworking machines each point of operation of any tool shall be

guarded as required for such a tool in a separate machine.

**29 CFR 1910.213(r)(3) (enhanced display)** **page 8 of 9**

**29 CFR 1910.213(r)(4)**

(4) The mention of specific machines in paragraphs (a) thru (q) and this paragraph (r) of this section,

inclusive, is not intended to exclude other woodworking machines from the requirement that suitable
guards and exhaust hoods be provided to reduce to a minimum the hazard due to the point of
operation of such machines.

(s) _Inspection and maintenance of woodworking machinery._

(1) Dull, badly set, improperly filed, or improperly tensioned saws shall be immediately removed from

service, before they begin to cause the material to stick, jam, or kick back when it is fed to the saw at
normal speed. Saws to which gum has adhered on the sides shall be immediately cleaned.

(2) All knives and cutting heads of woodworking machines shall be kept sharp, properly adjusted, and

firmly secured. Where two or more knives are used in one head, they shall be properly balanced.

(3) Bearings shall be kept free from lost motion and shall be well lubricated.

(4) Arbors of all circular saws shall be free from play.

(5) Sharpening or tensioning of saw blades or cutters shall be done only by persons of demonstrated

skill in this kind of work.

(6) Emphasis is placed upon the importance of maintaining cleanliness around woodworking machinery,

particularly as regards the effective functioning of guards and the prevention of fire hazards in
switch enclosures, bearings, and motors.

(7) All cracked saws shall be removed from service.

(8) The practice of inserting wedges between the saw disk and the collar to form what is commonly

known as a “wobble saw” shall not be permitted.

(9) Push sticks or push blocks shall be provided at the work place in the several sizes and types suitable

for the work to be done.

(10)-(11) [Reserved]

(12) The knife blade of jointers shall be so installed and adjusted that it does not protrude more than one
eighth inch beyond the cylindrical body of the head. Push sticks or push blocks shall be provided at
the work place in the several sizes and types suitable for the work to be done.

(13) Whenever veneer slicers or rotary veneer-cutting machines have been shutdown for the purpose of

inserting logs or to make adjustments, operators shall make sure that machine is clear and other
workmen are not in a hazardous position before starting the machine.

(14) Operators shall not ride the carriage of a veneer slicer.

_[[39 FR 23502, June 27, 1974, as amended at 43 FR 49750, Oct. 24, 1978; 49 FR 5323, Feb. 10, 1984]](https://www.federalregister.gov/citation/39-FR-23502)_

**29 CFR 1910.213(s)(14) (enhanced display)** **page 9 of 9**

**29 CFR 1910.215 (up to date as of 7/23/2025)**
**29 CFR 1910.215 (July 23, 2025)**
**Abrasive wheel machinery.**

**§ 1910.215 Abrasive wheel machinery.**

(a) _General requirements_ —

(1) _Machine guarding._ Abrasive wheels shall be used only on machines provided with safety guards as

defined in the following paragraphs of this section, except:

(i) Wheels used for internal work while within the work being ground;

(ii) Mounted wheels, used in portable operations, 2 inches and smaller in diameter; and

(iii) Types 16, 17, 18, 18R, and 19 cones, plugs, and threaded hole pot balls where the work offers

protection.

(2) _Guard design._ The safety guard shall cover the spindle end, nut, and flange projections. The safety

guard shall be mounted so as to maintain proper alignment with the wheel, and the strength of the
fastenings shall exceed the strength of the guard, except:

(i) Safety guards on all operations where the work provides a suitable measure of protection to the

operator, may be so constructed that the spindle end, nut, and outer flange are exposed; and
where the nature of the work is such as to entirely cover the side of the wheel, the side covers
of the guard may be omitted; and

(ii) The spindle end, nut, and outer flange may be exposed on machines designed as portable

saws.

(3) _Flanges._ Grinding machines shall be equipped with flanges in accordance with paragraph (c) of this

section.

(4) _Work rests._ On offhand grinding machines, work rests shall be used to support the work. They shall

be of rigid construction and designed to be adjustable to compensate for wheel wear. Work rests
shall be kept adjusted closely to the wheel with a maximum opening of one-eighth inch to prevent
the work from being jammed between the wheel and the rest, which may cause wheel breakage. The
work rest shall be securely clamped after each adjustment. The adjustment shall not be made with

the wheel in motion.

(5) _Excluded machinery._ Natural sandstone wheels and metal, wooden, cloth, or paper discs, having a

layer of abrasive on the surface are not covered by this section.

**29 CFR 1910.215(a)(5) (enhanced display)** **page 1 of 22**

**29 CFR 1910.215(b)**

(b) _Guarding of abrasive wheel machinery_ —

(1) _Cup wheels._ Cup wheels (Types 6 and 11) shall be protected by:

(i) Safety guards as specified in paragraphs (b) (1) through (10) of this section;

(ii) Band type guards as specified in paragraph (b)(11) of this section; and

(iii) Special “Revolving Cup Guards” which mount behind the wheel and turn with it. They shall be

made of steel or other material with adequate strength and shall enclose the wheel sides
upward from the back for one-third of the wheel thickness. The mounting features shall
conform with all requirements of this section. It is necessary to maintain clearance between the
wheel side and the guard. This clearance shall not exceed one-sixteenth inch.

(2) _Guard exposure angles._ The maximum exposure angles specified in paragraphs (b) (3) through (8) of

this section shall not be exceeded. Visors or other accessory equipment shall not be included as a
part of the guard when measuring the guard opening, unless such equipment has strength equal to
that of the guard.

(3) _Bench and floor stands._ The angular exposure of the grinding wheel periphery and sides for safety

guards used on machines known as bench and floor stands should not exceed 90° or one-fourth of
the periphery. This exposure shall begin at a point not more than 65° above the horizontal plane of
the wheel spindle. (See Figures O-6 and O-7 and paragraph (b)(9) of this section.)

F IGURE N O . O-6 F IGURE N O . O-7

Wherever the nature of the work requires contact with the wheel below the horizontal plane of the spindle,
the exposure shall not exceed 125°. (See Figures O-8 and O-9.)

F IGURE N O . O-8 F IGURE N O . O-9

**29 CFR 1910.215(b)(3) (enhanced display)** **page 2 of 22**

**29 CFR 1910.215(b)(4)**

(4) _Cylindrical grinders._ The maximum angular exposure of the grinding wheel periphery and sides for

safety guards used on cylindrical grinding machines shall not exceed 180°. This exposure shall begin
at a point not more than 65° above the horizontal plane of the wheel spindle. (See Figures O-10 and
O-11 and subparagraph (9) of this paragraph.)

F IGURE N O . O-10 F IGURE N O . O-11

(5) _Surface grinders and cutting-off machines._ The maximum angular exposure of the grinding wheel

periphery and sides for safety guards used on cutting-off machines and on surface grinding
machines which employ the wheel periphery shall not exceed 150°. This exposure shall begin at a
point not less than 15° below the horizontal plane of the wheel spindle. (See Figures O-12 and O-13)

F IGURE N O . O-12 F IGURE N O . O-13

(6) _Swing frame grinders._ The maximum angular exposure of the grinding wheel periphery and sides for

safety guards used on machines known as swing frame grinding machines shall not exceed 180°,
and the top half of the wheel shall be enclosed at all times. (See Figures O-14 and O-15.)

F IGURE N O . O-14 F IGURE N O . O-15

(7) _Automatic snagging machines._ The maximum angular exposure of the grinding wheel periphery and

sides for safety guards used on grinders known as automatic snagging machines shall not exceed
180° and the top half

C:\Users\megahefm\Dropbox\SIGHT Project\sight\app\data\29 CFR 1910.215 (up to date as of 7-23-2025).pdf

 which employ the wheel periphery shall not exceed 150°. This exposure shall begin at a

180° and the top half of the wheel shall be enclosed at all times. (See Figures O-14 and O-15.)

**29 CFR 1910.215(b)(7) (enhanced display)** **page 3 of 22**

**29 CFR 1910.215(b)(8)**

(8) _Top grinding._ Where the work is applied to the wheel above the horizontal centerline, the exposure of

the grinding wheel periphery shall be as small as possible and shall not exceed 60°. (See Figures
O-16 and O-17.)

F IGURE N O . O-16 F IGURE N O . O-17

(9) _Exposure adjustment._ Safety guards of the types described in subparagraphs (3) and (4) of this

paragraph, where the operator stands in front of the opening, shall be constructed so that the
peripheral protecting member can be adjusted to the constantly decreasing diameter of the wheel.
The maximum angular exposure above the horizontal plane of the wheel spindle as specified in
paragraphs (b) (3) and (4) of this section shall never be exceeded, and the distance between the
wheel periphery and the adjustable tongue or the end of the peripheral member at the top shall never
exceed one-fourth inch. (See Figures O-18, O-19, O-20, O-21, O-22, and O-23.)

(10) _Material requirements and minimum dimensions._

(i) See Figures O-36 and O-37 and Table O-9 for minimum basic thickness of peripheral and side

members for various types of safety guards and classes of service.

(ii) If operating speed does not exceed 8,000 surface feet per minute cast iron safety guards,

malleable iron guards or other guards as described in paragraph (b)(10)(iii) of this section shall
be used.

(iii) Cast steel, or structural steel, safety guards as specified in Figures O-36 and O-37 and Table O-9

shall be used where operating speeds of wheels are faster than 8,000 surface feet per minute
up to a maximum of 16,000 surface feet per minute.

(iv) For cutting-off wheels 16 inches diameter and smaller and where speed does not exceed

16,000 surface feet per minute, cast iron or malleable iron safety guards as specified in Figures
O-36 and O-37, and in Table O-9 shall be used.

F IGURE N O . O-18 F IGURE N O . O-19

**29 CFR 1910.215(b)(10)(iv) (enhanced display)** **page 4 of 22**

**29 CFR 1910.215(b)(10)(v)**

# correct

_Showing adjustable tongue giving required angular protection for all sizes of wheel used._

F IGURE N O . O-20 F IGURE N O . O-21

# correct

_Showing movable guard with opening small enough to give required protection for smallest size_

_wheel used._

F IGURE N O . O-22 F IGURE N O . O-23

# incorrect

_Showing movable guard with size of opening correct for full size wheel but too large for smaller_

_wheels._

(v) For cutting-off wheels larger than 16 inches diameter and where speed does not exceed 14,200

surface feet per minute, safety guards as specified in Figures O-27 and O-28, and in Table O-1

(vi) For thread grinding wheels not exceeding 1 inch in thickness cast iron or malleable iron safety

guards as specified in Figures O-36 and O-37, and in Table O-9 shall be used.

(11) _Band type guards—general specifications._ Band type guards shall conform to the following general

specifications:

**29 CFR 1910.215(b)(11) (enhanced display)** **page 5 of 22**

**29 CFR 1910.215(b)(11)(i)**

(i) The bands shall be of steel plate or other material of equal or greater strength. They shall be

continuous, the ends being either riveted, bolted, or welded together in such a manner as to
leave the inside free from projections.

(ii) The inside diameter of the band shall not be more than 1 inch larger than the outside diameter

of the wheel, and shall be mounted as nearly concentric with the wheel as practicable.

(iii) The band shall be of sufficient width and its position kept so adjusted that at no time will the

wheel protrude beyond the edge of the band a distance greater than that indicated in Figure
O-29 and in Table O-2 or the wall thickness (W), whichever is smaller.

(12) _Guard design specifications._ Abrasive wheel machinery guards shall meet the design specifications

of the American National Standard Safety Code for the Use, Care, and Protection of Abrasive Wheels,
[ANSI B7.1-1970, which is incorporated by reference as specified in § 1910.6. This requirement shall](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.6/)
not apply to natural sandstone wheels or metal, wooden, cloth, or paper discs, having a layer of
abrasive on the surface.

(c) _Flanges_ —

(1) _General requirements._ All abrasive wheels shall be mounted between flanges which shall not be less

than one-third the diameter of the wheel.

(i) Exceptions:

( _a_ ) Mounted wheels.

( _b_ ) Portable wheels with threaded inserts or projecting studs.

( _c_ ) Abrasive discs (inserted nut, inserted washer and projecting stud type).

( _d_ ) Plate mounted wheels.

( _e_ ) Cylinders, cup, or segmental wheels that are mounted in chucks.

( _f_ ) Types 27 and 28 wheels.

( _g_ ) Certain internal wheels.

( _h_ ) Modified types 6 and 11 wheels (terrazzo).

( _i_ ) Cutting-off wheels, Types 1 and 27A (see paragraphs (c)(1) (ii) and (iii) of this section).

(ii) Type 1 cutting-off wheels are to be mounted between properly relieved flanges which have

matching bearing surfaces. Such flanges shall be at least one-fourth the wheel diameter.

(iii) Type 27A cutting-off wheels are designed to be mounted by means of flat, not relieved, flanges

having matching bearing surfaces and which may be less than one-third but shall not be less
than one-fourth the wheel diameter. (See Figure O-24 for one such type of mounting.)

(iv) There are three general types of flanges:

( _a_ ) Straight relieved flanges (see Figure O-32);

( _b_ ) Straight unrelieved flanges (see Figure O-30);

( _c_ ) Adaptor flanges (see Figures O-33 and O-34);

**29 CFR 1910.215(c)(1)(iv)(c) (enhanced display)** **page 6 of 22**

**29 CFR 1910.215(c)(1)(v)**

(v) Regardless of flange type used, the wheel shall always be guarded. Blotters shall be used in

accordance with paragraph (c)(6) of this section.

F IGURE N O . O-24

_The Type 27 A Wheel is mounted between flat non-relieved flanges of equal bearing surfaces._

(3) _Finish and balance._ Flanges shall be dimensionally accurate and in good balance. There shall be no

rough surfaces or sharp edges.

(4) _Uniformity of diameter._

(i) Both flanges, of any type, between which a wheel is mounted, shall be of the same diameter

and have equal bearing surface. Exceptions are

 of 22**

and have equal bearing surface. Exceptions are set forth in the remaining subdivisions of this
subparagraph.

(ii) Type 27 and Type 28 wheels, because of their shape and usage, require specially designed

adaptors. The back flange shall extend beyond the central hub or raised portion and contact the
wheel to counteract the side pressure on the wheel in use. The adaptor nut which is less than
the minimum one-third diameter of wheel fits in the depressed side of wheel to prevent
interference in side grinding and serves to drive the wheel by its clamping force against the
depressed portion of the back flange. The variance in flange diameters, the adaptor nut being
less than one-third wheel diameter, and the use of side pressure in wheel operation limits the
use to reinforced organic bonded wheels. Mounts which are affixed to the wheel by the
manufacturer shall not be reused. Type 27 and Type 28 wheels shall be used only with a safety
guard located between wheel and operator during use. (See Figure O-24-A.)

**29 CFR 1910.215(c)(4)(ii) (enhanced display)** **page 7 of 22**

**29 CFR 1910.215(c)(4)(iii)**

F IGURE N O . O-24-A

_Types 27 and 28 wheels, because of their shape, require specially designed adaptors._

(iii) Modified Types 6 and 11 wheels (terrazzo) with tapered K dimension.

(5) _Recess and undercut._

(i) Straight relieved flanges made according to Table O-6 and Figure O-32 shall be recessed at

least one-sixteenth inch on the side next to the wheel for a distance as specified in Table O-6.

(ii) Straight flanges of the adaptor or sleeve type (Table O-7 and Figures O-33 and O-34) shall be

undercut so that there will be no bearing on the sides of the wheel within one-eighth inch of the

arbor hole.

(6) _Blotters._

(i) Blotters (compressible washers) shall always be used between flanges and abrasive wheel

surfaces to insure uniform distribution of flange pressure. (See paragraph (d)(5) of this
section.)

(ii) Exception:

( _b_ ) Abrasive discs (inserted nut, inserted washer, and projecting stud type).

( _c_ ) Plate mounted wheels.

( _d_ ) Cylinders, cups, or segmental wheels that are mounted in chucks.

( _e_ ) Types 27 and 28 wheels.

( _f_ ) Certain Type 1 and Type 27A cutting-off wheels.

( _h_ ) Type 4 tapered wheels.

( _i_ ) Diamond wheels, except certain vitrified diamond wheels.

**29 CFR 1910.215(c)(6)(ii)(i) (enhanced display)** **page 8 of 22**

**29 CFR 1910.215(c)(6)(ii)(j)**

( _j_ ) Modified Types 6 and 11 wheel (terrazzo)—blotters applied flat side of wheel only.

(7) _Driving flange._ The driving flange shall be securely fastened to the spindle and the bearing surface

shall run true. When more than one wheel is mounted between a single set of flanges, wheels may
be cemented together or separated by specially designed spacers. Spacers shall be equal in
diameter to the mounting flanges and have equal bearing surfaces. (See paragraph (d)(6) of this
section.)

(8) _Dimensions._

(i) Tables O-4 and O-6 and Figures O-30 and O-32 show minimum dimensions for straight relieved

and unrelieved flanges for use with wheels with small holes that fit directly on the machine
spindle. Dimensions of such flanges shall never be less than indicated.

(ii) Table O-5, and Table O-7 and Figures O-31, O-33, O-34 show minimum dimensions for straight

adaptor flanges for use with wheels having holes larger than the spindle. Dimensions of such
adaptor flanges shall never be less than indicated.

(iii) Table O-8 and Figure O-35 show minimum dimensions for straight flanges that are an integral

part of wheel sleeves which are frequently used on precision grinding machines. Dimensions of
such flanges shall never be less than indicated.

(9) _Repairs and maintenance._ All flanges shall be maintained in good condition. When the bearing

surfaces become worn, warped, sprung, or damaged they should be trued or refaced. When refacing
or truing, care shall be exercised to make sure that proper relief and rigidity is maintained as
specified in paragraphs (c) (2) and (5) of this section and they shall be replaced when they do not
conform to these subparagraphs and Table O-4, Figure O-30, Table O-5, Figure O-31, Table O-6, Figure
O-32, and Table O-8, Figure O-35. Failure to observe these rules might cause excessive flange
pressure around the hole of the wheel. This is especially true of wheel-sleeve or adaptor flanges.

(d) _Mounting_ —

(1) _Inspection._ Immediately before mounting, all wheels shall be closely inspected and sounded by the

user (ring test) to make sure they have not been damaged in transit, storage, or otherwise. The
spindle speed of the machine shall be checked before mounting of the wheel to be certain that it
does not exceed the maximum operating speed marked on the wheel. Wheels should be tapped
gently with a light nonmetallic implement, such as the handle of a screwdriver for light wheels, or a
wooden mallet for heavier wheels. If they sound cracked (dead), they shall not be used. This is
known as the “Ring Test”.

(i) Wheels must be dry and free from sawdust when applying the ring test, otherwise the sound

will be deadened. It should also be noted that organic bonded wheels do not emit the same
clear metallic ring as do vitrified and silicate wheels.

**29 CFR 1910.215(d)(1)(i) (enhanced display)** **page 9 of 22**

**29 CFR 1910.215(d)(1)(ii)**

F IGURE N O . O-25 F IGURE N O . O-26

(ii) “Tap” wheels about 45° each side of the vertical centerline and about 1 or 2 inches from the

periphery as indicated by the spots in Figure O-25 and Figure O-26. Then rotate the wheel 45°
and repeat the test. A sound and undamaged wheel will give a clear metallic tone. If cracked,
there will be a dead sound and not a clear “ring.”

(2) _Arbor size._ Grinding wheels shall fit freely on the spindle and remain free under all grinding

conditions. A controlled clearance between the wheel hole and the machine spindle (or wheel
sleeves or adaptors) is essential to avoid excessive pressure from mounting and spindle expansion.
To accomplish this, the machine spindle shall be made to nominal (standard) size plus zero minus
.002 inch, and the wheel hole shall be made suitably oversize to assure safety clearance under the
conditions of operating heat and pressure.

(3) _Surface condition._ All contact surfaces of wheels, blotters and flanges shall be flat and free of

foreign matter.

(4) _Bushing._ When a bushing is used in the wheel hole it shall not exceed the width of the wheel and

shall not contact the flanges.

(5) _Blotters._ When blotters or flange facings of compressible material are required, they shall cover

entire contact area of wheel flanges. Blotters need not be used with the following types of wheels:

(i)

 A controlled clearance between the wheel hole and the machine spindle (or wheel

(i) Mounted wheels.

(ii) Abrasive discs (inserted nut, inserted washer, and projecting-stud type).

(iii) Plate mounted wheels.

(iv) Cylinders, cups, or segmental wheels that are mounted in chucks.

(v) Types 27 and 28 wheels.

(vi) Certain Type 1 and Type 27A cutting-off wheels.

(vii) Certain internal wheels.

(viii) Type 4 tapered wheels.

**29 CFR 1910.215(d)(5)(viii) (enhanced display)** **page 10 of 22**

**29 CFR 1910.215(d)(5)(ix)**

(ix) Diamond wheels, except certain vitrified diamond wheels.

(6) _Multiple wheel mounting._ When more than one wheel is mounted between a single set of flanges,

wheels may be cemented together or separated by specially designed spacers. Spacers shall be
equal in diameter to the mounting flanges and have equal bearing surfaces. When mounting wheels
which have not been cemented together, or ones which do not utilize separating spacers, care must
be exercised to use wheels specially manufactured for that purpose.

**29 CFR 1910.215(d)(6) (enhanced display)** **page 11 of 22**

**29 CFR 1910.215(d)(6)**

**T** **ABLE** **O-1—M** **INIMUM** **B** **ASIC** **T** **HICKNESS** **FOR** **P** **ERIPHERAL** **AND** **S** **IDE** **M** **EMBERS** **FOR** **S** **AFETY** **G** **UARDS** **U** **SED** **W** **ITH** **C** **UTTING** **-O** **FF** **W** **HEELS**

**29 CFR 1910.215(d)(6) (enhanced display)** **page 12 of 22**

## **T ABLE O-3—G UIDE FOR C ONSTRUCTION OF B AND T YPE G UARDS** **[M AXIMUM W HEEL S PEED 7,000 SFPM]**

**29 CFR 1910.215(d)(6) (enhanced display)** **page 13 of 22**

## **—** **T ABLE O-5—M INIMUM D IMENSIONS FOR S TRAIGHT A DAPTOR F LANGE FOR** **O RGANIC B ONDED W HEELS O VER 11/4 I NCHES T HICK [1]** **[I N INCHES ]**

_1_ _For wheels under 11/4 inches thick F dimension shall not exceed 40 percent of wheel thickness._

**29 CFR 1910.215(d)(6) (enhanced display)** **page 14 of 22**

## **T ABLE O-6—M INIMUM D IMENSIONS FOR S TRAIGHT R ELIEVED F LANGES [1]** **[I N INCHES ]**

_1_ _Flanges for wheels under 2 inches diameter may be unrelieved and shall be maintained flat and true._

**29 CFR 1910.215(d)(6) (enhanced display)** **page 15 of 22**

**29 CFR 1910.215(d)(6) (enhanced display)** **page 16 of 22**

## **—** **T ABLE O-7—M INIMUM D IMENSIONS FOR S TRAIGHT F LANGES FOR M ECHANICAL** **G RINDERS 12,500 S.F.P.M. TO 16,5 S.F.P.M. [1]**

_1_ _Flanges shall be of steel, quality SAE 1040 or equivalent, annealed plate, heat treated to R. 25-30._

_2_ _For wheels under 11/4 inch thick F dimension shall not exceed 40 percent of wheel thickness._

**29 CFR 1910.215(d)(6) (enhanced display)** **page 17 of 22**

## **T ABLE O-8—M INIMUM D IMENSIONS FOR S TRAIGHT F LANGES U SED AS W HEEL** **S LEEVES FOR P RECISION G RINDING O NLY** **[I N INCHES ]**

_Note: These flanges may be clamped together by means of a central nut, or by a series of bolts or_
_some other equivalent means of fastening. For hole sizes smaller than shown in this table, use table_

_12._

**29 CFR 1910.215(d)(6) (enhanced display)** **page 18 of 22**

_12._

**29 CFR 1910.215(d)(6) (enhanced display)** **page 19 of 22**

**T** **ABLE** **O-9—M** **INIMUM** **B** **ASIC** **T** **HICKNESSES** **OF** **P** **ERIPHERAL** **AND** **S** **IDE** **M** **EMBERS** **FOR** **S** **AFETY** **G** **UARDS**

**[I** **N** **INCHES** **]**

_1_ _The recommendations listed in the above table are guides for the conditions stated. Other material, designs or dimensions affording equal or superior protection are also acceptable._

**29 CFR 1910.215(d)(6) (enhanced display)** **page 20 of 22**

**29 CFR 

 CFR 1910.215 (up to date as of 7/23/2025)**

**29 CFR 1910.215(d)(6) (enhanced display)** **page 21 of 22**

## **T ABLE O-2—E XPOSURE V ERSUS W HEEL T HICKNESS** **[I N INCHES ]**

## **T ABLE O-4—M INIMUM D IMENSIONS FOR S TRAIGHT U NRELIEVED F LANGES FOR** **W HEELS WITH T HREADED I NSERTS OR P ROJECTING S TUDS**

_1_ _Note: Must be large enough to extend beyond the bushing. Where prong anchor or cupback bushing_
_are used, this footnote does not apply._

_[[39 FR 23502, June 27, 1974, as amended at 43 FR 49750, Oct. 24, 1978; 49 FR 5323, Feb. 10, 1984; 61 FR 9240, Mar. 7, 1996]](https://www.federalregister.gov/citation/39-FR-23502)_

**29 CFR 1910.215(d)(6) (enhanced display)** **page 22 of 22**

**29 CFR 1910.217 (up to date as of 7/23/2025)**
**29 CFR 1910.217 (July 23, 2025)**
**Mechanical power presses.**

**§ 1910.217 Mechanical power presses.**

(1)-(3) [Reserved]

(4) _Reconstruction and modification._ It shall be the responsibility of any person reconstructing, or

modifying a mechanical power press to do so in accordance with paragraph (b) of this section.

(5) _Excluded machines._ Press brakes, hydraulic and pneumatic power presses, bulldozers, hot bending

and hot metal presses, forging presses and hammers, riveting machines and similar types of
fastener applicators are excluded from the requirements of this section.

(b) _Mechanical power press guarding and construction, general_ —

(1) _Hazards to personnel associated with broken or falling machine components._ Machine components

shall be designed, secured, or covered to minimize hazards caused by breakage, or loosening and
falling or release of mechanical energy (i.e. broken springs).

(2) _Brakes._ Friction brakes provided for stopping or holding a slide movement shall be inherently self
engaging by requiring power or force from an external source to cause disengagement. Brake
capacity shall be sufficient to stop the motion of the slide quickly and capable of holding the slide
and its attachments at any point in its travel.

(3) _Machines using full revolution positive clutches._

(i) Machines using full revolution clutches shall incorporate a single-stroke mechanism.

(ii) If the single-stroke mechanism is dependent upon spring action, the spring(s) shall be of the

compression type, operating on a rod or guided within a hole or tube, and designed to prevent
interleaving of the spring coils in event of breakage.

(4) _Foot pedals (treadle)._

(i) The pedal mechanism shall be protected to prevent unintended operation from falling or

moving objects or by accidental stepping onto the pedal.

(ii) A pad with a nonslip contact area shall be firmly attached to the pedal.

**29 CFR 1910.217(b)(4)(ii) (enhanced display)** **page 1 of 43**

**29 CFR 1910.217(b)(4)(iii)**

(iii) The pedal return spring(s) shall be of the compression type, operating on a rod or guided within

a hole or tube, or designed to prevent interleaving of spring coils in event of breakage.

(iv) If pedal counterweights are provided, the path of the travel of the weight shall be enclosed.

(5) _Hand operated levers._

(i) Hand-lever-operated power presses shall be equipped with a spring latch on the operating lever

to prevent premature or accidental tripping.

(ii) The operating levers on hand-tripped presses having more than one operating station shall be

interlocked to prevent the tripping of the press except by the “concurrent” use of all levers.

(6) _Two-hand trip._

(i) A two-hand trip shall have the individual operator's hand controls protected against

unintentional operation and have the individual operator's hand controls arranged by design and
construction and/or separation to require the use of both hands to trip the press and use a
control arrangement requiring concurrent operation of the individual operator's hand controls.

(ii) Two-hand trip systems on full revolution clutch machines shall incorporate an antirepeat

feature.

(iii) If two-hand trip systems are used on multiple operator presses, each operator shall have a

separate set of controls.

(7) _Machines using part revolution clutches._

(i) The clutch shall release and the brake shall be applied when the external clutch engaging

means is removed, deactivated, or deenergized.

(ii) A red color stop control shall be provided with the clutch/brake control system. Momentary

operation of the stop control shall immediately deactivate the clutch and apply the brake. The
stop control shall override any other control, and reactuation of the clutch shall require use of
the operating (tripping) means which has been selected.

(iii) A means of selecting Off, “Inch,” Single Stroke, and Continuous (when the continuous function

is furnished) shall be supplied with the clutch/brake control to select type of operation of the
press. Fixing of selection shall be by means capable of supervision by the employer.

(iv) The “Inch” operating means shall be designed to prevent exposure of the workers hands within

the point of operation by:

( _a_ ) Requiring the concurrent use of both hands to actuate the clutch, or

( _b_ ) Being a single control protected against accidental actuation and so located that the

worker cannot reach into the point of operation while operating the single control.

(v) Two-hand controls for single stroke shall conform to the following requirements:

( _a_ ) Each hand control shall be protected against unintended operation and arranged by

design, construction, and/or separation so that the concurrent use of both hands is
required to trip the press.

( _b_ ) The control system shall be designed to permit an adjustment which will require

concurrent pressure from both hands during the die closing portion of the stroke.

**29 CFR 1910.217(b)(7)(v)(b) (enhanced display)** **page 2 of 43**

**29 CFR 1910.217(b)(7)(v)(c)**

( _c_ ) The control system shall incorporate an antirepeat feature.

( _d_ ) The control systems shall be designed to require release of all operators' hand controls

before an interrupted stroke can be resumed. This requirement pertains only to those
single-stroke, two-hand controls manufactured and installed on or after August 31, 1971.

(vi) [Reserved]

(vii) Controls for more than one operating station shall be designed to be activated and deactivated

in complete sets of two operator's hand controls per operating station by means capable of
being supervised by the employer. The clutch/brake control system shall be designed and
constructed to prevent actuation of the clutch if all operating stations are bypassed.

(viii) Those clutch/brake control systems which contain both single and continuous functions shall

be designed so that completion

C:\Users\megahefm\Dropbox\SIGHT Project\sight\app\data\29 CFR 1910.217 (up to date as of 7-23-2025).pdf

**

be designed so that completion of continuous circuits may be supervised by the employer. The
initiation of continuous run shall require a prior action or decision by the operator in addition to
the selection of Continuous on the stroking selector, before actuation of the operating means
will result in continuous stroking.

(ix) If foot control is provided, the selection method between hand and foot control shall be

separate from the stroking selector and shall be designed so that the selection may be
supervised by the employer.

(x) Foot operated tripping controls, if used, shall be protected so as to prevent operation from

falling or moving objects, or from unintended operation by accidental stepping onto the foot

control.

(xi) The control of air-clutch machines shall be designed to prevent a significant increase in the

normal stopping time due to a failure within the operating value mechanism, and to inhibit
further operation if such failure does occur. This requirement shall apply only to those clutch/
brake air-valve controls manufactured and installed on or after August 31, 1971, but shall not
apply to machines intended only for continuous, automatic feeding applications.

(xii) The clutch/brake control shall incorporate an automatic means to prevent initiation or

continued activation of the Single Stroke or Continuous functions unless the press drive motor
is energized and in the forward direction.

(xiii) The clutch/brake control shall automatically deactivate in event of failure of the power or

pressure supply for the clutch engaging means. Reactivation of the clutch shall require
restoration of normal supply and the use of the tripping mechanism(s).

(xiv) The clutch/brake control shall automatically deactivate in event of failure of the

counterbalance(s) air supply. Reactivation of the clutch shall require restoration of normal air
supply and use of the tripping mechanism(s).

(xv) Selection of bar operation shall be by means capable of being supervised by the employer. A

separate pushbutton shall be employed to activate the clutch, and the clutch shall be activated
only if the driver motor is deenergized.

(8) _Electrical._

(i) A main power disconnect switch capable of being locked only in the Off position shall be

provided with every power press control system.

**29 CFR 1910.217(b)(8)(i) (enhanced display)** **page 3 of 43**

**29 CFR 1910.217(b)(8)(ii)**

(ii) The motor start button shall be protected against accidental operation.

(iii) All mechanical power press controls shall incorporate a type of drive motor starter that will

disconnect the drive motor from the power source in event of control voltage or power source
failure, and require operation of the motor start button to restart the motor when voltage

conditions are restored to normal.

(iv) All a.c. control circuits and solenoid value coils shall be powered by not more than a nominal

120-volt a.c. supply obtained from a transformer with an isolated secondary. Higher voltages
that may be necessary for operation of machine or control mechanisms shall be isolated from
any control mechanism handled by the operator, but motor starters with integral Start-Stop
buttons may utilize line voltage control. All d.c. control circuits shall be powered by not more
than a nominal 240-volt d.c. supply isolated from any higher voltages.

(v) All clutch/brake control electrical circuits shall be protected against the possibility of an

accidental ground in the control circuit causing false operation of the press.

(vi) Electrical clutch/brake control circuits shall incorporate features to minimize the possibility of

an unintended stroke in the event of the failure of a control component to function properly,
including relays, limit switches, and static output circuits.

(9) _Slide counterbalance systems._

(i) Spring counterbalance systems when used shall incorporate means to retain system parts in

event of breakage.

(ii) Spring counterbalances when used shall have the capability to hold the slide and its

attachments at midstroke, without brake applied.

(iii) Air counterbalance cylinders shall incorporate means to retain the piston and rod in case of

breakage or loosening.

(iv) Air counterbalance cylinders shall have adequate capability to hold the slide and its

attachments at any point in stroke, without brake applied.

(v) Air counterbalance cylinders shall incorporate means to prevent failure of capability (sudden

loss of pressure) in event of air supply failure.

(10) _Air controlling equipment._ Air controlling equipment shall be protected against foreign material and

water entering the pneumatic system of the press. A means of air lubrication shall be provided when

needed.

(11) _Hydraulic equipment._ The maximum anticipated working pressures in any hydraulic system on a

mechanical power press shall not exceed the safe working pressure rating of any component used in
that system.

(12) _Pressure vessels._ All pressure vessels used in conjunction with power presses shall conform to the

American Society of Mechanical Engineers Code for Pressure Vessels, 1968 Edition, which is
[incorporated by reference as specified in § 1910.6.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.6/)

(13) _Control reliability._ When required by paragraph (c)(5) of this section, the control system shall be

constructed so that a failure within the system does not prevent the normal stopping action from
being applied to the press when required, but does prevent initiation of a successive stroke until the

**29 CFR 1910.217(b)(13) (enhanced display)** **page 4 of 43**

**29 CFR 1910.217(b)(14)**

failure is corrected. The failure shall be detectable by a simple test, or indicated by the control
system. This requirement does not apply to those elements of the control system which have no
effect on the protection against point of operation injuries.

(14) _Brake system monitoring._ When required by paragraph (c)(5) of this section, the brake monitor shall

meet the following requirements:

(i) Be so constructed as to automatically prevent the activation of a successive stroke if the

stopping time or braking distance deteriorates to a point where the safety distance being
utilized does not meet the requirements set forth in paragraph (c)(3)(iii)( _e_ ) or (c)(3)(vii)( _c_ ) of
this section. The brake monitor used with the Type B gate or movable barrier device shall be
installed in a manner to detect slide top-stop overrun beyond the normal limit reasonably
established by the employer.

(ii) Be installed on a press such that it indicates when the performance of the braking system has

deteriorated to the extent described in paragraph (b)(14)(i) of this section; and

(iii) Be constructed and installed in a manner to monitor brake system performance on each stroke.

(c) _Safeguarding the point of operation_ —

(1) _General requirements._

(i) It shall be the responsibility of the employer to provide and insure the usage of “point of

operation guards” or properly applied and adjusted point of operation devices on every
operation performed on a mechanical power press. See Table O-10.

(ii) The requirement of paragraph (c)(1)(i) of this section shall not apply when the point of

operation opening is one-fourth inch or less. See Table O-10.

(2) _Point of operation guards._

(i) Every point of operation guard shall meet the following design, construction, application, and

adjustment requirements:

( _a_ ) It shall prevent entry of hands or fingers into the point of operation by reaching through,

over, under or around the guard;

( _b_ ) It shall conform to the maximum permissible openings of Table O-10;

( _c_ ) It shall, in itself, create no pinch point between the guard and moving machine parts;

( _d_ ) It shall utilize fasteners not readily removable by operator, so as to minimize the possibility

of misuse or removal of essential parts;

( _e_ ) It shall facilitate its inspection, and

( _f_ ) It shall offer maximum visibility of the point of operation consistent with the other

requirements.

(ii) A die enclosure guard shall be attached to the die shoe or stripper in a fixed

th inch or less. See Table O-10.

(ii) A die enclosure guard shall be attached to the die shoe or stripper in a fixed position.

(iii) A fixed barrier guard shall be attached securely to the frame of the press or to the bolster plate.

**29 CFR 1910.217(c)(2)(iii) (enhanced display)** **page 5 of 43**

**29 CFR 1910.217(c)(2)(iv)**

(iv) An interlocked press barrier guard shall be attached to the press frame or bolster and shall be

interlocked with the press clutch control so that the clutch cannot be activated unless the guard
itself, or the hinged or movable sections of the guard are in position to conform to the
requirements of Table O-10.

(v) The hinged or movable sections of an interlocked press barrier guard shall not be used for

manual feeding. The guard shall prevent opening of the interlocked section and reaching into
the point of operation prior to die closure or prior to the cessation of slide motion. See
paragraph (c)(3)(ii) of this section regarding manual feeding through interlocked press barrier
devices.

(vi) The adjustable barrier guard shall be securely attached to the press bed, bolster plate, or die

shoe, and shall be adjusted and operated in conformity with Table O-10 and the requirements of
this subparagraph. Adjustments shall be made only by authorized personnel whose
qualifications include a knowledge of the provisions of Table O-10 and this subparagraph.

(vii) A point of operation enclosure which does not meet the requirements of this subparagraph and

Table O-10 shall be used only in conjunction with point of operation devices.

(3) _Point of operation devices._

(i) Point of operation devices shall protect the operator by:

( _a_ ) Preventing and/or stopping normal stroking of the press if the operator's hands are

inadvertently placed in the point of operation; or

( _b_ ) Preventing the operator from inadvertently reaching into the point of operation, or

withdrawing his hands if they are inadvertently located in the point of operation, as the
dies close; or

( _c_ ) Preventing the operator from inadvertently reaching into the point of operation at all times;

or

( _d_ ) [Reserved]

( _e_ ) Requiring application of both of the operator's hands to machine operating controls and

locating such controls at such a safety distance from the point of operation that the slide
completes the downward travel or stops before the operator can reach into the point of
operation with his hands; or

( _f_ ) Enclosing the point of operation before a press stroke can be initiated, and maintaining

this closed condition until the motion of the slide had ceased; or

( _g_ ) Enclosing the point of operation before a press stroke can be initiated, so as to prevent an

operator from reaching into the point of operation prior to die closure or prior to cessation
of slide motion during the downward stroke.

(ii) A gate or movable barrier device shall protect the operator as follows:

( _a_ ) A Type A gate or movable barrier device shall protect the operator in the manner specified

in paragraph (c)(3)(i)( _f_ ) of this section, and

( _b_ ) A Type B gate or movable barrier device shall protect the operator in the manner specified

in paragraph (c)(3)(i)( _g_ ) of this section.

**29 CFR 1910.217(c)(3)(ii)(b) (enhanced display)** **page 6 of 43**

**29 CFR 1910.217(c)(3)(iii)**

(iii) A presence sensing point of operation device shall protect the operator as provided in

paragraph (c)(3)(i)( _a_ ) of this section, and shall be interlocked into the control circuit to prevent
or stop slide motion if the operator's hand or other part of his body is within the sensing field of
the device during the downstroke of the press slide.

( _a_ ) The device may not be used on machines using full revolution clutches.

( _b_ ) The device may not be used as a tripping means to initiate slide motion, except when used

in total conformance with paragraph (h) of this section.

( _c_ ) The device shall be constructed so that a failure within the system does not prevent the

normal stopping action from being applied to the press when required, but does prevent
the initiation of a successive stroke until the failure is corrected. The failure shall be

indicated by the system.

( _d_ ) Muting (bypassing of the protective function) of such device, during the upstroke of the

press slide, is permitted for the purpose of parts ejection, circuit checking, and feeding.

( _e_ ) The safety distance (D s ) from the sensing field to the point of operation shall be greater

than the distance determined by the following formula:

D s = 63 inches/second × T s

where:

D s = minimum safety distance (inches); 63 inches/second = hand speed constant;

and

T s = stopping time of the press measured at approximately 90° position of crankshaft rotation
(seconds).

( _f_ ) Guards shall be used to protect all areas of entry to the point of operation not protected by

the presence sensing device.

(iv) The pull-out device shall protect the operator as specified in paragraph (c)(3)(i)( _b_ ) of this

section, and shall include attachments for each of the operator's hands.

( _a_ ) Attachments shall be connected to and operated only by the press slide or upper die.

( _b_ ) Attachments shall be adjusted to prevent the operator from reaching into the point of

operation or to withdraw the operator's hands from the point of operation before the dies

close.

( _c_ ) A separate pull-out device shall be provided for each operator if more than one operator is

used on a press.

( _d_ ) Each pull-out device in use shall be visually inspected and checked for proper adjustment

at the start of each operator shift, following a new die set-up, and when operators are
changed. Necessary maintenance or repair or both shall be performed and completed
before the press is operated. Records of inspections and maintenance shall be kept in
accordance with paragraph (e) of this section.

(v) The sweep device may not be used for point of operation safeguarding.

**29 CFR 1910.217(c)(3)(v) (enhanced display)** **page 7 of 43**

**29 CFR 1910.217(c)(3)(vi)**

(vi) A holdout or a restraint device shall protect the operator as specified in paragraph (c)(3)(i)( _c_ ) of

this section and shall include attachments for each of the operator's hands. Such attachments
shall be securely anchored and adjusted in such a way that the operator is restrained from
reaching into the point of operation. A separate set of restraints shall be provided for each
operator if more than one operator is required on a press.

(vii) The two hand control device shall protect the operator as specified in paragraph (c)(3)(i)( _e_ ) of

this section.

( _a_ ) When used in press operations requiring more than one operator, separate two hand

controls shall be provided for each operator, and shall be designed to require concurrent
application of all operators' controls to activate the slide. The removal of a hand from any
control button shall cause the slide to stop.

( _b_ ) Each two hand control shall meet the construction requirements of paragraph (b)(7)(v) of

( _c_ ) The safety distance (D s ) between each two hand control device and the point of operation

shall be greater than the distance determined by the following formula:

D s = 63 inches/second × T s ;

where:

and

( _d_ ) Two hand controls shall

 of

where:

and

( _d_ ) Two hand controls shall be fixed in position so that only a supervisor or safety engineer is

capable of relocating the controls.

(viii) The two hand trip device shall protect the operator as specified in paragraph (c)(3)(i)( _e_ ) of this

section.

( _a_ ) When used in press operations requiring more than one operator, separate two hand trips

shall be provided for each operator, and shall be designed to require concurrent
application of all operators' to activate the slide.

( _b_ ) Each two hand trip shall meet the construction requirements of paragraph (b)(6) of this

section.

( _c_ ) The safety distance (D m ) between the two hand trip and the point of operation shall be

greater than the distance determined by the following formula:

D m = 63 inches/second × T m ;

where:

D m = minimum safety distance (inches); 63 inches/second = hand speed constant;

and

**29 CFR 1910.217(c)(3)(viii)(c) (enhanced display)** **page 8 of 43**

**29 CFR 1910.217(c)(3)(viii)(d)**

T m = the maximum time the press takes for the die closure after it has been tripped (seconds).
For full revolution clutch presses with only one engaging point T m is equal to the time
necessary for one and one-half revolutions of the crankshaft. For full revolution clutch presses
with more than one engaging point, T m shall be calculated as follows:

T m = [ [1] ⁄2 + (1 ÷ Number of engaging points per revolution)] × time necessary to complete one
revolution of the crankshaft (seconds).

( _d_ ) Two hand trips shall be fixed in position so that only a supervisor or safety engineer is

(4) _Hand feeding tools._ Hand feeding tools are intended for placing and removing materials in and from

the press. Hand feeding tools are not a point of operation guard or protection device and shall not be
used in lieu of the “guards” or devices required in this section.

(5) _Additional requirements for safe-guarding._ Where the operator feeds or removes parts by placing one

or both hands in the point of operation, and a two hand control, presence sensing device, Type B
gate or movable barrier (on a part revolution clutch) is used for safeguarding:

(i) The employer shall use a control system and a brake monitor which comply with paragraphs (b)

(13) and (14) of this section;

(ii) The exception in paragraph (b)(7)(v)( _d_ ) of this section for two hand controls manufactured and

installed before August 31, 1971 is not applicable under this paragraph (c)(5);

(iii) The control of air clutch machines shall be designed to prevent a significant increase in the

normal stopping time due to a failure within the operating valve mechanism, and to inhibit
further operation if such failure does occur, where a part revolution clutch is employed. The
exception in paragraph (b)(7)(xi) of this section for controls manufactured and installed before
August 31, 1971, is not applicable under this paragraph (c)(5).

(d) _Design, construction, setting and feeding of dies_ —

(1) _General requirements._ The employer shall:

(i) Use dies and operating methods designed to control or eliminate hazards to operating

personnel, and

(ii) furnish and enforce the use of hand tools for freeing and removing stuck work or scrap pieces

from the die, so that no employee need reach into the point of operation for such purposes.

(3) _Scrap handling._ The employer shall provide means for handling scrap from roll feed or random length

stock operations. Scrap cutters used in conjunction with scrap handling systems shall be
[safeguarded in accordance with paragraph (c) of this section and with § 1910.219.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.219/)

(4) _Guide post hazard._ The hazard created by a guide post (when it is located in the immediate vicinity of

the operator) when separated from its bushing by more than one-fourth inch shall be considered as
a point of operation hazard and be protected in accordance with paragraph (c) of this section.

(5) _Unitized tooling._ If unitized tooling is used, the opening between the top of the punch holder and the

face of the slide, or striking pad, shall be safeguarded in accordance with the requirements of
paragraph (c) of this section.

**29 CFR 1910.217(d)(5) (enhanced display)** **page 9 of 43**

**29 CFR 1910.217(d)(6)**

(6) _Tonnage, stroke, and weight designation._ All dies shall be:

(i) Stamped with the tonnage and stroke requirements, or have these characteristics recorded if

these records are readily available to the die setter;

(ii) Stamped to indicate upper die weight when necessary for air counterbalance pressure

adjustment; and

(iii) Stamped to indicate complete die weight when handling equipment may become overloaded.

(7) _Die fastening._ Provision shall be made in both the upper and lower shoes for securely mounting the

die to the bolster and slide. Where clamp caps or setscrews are used in conjunction with punch
stems, additional means of securing the upper shoe to the slide shall be used.

(8) _Die handling._ Handling equipment attach points shall be provided on all dies requiring mechanical

handling.

(9) _Diesetting._

(i) The employer shall establish a diesetting procedure that will insure compliance with paragraph

(c) of this section.

(ii) The employer shall provide spring loaded turnover bars, for presses designed to accept such

turnover bars.

(iii) The employer shall provide die stops or other means to prevent losing control of the die while

setting or removing dies in presses which are inclined.

(iv) The employer shall provide and enforce the use of safety blocks for use whenever dies are

being adjusted or repaired in the press.

(v) The employer shall provide brushes, swabs, lubricating rolls, and automatic or manual pressure

guns so that operators and diesetters shall not be required to reach into the point of operation
or other hazard areas to lubricate material, punches or dies.

(e) _Inspection, maintenance, and modification of presses_ —

(1) _Inspection and maintenance records._ The employer shall establish and follow an inspection program

having a general component and a directed component.

(i) Under the general component of the inspection program, the employer shall:

(A) Conduct periodic and regular inspections of each power press to ensure that all of its parts,
auxiliary equipment, and safeguards, including the clutch/brake mechanism, antirepeat feature,
and single-stroke mechanism, are in a safe operating condition and adjustment;

(B) Perform and complete necessary maintenance or repair, or both, before operating the press;
and

(C) Maintain a certification record of each inspection, and each maintenance and repair task
performed, under the general component of the inspection program that includes the date of
the inspection, maintenance, or repair work, the signature of the person who performed the
inspection, maintenance, or repair work, and the serial number, or other identifier, of the power
press inspected, maintained, and repaired.

(ii) Under the directed component of the inspection program, the employer shall:

**29 CFR 1910.217(e)(1)(ii) (enhanced display)** **page 10 of 43**

**29 CFR 1910.217(e)(1)(iii)**

(A) Inspect and test each press on a regular basis at least once a week to determine the
condition of the clutch/brake mechanism, antirepeat feature, and single-stroke mechanism;

(B) Perform and complete necessary maintenance or repair, or both, on the clutch/brake
mechanism, antirepeat feature, and single-stroke mechanism before operating

 person who performed the

mechanism, antirepeat feature, and single-stroke mechanism before operating the press; and

(C) Maintain a certification record of each maintenance task performed under the directed
component of the inspection program that includes the date of the maintenance task, the
signature of the person who performed the maintenance task, and the serial number, or other
identifier, of the power press maintained.

Note to paragraph (e)(1)(ii): Inspections of the clutch/brake mechanism, antirepeat

feature, and single-stroke mechanism conducted under the directed component of the

inspection program are exempt from the requirement to maintain certification records

[specified by paragraph (e)(1)(i)(C) of this section, but inspections of the clutch/brake](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/?#p-1910.217(e)(1)(i)(C))

mechanism, antirepeat feature, and single-stroke mechanism conducted under the

general component of the inspection program are not exempt from this requirement.

(iii) Paragraph (e)(1)(ii) of this section does not apply to presses that comply with paragraphs

(b)(13) and (14) of this section.

(2) _Modification._ It shall be the responsibility of any person modifying a power press to furnish

instructions with the modification to establish new or changed guidelines for use and care of the
power press so modified.

(3) _Training of maintenance personnel._ It shall be the responsibility of the employer to insure the original

and continuing competence of personnel caring for, inspecting, and maintaining power presses.

(f) _Operation of power presses_ —

(2) _Instruction to operators._ The employer shall train and instruct the operator in the safe method of work

before starting work on any operation covered by this section. The employer shall insure by
adequate supervision that correct operating procedures are being followed.

(3) _Work area._ The employer shall provide clearance between machines so that movement of one

operator will not interfere with the work of another. Ample room for cleaning machines, handling
material, work pieces, and scrap shall also be provided. All surrounding floors shall be kept in good
condition and free from obstructions, grease, oil, and water.

(4) _Overloading._ The employer shall operate his presses within the tonnage and attachment weight

ratings specified by the manufacturer.

**29 CFR 1910.217(f)(4) (enhanced display)** **page 11 of 43**

**29 CFR 1910.217(f)(4)**

**29 CFR 1910.217(f)(4) (enhanced display)** **page 12 of 43**

**29 CFR 1910.217(g)**

This table shows the distances that guards shall be positioned from the danger line in accordance with the
required openings.

(g) _Reports of injuries to employees operating mechanical power presses._

(1) The employer shall report, within 30 days of the occurrence, all point-of-operation injuries to

operators or other employees to either the Director of the Directorate of Standards and Guidance at
OSHA, U.S. Department of Labor, Washington, DC 20210 or electronically at _[http://www.osha.gov/pls/](http://www.osha.gov/pls/oshaweb/mechanical.html)_
_[oshaweb/mechanical.html;](http://www.osha.gov/pls/oshaweb/mechanical.html)_ or to the State Agency administering a plan approved by the Assistant
Secretary of Labor for Occupational Safety and Health.

(2) The report shall include the following information:

(i) Employer's name, address and location of the workplace (establishment).

(ii) Employee's name, injury sustained, and the task being performed (operation, set-up,

maintenance, or other).

(iii) Type of clutch used on the press (full revolution, part revolution, or direct drive).

(iv) Type of safeguard(s) being used (two hand control, two hand trip, pullouts, sweeps, or other). If

the safeguard is not described in this section, give a complete description.

(v) Cause of the accident (repeat of press, safeguard failure, removing stuck part or scrap, no

safeguard provided, no safeguard in use, or other).

(vi) Type of feeding (manual with hands in dies or with hands out of dies, semiautomatic,

automatic, or other).

(vii) Means used to actuate press stroke (foot trip, foot control, hand trip, hand control, or other).

(viii) Number of operators required for the operation and the number of operators provided with

controls and safeguards.

(h) _Presence sensing device initiation (PSDI)_ —

(1) _General._

(i) The requirements of paragraph (h) shall apply to all part revolution mechanical power presses

used in the PSDI mode of operation.

**29 CFR 1910.217(h)(1)(i) (enhanced display)** **page 13 of 43**

**29 CFR 1910.217(h)(1)(ii)**

(ii) The relevant requirements of paragraphs (a) through (g) of this section also shall apply to all

presses used in the PSDI mode of operation, whether or not cross referenced in this paragraph
(h). Such cross-referencing of specific requirements from paragraphs (a) through (g) of this
section is intended only to enhance convenience and understanding in relating to the new
provisions to the existing standard, and is not to be construed as limiting the applicability of
other provisions in paragraphs (a) through (g) of this section.

(iii) Full revolution mechanical power presses shall not be used in the PSDI mode of operation.

(iv) Mechanical power presses with a configuration which would allow a person to enter, pass

through, and become clear of the sensing field into the hazardous portion of the press shall not
be used in the PSDI mode of operation.

(v) The PSDI mode of operation shall be used only for normal production operations. Die-setting

and maintenance procedures shall comply with paragraphs (a) through (g) of this section, and
shall not be done in the PSDI mode.

(2) _Brake and clutch requirements._

(i) Presses with flexible steel band brakes or with mechanical linkage actuated brakes or clutches

shall not be used in the PSDI mode.

(ii) Brake systems on presses used in the PSDI mode shall have sufficient torque so that each

average value of stopping times (Ts) for stops initiated at approximately 45 degrees, 60
degrees, and 90 degrees, respectively, of crankshaft angular position, shall not be more than
125 percent of the average value of the stopping time at the top crankshaft position.
Compliance with this requirement shall be determined by using the heaviest upper die to be
used on the press, and operating at the fastest press speed if there is speed selection.

(iii) Where brake engagement and clutch release is effected by spring action, such spring(s) shall

operate in compression on a rod or within a hole or tube, and shall be of non-interleaving
design.

(3) _Pneumatic systems._

(i) Air valve and air pressure supply/control.

(A) The requirements of paragraphs (b)(7)(xiii), (b)(7)(xiv), (b)(10), (b)(12) and (c)(5)(iii) of this
section apply to the pneumatic systems of machines used in the PSDI mode.

(B) The air supply for pneumatic clutch/brake control valves shall incorporate a filter, an air
regulator, and, when necessary for proper operation, a lubricator.

(C) The air pressure supply for clutch/brake valves on machines used in the PSDI mode shall be
regulated to pressures less than or equal to the air pressure used when making the stop time
measurements required by paragraph (h)(2)(ii) of this section.

(ii) Air counterbalance systems.

(A) Where presses that have slide counterbalance systems are used in the PSDI mode, the
counterbalance system shall also meet the requirements of paragraph (b)(

 Air valve and air pressure supply/control.

counterbalance system shall also meet the requirements of paragraph (b)(9) of this section.

**29 CFR 1910.217(h)(3)(ii) (enhanced display)** **page 14 of 43**

**29 CFR 1910.217(h)(4)**

(B) Counterbalances shall be adjusted in accordance with the press manufacturer's
recommendations to assure correct counterbalancing of the slide attachment (upper die)
weight for all operations performed on presses used in the PSDI mode. The adjustments shall
be made before performing the stopping time measurements required by paragraphs (h)(2)(ii),
(h)(5)(iii), and (h)(9)(v) of this section.

(4) _Flywheels and bearings._ Presses whose designs incorporate flywheels running on journals on the

crankshaft or back shaft, or bull gears running on journals mounted on the crankshaft, shall be
inspected, lubricated, and maintained as provided in paragraph (h)(10) of this section to reduce the
possibility of unintended and uncontrolled press strokes caused by bearing seizure.

(5) _Brake monitoring._

(i) Presses operated in the PSDI mode shall be equipped with a brake monitor that meets the

requirements of paragraphs (b)(13) and (b)(14) of this section. In addition, the brake monitor
shall be adjusted during installation certification to prevent successive stroking of the press if
increases in stopping time cause an increase in the safety distance above that required by
paragraph (h)(9)(v) of this section.

(ii) Once the PSDI safety system has been certified/validated, adjustment of the brake monitor

shall not be done without prior approval of the validation organization for both the brake
monitor adjustment and the corresponding adjustment of the safety distance. The validation
organization shall in its installation validation, state that in what circumstances, if any, the
employer has advance approval for adjustment, when prior oral approval is appropriate and
when prior approval must be in writing. The adjustment shall be done under the supervision of
an authorized person whose qualifications include knowledge of safety distance requirements
and experience with the brake system and its adjustment. When brake wear or other factors
extend press stopping time beyond the limit permitted by the brake monitor, adjustment, repair,
or maintenance shall be performed on the brake or other press system element that extends
the stopping time.

(iii) The brake monitor setting shall allow an increase of no more than 10 percent of the longest

stopping time for the press, or 10 milliseconds, whichever is longer, measured at the top of the

stroke.

(6) _Cycle control and control systems._

(i) The control system on presses used in the PSDI mode shall meet the applicable requirements

of paragraphs (b)(7), (b)(8), (b)(13), and (c)(5) of this section.

(ii) The control system shall incorporate a means of dynamically monitoring for decoupling of the

rotary position indicating mechanism drive from the crankshaft. This monitor shall stop slide
motion and prevent successive press strokes if decoupling occurs, or if the monitor itself fails.

(iii) The mode selection means of paragraph (b)(7)(iii) of this section shall have at least one

position for selection of the PSDI mode. Where more than one interruption of the light sensing
field is used in the initiation of a stroke, either the mode selection means must have one
position for each function, or a separate selection means shall be provided which becomes
operable when the PSDI mode is selected. Selection of PSDI mode and the number of
interruptions/withdrawals of the light sensing field required to initiate a press cycle shall be by
means capable of supervision by the employer.

**29 CFR 1910.217(h)(6)(iii) (enhanced display)** **page 15 of 43**

**29 CFR 1910.217(h)(6)(iv)**

(iv) A PSDI set-up/reset means shall be provided which requires an overt action by the operator, in

addition to PSDI mode selection, before operation of the press by means of PSDI can be

started.

(v) An indicator visible to the operator and readily seen by the employer shall be provided which

shall clearly indicate that the system is set-up for cycling in the PSDI mode.

(vi) The control system shall incorporate a timer to deactivate PSDI when the press does not stroke

within the period of time set by the timer. The timer shall be manually adjustable, to a maximum
time of 30 seconds. For any timer setting greater than 15 seconds, the adjustment shall be
made by the use of a special tool available only to authorized persons. Following a deactivation
of PSDI by the timer, the system shall make it necessary to reset the set-up/reset means in

order to reactivate the PSDI mode.

(vii) Reactivation of PSDI operation following deactivation of the PSDI mode from any other cause,

such as activation of the red color stop control required by paragraph (b)(7)(ii) of this section,
interruption of the presence sensing field, opening of an interlock, or reselection of the number
of sensing field interruptions/withdrawals required to cycle the press, shall require resetting of
the set-up/reset means.

(viii) The control system shall incorporate an automatic means to prevent initiation or continued

operation in the PSDI mode unless the press drive motor is energized in the forward direction of
crankshaft rotation.

(ix) The control design shall preclude any movement of the slide caused by operation of power on,

power off, or selector switches, or from checks for proper operations as required by paragraph
(h)(6)(xiv) of this section.

(x) All components and subsystems of the control system shall be designed to operate together to

provide total control system compliance with the requirements of this section.

(xi) Where there is more than one operator of a press used for PSDI, each operator shall be

protected by a separate, independently functioning, presence sensing device. The control
system shall require that each sensing field be interrupted the selected number of times prior
to initiating a stroke. Further, each operator shall be provided with a set-up/reset means that
meets the requirements of paragraph (h)(6) of this section, and which must be actuated to
initiate operation of the press in the PSDI mode.

(xii) [Reserved]

(xiii) The Control system shall incorporate interlocks for supplemental guards, if used, which will

prevent stroke initiation or will stop a stroke in progress if any supplemental guard fails or is

deactivated.

(xiv) The control system shall perform checks for proper operation of all cycle control logic element

switches and contacts at least once each cycle. Control elements shall be checked for correct
status after power “on” and before the initial PSDI stroke.

(xv) The control system shall have provisions for an “inch” operating means meeting the

requirements of paragraph (b)(7)(iv) of this section. Die-setting shall not be done in the PSDI
mode. Production shall not be done in the “inch” mode.

(xvi) The control system shall permit only a single stroke per initiation command.

**29 CFR 1910.217(h)(6)(xvi) (enhanced display)** **page 16 of 43**

**29 CFR 1910.217(h)(6)(xvii)**

(xvii) Controls with internally stored programs (e.g., mechanical, electro-mechanical, or electronic)

shall meet the requirements of paragraph (b)(13) of this section, and shall default to a
predetermined safe condition in the event of any single failure within the system.
Programmable controllers which meet the requirements for controls with internally stored
programs stated above shall be permitted only if all logic elements affecting the safety system
and point of operation safety are internally stored and protected in such a manner that they
cannot be altered or manipulated by the user to an unsafe condition.

(7) _Environmental requirements._ Control components shall be selected, constructed, and connected

together in such a way as to withstand expected operational and environmental stresses, at least
including those outlined in

217 (up to date as of 7/23/2025)**

including those outlined in appendix A. Such stresses shall not so affect the control system as to
cause unsafe operation.

(8) _Safety system._

(i) Mechanical power presses used in the PSDI mode shall be operated under the control of a

safety system which, in addition to meeting the applicable requirements of paragraphs (b)(13)
and (c)(5) and other applicable provisions of this section, shall function such that a single
failure or single operating error shall not cause injury to personnel from point of operation

hazards.

(ii) The safety system shall be designed, constructed, and arranged as an integral total system,

including all elements of the press, the controls, the safeguarding and any required
supplemental safeguarding, and their interfaces with the operator and that part of the
environment which has effect on the protection against point of operation hazards.

(9) _Safeguarding the point of operation._

(i) The point of operation of presses operated in the PSDI mode shall be safeguarded in

accordance with the requirements of paragraph (c) of this section, except that the safety
distance requirements of paragraph (h)(9)(v) of this section shall be used for PSDI operation.

(ii) (A) PSDI shall be implemented only by use of light curtain (photo-electric) presence sensing

devices which meet the requirements of paragraph (c)(3)(iii)( _c_ ) of this section unless the
requirements of the following paragraph have been met.

(B) Alternatives to photo-electric light curtains may be used for PSDI when the employer can
demonstrate, through tests and analysis by the employer or the manufacturer, that the
alternative is as safe as the photo-electric light curtain, that the alternative meets the
conditions of this section, has the same long term reliability as light curtains and can be
integrated into the entire safety system as provided for in this section. Prior to use, both the
employer and manufacturer must certify that these requirements and all the other applicable
requirements of this section are met and these certifications must be validated by an OSHArecognized third-party validation organization to meet these additional requirements and all the
other applicable requirements of paragraphs (a) through (h) and appendix A of this section.
Three months prior to the operation of any alternative system, the employer must notify the
OSHA Directorate of Safety Standards Programs of the name of the system to be installed, the
manufacturer and the OSHA-recognized third-party validation organization immediately. Upon
request, the employer must make available to that office all tests and analyses for OSHA

review.

**29 CFR 1910.217(h)(9)(ii) (enhanced display)** **page 17 of 43**

**29 CFR 1910.217(h)(9)(iii)**

(iii) Individual sensing fields of presence sensing devices used to initiate strokes in the PSDI mode

shall cover only one side of the press.

(iv) Light curtains used for PSDI operation shall have minimum object sensitivity not to exceed one

and one-fourth inches (31.75 mm). Where light curtain object sensitivity is user-adjustable,
either discretely or continuously, design features shall limit the minimum object sensitivity
adjustment not to exceed one and one-fourth inches (31.75 mm). Blanking of the sensing field
is not permitted.

(v) The safety distance (Ds) from the sensing field of the presence sensing device to the point of

operation shall be greater than or equal to the distance determined by the formula:

Ds = Hs × (Ts + Tp + Tr + 2Tm) + Dp

Where:

Ds = Minimum safety distance.

Hs = Hand speed constant of 63 inches per second (1.6 m/s).

Ts = Longest press stopping time, in seconds, computed by taking averages of multiple
measurements at each of three positions (45 degrees, 60 degrees, and 90 degrees) of crankshaft
angular position; the longest of the three averages is the stopping time to use. (Ts is defined as the
sum of the kinetic energy dissipation time plus the pneumatic/magnetic/hydraulic reaction time of
the clutch/brake operating mechanism(s).)

Tp = Longest presence sensing device response time, in seconds.

Tr = Longest response time, in seconds, of all interposing control elements between the presence
sensing device and the clutch/brake operating mechanism(s).

Tm = Increase in the press stopping time at the top of the stroke, in seconds, allowed by the brake
monitor for brake wear. The time increase allowed shall be limited to no more than 10 percent of the
longest press stopping time measured at the top of the stroke, or 10 milliseconds, whichever is
longer.

Dp = Penetration depth factor, required to provide for possible penetration through the presence
sensing field by fingers or hand before detection occurs. The penetration depth factor shall be
determined from Graph h-1 using the minimum object sensitivity size.

**29 CFR 1910.217(h)(9)(v) (enhanced display)** **page 18 of 43**

**29 CFR 1910.217(h)(9)(v)**

**29 CFR 1910.217(h)(9)(vi)**

(vi) The presence sensing device location shall either be set at each tool change and set-up to

provide at least the minimum safety distance, or fixed in location to provide a safety distance
greater than or equal to the minimum safety distance for all tooling set-ups which are to be
used on that press.

(vii) Where presence sensing device location is adjustable, adjustment shall require the use of a

special tool available only to authorized persons.

(viii) Supplemental safeguarding shall be used to protect all areas of access to the point of operation

which are unprotected by the PSDI presence sensing device. Such supplemental safeguarding
shall consist of either additional light curtain (photo-electric) presence sensing devices or other
types of guards which meet the requirements of paragraphs (c) and (h) of this section.

(A) Presence sensing devices used as supplemental safeguarding shall not initiate a press
stroke, and shall conform to the requirements of paragraph (c)(3)(iii) and other applicable
provisions of this section, except that the safety distance shall comply with paragraph (h)(9)(v)
of this section.

(B) Guards used as supplemental safeguarding shall conform to the design, construction and
application requirements of paragraph (c)(2) of this section, and shall be interlocked with the
press control to prevent press PSDI operation if the guard fails, is removed, or is out of position.

(ix) Barriers shall be fixed to the press frame or bolster to prevent personnel from passing

completely through the sensing field, where safety distance or press configuration is such that
personnel could pass through the PSDI presence sensing field and assume a position where
the point of operation could be accessed without detection by the PSDI presence sensing
device. As an alternative, supplemental presence sensing devices used only in the safeguard
mode may be provided. If used, these devices shall be located so as to detect all operator
locations and positions not detected by the PSDI sensing field, and shall prevent stroking or
stop a stroke in process when any supplemental sensing field(s) are interrupted.

(x) Hand tools. Where tools are used for feeding, removal of scrap, lubrication of parts, or removal

of parts that stick on the die in PSDI operations:

(A) The minimum diameter of the tool handle extension shall be greater than the minimum
object sensitivity of the presence sensing device(s) used to initiate press strokes; or

(B) The length of the hand tool shall be such as to ensure that the operator's hand will be
detected for any safety distance required by the press set-ups.

(10) _Inspection and maintenance._

(i) Any press equipped with presence sensing devices for use in PSDI, or for supplemental

safeguarding on presses used in the PSDI mode, shall be equipped with a test rod of diameter
specified by the presence sensing device manufacturer to represent the minimum object
sensitivity of the sensing field. Instructions for use

 prevent stroking or

sensitivity of the sensing field. Instructions for use of the test rod shall be noted on a label
affixed to the presence sensing device.

(ii) The following checks shall be made at the beginning of each shift and whenever a die change is

made.

**29 CFR 1910.217(h)(10)(ii) (enhanced display)** **page 20 of 43**

**29 CFR 1910.217(h)(10)(iii)**

(A) A check shall be performed using the test rod according to the presence sensing device
manufacturer's instructions to determine that the presence sensing device used for PSDI is
operational.

(B) The safety distance shall be checked for compliance with (h)(9)(v) of this section.

(C) A check shall be made to determine that all supplemental safeguarding is in place. Where
presence sensing devices are used for supplemental safeguarding, a check for proper
operation shall be performed using the test rod according to the presence sensing device
manufacturer's instructions.

(D) A check shall be made to assure that the barriers and/or supplemental presence sensing
devices required by paragraph (h)(9)(ix) of this section are operating properly.

(E) A system or visual check shall be made to verify correct counterbalance adjustment for die
weight according to the press manufacturer's instructions, when a press is equipped with a
slide counterbalance system.

(iii) When presses used in the PSDI mode have flywheel or bullgear running on crankshaft mounted

journals and bearings, or a flywheel mounted on back shaft journals and bearings, periodic
inspections following the press manufacturer's recommendations shall be made to ascertain
that bearings are in good working order, and that automatic lubrication systems for these
bearings (if automatic lubrication is provided) are supplying proper lubrication. On presses with
provision for manual lubrication of flywheel or bullgear bearings, lubrication shall be provided
according to the press manufacturer's recommendations.

(iv) Periodic inspections of clutch and brake mechanisms shall be performed to assure they are in

proper operating condition. The press manufacturer's recommendations shall be followed.

(v) When any check of the press, including those performed in accordance with the requirements

of paragraphs (h)(10)(ii), (iii) or (iv) of this section, reveals a condition of noncompliance,
improper adjustment, or failure, the press shall not be operated until the condition has been
corrected by adjustment, replacement, or repair.

(vi) It shall be the responsibility of the employer to ensure the competence of personnel caring for,

inspecting, and maintaining power presses equipped for PSDI operation, through initial and
periodic training.

(11) _Safety system certification/validation._

(i) Prior to the initial use of any mechanical press in the PSDI mode, two sets of certification and

validation are required:

(A) The design of the safety system required for the use of a press in the PSDI mode shall be
certified and validated prior to installation. The manufacturer's certification shall be validated
by an OSHA-recognized third-party validation organization to meet all applicable requirements
of paragraphs (a) through (h) and appendix A of this section.

(B) After a press has been equipped with a safety system whose design has been certified and
validated in accordance with paragraph (h)(11)(i) of this section, the safety system installation
shall be certified by the employer, and then shall be validated by an OSHA-recognized thirdparty validation organization to meet all applicable requirements of paragraphs (a) through (h)
and appendix A of this section.

**29 CFR 1910.217(h)(11)(i) (enhanced display)** **page 21 of 43**

**29 CFR 1910.217(h)(11)(ii)**

(ii) At least annually thereafter, the safety system on a mechanical power press used in the PSDI

mode shall be recertified by the employer and revalidated by an OSHA-recognized third-party
validation organization to meet all applicable requirements of paragraphs (a) through (h) and
appendix A of this section. Any press whose safety system has not been recertified and
revalidated within the preceding 12 months shall be removed from service in the PSDI mode
until the safety system is recertified and revalidated.

(iii) A label shall be affixed to the press as part of each installation certification/validation and the

most recent recertification/revalidation. The label shall indicate the press serial number, the
minimum safety distance (Ds) required by paragraph (h)(9)(v) of this section, the fulfillment of
design certification/validation, the employer's signed certification, the identification of the
OSHA-recognized third-party validation organization, its signed validation, and the date the
certification/validation and recertification/revalidation are issued.

(iv) Records of the installation certification and validation and the most recent recertification and

revalidation shall be maintained for each safety system equipped press by the employer as long
as the press is in use. The records shall include the manufacture and model number of each
component and subsystem, the calculations of the safety distance as required by paragraph
(h)(9)(v) of this section, and the stopping time measurements required by paragraph (h)(2)(ii)
of this section. The most recent records shall be made available to OSHA upon request.

(v) The employer shall notify the OSHA-recognized third-party validation organization within five

days whenever a component or a subsystem of the safety system fails or modifications are
made which may affect the safety of the system. The failure of a critical component shall
necessitate the removal of the safety system from service until it is recertified and revalidated,
except recertification by the employer without revalidation is permitted when a non-critical
component or subsystem is replaced by one of the same manufacture and design as the
original, or determined by the third-party validation organization to be equivalent by similarity
analysis, as set forth in appendix A.

(vi) The employer shall notify the OSHA-recognized third-party validation organization within five

days of the occurrence of any point of operation injury while a press is used in the PSDI mode.
This is in addition to the report of injury required by paragraph (g) of this section; however, a
copy of that report may be used for this purpose.

(12) _Die setting and work set-up._

(i) Die setting on presses used in the PSDI mode shall be performed in accordance with

paragraphs (d) and (h) of this section.

(ii) The PSDI mode shall not be used for die setting or set-up. An alternative manual cycle initiation

and control means shall be supplied for use in die setting which meets the requirements of
paragraph (b)(7) of this section.

(iii) Following a die change, the safety distance, the proper application of supplemental

safeguarding, and the slide counterbalance adjustment (if the press is equipped with a
counterbalance) shall be checked and maintained by authorized persons whose qualifications
include knowledge of the safety distance, supplemental safeguarding requirements, and the
manufacturer's specifications for counterbalance adjustment. Adjustment of the location of the
PSDI presence sensing device shall require use of a special tool available only to the authorized

persons.

**29 CFR 1910.217(h)(12)(iii) (enhanced display)** **page 22 of 43**

**29 CFR 1910.217(h)(13)**

(13) _Operator training._ (i) The operator training required by paragraph (f)(2) of this section shall be

provided to the employee before the employee initially operates the press and as needed to maintain
competence, but not less than annually thereafter. It shall include instruction relative to the following
items for presses used in the PSDI mode.

(A) The manufacturer's recommended test procedures for checking operation of the presence
sensing device. This shall include the use of the test rod required by paragraph (h)(10)(i) of this

section.

(B) The safety distance required.

(C) The operation, function and performance of the PSDI mode.

(D) The requirements for hand tools that may be used in the PSDI mode

43**

section.

(D) The requirements for hand tools that may be used in the PSDI mode.

(E) The severe consequences that can result if he or she attempts to circumvent or by-pass any of
the safeguard or operating functions of the PSDI system.

(ii) The employer shall certify that employees have been trained by preparing a certification record

which includes the identity of the person trained, the signature of the employer or the person
who conducted the training, and the date the training was completed. The certification record
shall be prepared at the completion of training and shall be maintained on file for the duration
of the employee's employment. The certification record shall be made available upon request to
the Assistant Secretary for Occupational Safety and Health.

# Appendix A to § 1910.217—Mandatory Requirements for Certification/ Validation of Safety Systems for Presence Sensing Device Initiation of Mechanical Power Presses

## Purpose

The purpose of the certification/validation of safety systems for presence sensing device initiation (PSDI) of
mechanical power presses is to ensure that the safety systems are designed, installed, and maintained in
accordance with all applicable requirements of 29 CFR 1910.217 (a) through (h) and this appendix A.

## General

The certification/validation process shall utilize an independent third-party validation organization recognized
by OSHA in accordance with the requirements specified in appendix C of this section.

While the employer is responsible for assuring that the certification/validation requirements in §
1910.217(h)(11) are fulfilled, the design certification of PSDI safety systems may be initiated by manufacturers,
employers, and/or their representatives. The term _manufacturers_ refers to the manufacturer of any of the
components of the safety system. An employer who assembles a PSDI safety system would be a manufacturer
as well as employer for purposes of this standard and appendix.

The certification/validation process includes two stages. For design certification, in the first stage, the
manufacturer (which can be an employer) certifies that the PSDI safety system meets the requirements of 29
CFR 1910.217 (a) through (h) and this appendix A, based on appropriate design criteria and tests. In the

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 23 of 43**

**29 CFR 1910.217(h)(13)(ii)**

second stage, the OSHA-recognized third-party validation organization validates that the PSDI safety system
meets the requirements of 29 CFR 1910.217 (a) through (h) and this appendix A and the manufacturer's
certification by reviewing the manufacturer's design and test data and performing any additional reviews
required by this standard or which it believes appropriate.

For installation certification/validation and annual recertification/revalidation, in the first stage the employer
certifies or recertifies that the employer is installing or utilizing a PSDI safety system validated as meeting the
design requirements of 29 CFR 1910.217 (a) through (h) and this appendix A by an OSHA-recognized thirdparty validation organization and that the installation, operation and maintenance meet the requirements of 29
CFR 1910.217 (a) through (h) and this appendix A. In the second stage, the OSHA-recognized third-party
validation organization validates or revalidates that the PSDI safety system installation meets the requirements
of 29 CFR 1910.217 (a) through (h) and this appendix A and the employer's certification, by reviewing that the
PSDI safety system has been certified; the employer's certification, designs and tests, if any; the installation,
operation, maintenance and training; and by performing any additional tests and reviews which the validation
organization believes is necessary.

## Summary

The certification/validation of safety systems for PSDI shall consider the press, controls, safeguards, operator,
and environment as an integrated system which shall comply with all of the requirements in 29 CFR 1910.217
(a) through (h) and this appendix A. The certification/validation process shall verify that the safety system
complies with the OSHA safety requirements as follows:

A. D ESIGN C ERTIFICATION /V ALIDATION

1. The major parts, components and subsystems used shall be defined by part number or serial number, as
appropriate, and by manufacturer to establish the configuration of the system.

2. The identified parts, components and subsystems shall be certified by the manufacturer to be able to
withstand the functional and operational environments of the PSDI safety system.

3. The total system design shall be certified by the manufacturer as complying with all requirements in 29 CFR
1910.217 (a) through (h) and this appendix A.

4. The third-party validation organization shall validate the manufacturer's certification under paragraphs 2 and

3.

B. I NSTALLATION C ERTIFICATION /V ALIDATION

1. The employer shall certify that the PSDI safety system has been design certified and validated, that the
installation meets the operational and environmental requirements specified by the manufacturer, that the
installation drawings are accurate, and that the installation meets the requirements of 29 CFR 1910.217 (a)
through (h) and this appendix A. (The operational and installation requirements of the PSDI safety system may
vary for different applications.)

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 24 of 43**

2. The third-party validation organization shall validate the employer's certifications that the PSDI safety
system is design certified and validated, that the installation meets the installation and environmental
requirements specified by the manufacturer, and that the installation meets the requirements of 29 CFR

C. R ECERTIFICATION /R EVALIDATION

1. The PSDI safety system shall remain under certification/validation for the shorter of one year or until the
system hardware is changed, modified or refurbished, or operating conditions are changed (including
environmental, application or facility changes), or a failure of a critical component has occurred.

2. Annually, or after a change specified in paragraph 1., the employer shall inspect and recertify the installation
as meeting the requirements set forth under B., Installation Certification/Validation.

3. The third-party validation organization, annually or after a change specified in paragraph 1., shall validate the
employer's certification that the requirements of paragraph B., Installation Certification/Validation have been

met.

(Note: Such changes in operational conditions as die changes or press relocations not

involving disassembly or revision to the safety system would not require recertification/

revalidation.)

## Certification/Validation Requirements

A. G ENERAL D ESIGN C ERTIFICATION /V ALIDATION R EQUIREMENTS

1. _Certification/Validation Program Requirements._ The manufacturer shall certify and the OSHA-recognized
third-party validation organization shall validate that:

(a) The design of components, subsystems, software and assemblies meets OSHA performance requirements
and are ready for the intended use; and

(b) The performance of combined subsystems meets OSHA's operational requirements.

2. _Certification/Validation Program Level of Risk Evaluation Requirements._ The manufacturer shall evaluate and
certify, and the OSHA-recognized third-party validation organization shall validate, the design and operation of
the safety system by determining conformance with the following:

a. The safety system shall have the ability to sustain a single failure or a single operating error and not cause
injury to personnel from point of operation hazards. Acceptable design features shall demonstrate, in the
following order or precedence, that:

(1) No single failure points may cause injury; or

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 25 of 43**

(2) Redundancy, and comparison and/or diagnostic checking, exist for the critical items that may cause injury,
and the electrical, electronic, electromechanical and mechanical parts and components are selected so that

 shall validate, the design and operation of

they can withstand operational and external environments. The safety factor and/or derated percentage shall
be specifically noted and complied with.

b. The manufacturer shall design, evaluate, test and certify, and the third-party validation organization shall
evaluate and validate, that the PSDI safety system meets appropriate requirements in the following areas.

(1) Environmental Limits

(a) Temperature

(b) Relative humidity

(c) Vibration

(d) Fluid compatability with other materials

(2) Design Limits

(a) Power requirements

(b) Power transient tolerances

(c) Compatability of materials used

(d) Material stress tolerances and limits

(e) Stability to long term power fluctuations

(f) Sensitivity to signal acquisition

(g) Repeatability of measured parameter without inadvertent initiation of a press stroke

(h) Operational life of components in cycles, hours, or both

(i) Electromagnetic tolerance to:

( _1_ ) Specific operational wave lengths; and

( _2_ ) Externally generated wave lengths

(3) _New Design Certification/Validation._ Design certification/validation for a new safety system, i.e., a new
design or new integration of specifically identified components and subsystems, would entail a single
certification/validation which would be applicable to all identical safety systems. It would not be necessary to
repeat the tests on individual safety systems of the same manufacture or design. Nor would it be necessary to

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 26 of 43**

repeat these tests in the case of modifications where determined by the manufacturer and validated by the
third-party validation organization to be equivalent by similarity analysis. Minor modifications not affecting the
safety of the system may be made by the manufacturer without revalidation.

Substantial modifications would require testing as a new safety system, as deemed necessary by the validation
organization.

B. A DDITIONAL D ETAILED D ESIGN C ERTIFICATION /V ALIDATION R EQUIREMENTS

1. _General._ The manufacturer or the manufacturer's representative shall certify to and submit to an OSHArecognized third-party validation organization the documentation necessary to demonstrate that the PSDI
safety system design is in full compliance with the requirements of 29 CFR 1910.217(a)-(h) and this appendix
A, as applicable, by means of analysis, tests, or combination of both, establishing that the following additional
certification/validation requirements are fulfilled.

2. _Reaction Times._ For the purpose of demonstrating compliance with the reaction time required by §
1910.217(h), the tests shall use the following definitions and requirements:

a. _Reaction time_ means the time, in seconds, it takes the signal, required to activate/deactivate the system, to
travel through the system, measured from the time of signal initiation to the time the function being measured
is completed.

b. _Full stop_ or _No movement of the slide or ram_ means when the crankshaft rotation has slowed to two or less
revolutions per minute, just before stopping completely.

c. _Function completion_ means for, electrical, electromechanical and electronic devices, when the circuit
produces a change of state in the output element of the device.

d. When the change of state is motion, the measurement shall be made at the completion of the motion.

e. The generation of the test signal introduced into the system for measuring reaction time shall be such that
the initiation time can be established with an error of less than 0.5 percent of the reaction time measured.

f. The instrument used to measure reaction time shall be calibrated to be accurate to within 0.001 second.

3. _Compliance with § 1910.217(h)(2)(ii)._ For compliance with these requirements, the average value of the
stopping time, Ts, shall be the arithmetic mean of at least 25 stops for each stop angle initiation measured with
the brake and/or clutch unused, 50 percent worn, and 90 percent worn. The recommendations of the brake
system manufacturer shall be used to simulate or estimate the brake wear. The manufacturer's recommended
minimum lining depth shall be identified and documented, and an evaluation made that the minimum depth will
not be exceeded before the next (annual) recertification/revalidation. A correlation of the brake and/or clutch
degradation based on the above tests and/or estimates shall be made and documented. The results shall
document the conditions under which the brake and/or clutch will and will not comply with the requirement.
Based upon this determination, a scale shall be developed to indicate the allowable 10 percent of the stopping
time at the top of the stroke for slide or ram overtravel due to brake wear. The scale shall be marked to indicate
that brake adjustment and/or replacement is required. The explanation and use of the scale shall be

documented.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 27 of 43**

The test specification and procedure shall be submitted to the validation organization for review and validation
prior to the test. The validation organization representative shall witness at least one set of tests.

4. _Compliance with §§ 1910.217(h)(5)(iii) and (h)(9)(v)._ Each reaction time required to calculate the Safety
Distance, including the brake monitor setting, shall be documented in separate reaction time tests. These tests
shall specify the acceptable tolerance band sufficient to assure that tolerance build-up will not render the
safety distance unsafe.

a. Integrated test of the press fully equipped to operate in the PSDI mode shall be conducted to establish the
total system reaction time.

b. Brakes which are the adjustable type shall be adjusted properly before the test.

5. _Compliance with § 1910.217(h)(2)(iii)._ a. Prior to conducting the brake system test required by paragraph
(h)(2)(ii), a visual check shall be made of the springs. The visual check shall include a determination that the
spring housing or rod does not show damage sufficient to degrade the structural integrity of the unit, and the
spring does not show any tendency to interleave.

b. Any detected broken or unserviceable springs shall be replaced before the test is conducted. The test shall
be considered successful if the stopping time remains within that which is determined by paragraph (h)(9)(v)
for the safety distance setting. If the increase in press stopping time exceeds the brake monitor setting limit
defined in paragraph (h)(5)(iii), the test shall be considered unsuccessful, and the cause of the excessive
stopping time shall be investigated. It shall be ascertained that the springs have not been broken and that they
are functioning properly.

6. _Compliance with § 1910.217(h)(7)._ a. Tests which are conducted by the manufacturers of electrical
components to establish stress, life, temperature and loading limits must be tests which are in compliance with
the provisions of the National Electrical Code.

b. Electrical and/or electronic cards or boards assembled with discreet components shall be considered a
subsystem and shall require separate testing that the subsystems do not degrade in any of the following

conditions:

(1) Ambient temperature variation from −20 °C to + 50 °C.

(2) Ambient relative humidity of 99 percent.

(3) Vibration of 45G for one millisecond per stroke when the item is to be mounted on the press frame.

(4) Electromagnetic interference at the same wavelengths used for the radiation sensing field, at the power line
frequency fundamental and harmonics, and also from outogenous radiation due to system switching.

(5) Electrical power supply variations of ±15 percent.

c. The manufacturer shall specify the test requirements and procedures from existing consensus tests in
compliance with the provisions of the National Electrical Code.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 28 of 43**

 °C to + 50 °C.

d. Tests designed by the manufacturer shall be made available upon request to the validation organization. The
validation organization representative shall witness at least one set of each of these tests.

7. _Compliance with § 1910.217(h)(9)(iv)._ a. The manufacturer shall design a test to demonstrate that the
prescribed minimum object sensitivity of the presence sensing device is met.

b. The test specifications and procedures shall be made available upon request to the validation organization.

8. _Compliance with § 1910.217(h)(9)(x)._ a. The manufacturer shall design a test(s) to establish the hand tool
extension diameters allowed for variations in minimum object sensitivity response.

b. The test(s) shall document the range of object diameter sizes which will produce both single and double
break conditions.

c. The test(s) specifications and procedures shall be made available upon request to the validation

9. _Integrated Tests Certification/Validation._ a. The manufacturer shall design a set of integrated tests to
demonstrate compliance with the following requirements:

Sections 1910.217(h)(6) (ii); (iii); (iv); (v); (vi); (vii); (viii); (ix); (xi); (xii); (xiii); (xiv); (xv); and (xvii).

b. The integrated test specifications and procedures shall be made available to the validation organization.

10. _Analysis._ a. The manufacturer shall submit to the validation organization the technical analysis such as
Hazard Analysis, Failure Mode and Effect Analysis, Stress Analysis, Component and Material Selection
Analysis, Fluid Compatability, and/or other analyses which may be necessary to demonstrate, compliance with
the following requirements:

Sections 1910.217(h)(8) (i) and (ii); (h)(2) (ii) and (iii); (h)(3)(i) (A) and (C), and (ii); (h)(5) (i), (ii) and (iii); (h)(6)
(i), (iii), (iv), (vi), (vii), (viii), (ix), (x), (xi), (xiii), (xiv), (xv), (xvi), and (xvii); (h)(7) (i) and (ii); (h)(9) (iv), (v), (viii), (ix)
and (x); (h)(10) (i) and (ii).

11. _Types of Tests Acceptable for Certification/Validation._ a. Test results obtained from development testing
may be used to certify/validate the design.

b. The test results shall provide the engineering data necessary to establish confidence that the hardware and
software will meet specifications, the manufacturing process has adequate quality control and the data
acquired was used to establish processes, procedures, and test levels supporting subsequent hardware design,
production, installation and maintenance.

12. _Validation for Design Certification/Validation._ If, after review of all documentation, tests, analyses,
manufacturer's certifications, and any additional tests which the third-party validation organization believes are
necessary, the third-party validation organization determines that the PSDI safety system is in full compliance
with the applicable requirements of 29 CFR 1910.217(a) through (h) and this appendix A, it shall validate the
manufacturer's certification that it so meets the stated requirements.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 29 of 43**

C. I NSTALLATION C ERTIFICATION /V ALIDATION R EQUIREMENTS

1. The employer shall evaluate and test the PSDI system installation, shall submit to the OSHA-recognized
third-party validation organization the necessary supporting documentation, and shall certify that the
requirements of § 1910.217(a) through (h) and this appendix A have been met and that the installation is

proper.

2. The OSHA-recognized third-party validation organization shall conduct tests, and/or review and evaluate the
employer's installation tests, documentation and representations. If it so determines, it shall validate the
employer's certification that the PSDI safety system is in full conformance with all requirements of 29 CFR
1910.217(a) through (h) and this appendix A.

D. R ECERTIFICATION /R EVALIDATION R EQUIREMENTS

1. A PSDI safety system which has received installation certification/validation shall undergo recertification/
revalidation the earlier of:

a. Each time the systems hardware is significantly changed, modified, or refurbished;

b. Each time the operational conditions are significantly changed (including environmental, application or
facility changes, but excluding such changes as die changes or press relocations not involving revision to the
safety system);

c. When a failure of a significant component has occurred or a change has been made which may affect safety;

or

d. When one year has elapsed since the installation certification/validation or the last recertification/
revalidation.

2. _Conduct or recertification/revalidation._ The employer shall evaluate and test the PSDI safety system
installation, shall submit to the OSHA-recognized third-party validation organization the necessary supporting
documentation, and shall recertify that the requirements of § 1910.217(a) through (h) and this appendix are
being met. The documentation shall include, but not be limited to, the following items:

a. Demonstration of a thorough inspection of the entire press and PSDI safety system to ascertain that the
installation, components and safeguarding have not been changed, modified or tampered with since the
installation certification/validation or last recertification/revalidation was made.

b. Demonstrations that such adjustments as may be needed (such as to the brake monitor setting) have been
accomplished with proper changes made in the records and on such notices as are located on the press and
safety system.

c. Demonstration that review has been made of the reports covering the design certification/validation, the
installation certification/validation, and all recertification/revalidations, in order to detect any degradation to an
unsafe condition, and that necessary changes have been made to restore the safety system to previous
certification/validation levels.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 30 of 43**

3. The OSHA-recognized third-party validation organization shall conduct tests, and/or review and evaluate the
employer's installation, tests, documentation and representations. If it so determines, it shall revalidate the
employer's recertification that the PSDI system is in full conformance with all requirements of 29 CFR

# Appendix B to § 1910.217—Nonmandatory Guidelines for Certification/ Validation of Safety Systems for Presence Sensing Device Initiation of Mechanical Power Presses

## Objectives

This appendix provides employers, manufacturers, and their representatives, with nonmandatory guidelines for
use in developing certification documents. Employers and manufacturers are encouraged to recommend other
approaches if there is a potential for improving safety and reducing cost. The guidelines apply to certification/
validation activity from design evaluation through the completion of the installation test and the annual
recertification/revalidation tests.

## General Guidelines

A. The certification/validation process should confirm that hazards identified by hazard analysis, (HA), failure
mode effect analysis (FMEA), and other system analyses have been eliminated by design or reduced to an
acceptable level through the use of appropriate design features, safety devices, warning devices, or special
procedures. The certification/validation process should also confirm that residual hazards identified by
operational analysis are addressed by warning, labeling safety instructions or other appropriate means.

B. The objective of the certification/validation program is to demonstrate and document that the system
satisfies specification and operational requirements for safe operations.

## Quality Control

The safety attributes of a certified/validated PSDI safety system are more likely to be maintained if the quality
of the system and its parts, components and subsystem is consistently controlled. Each manufacturer
supplying parts, components, subsystems, and assemblies

 from design evaluation through the completion of the installation test and the annual

supplying parts, components, subsystems, and assemblies needs to maintain the quality of the product, and
each employer needs to maintain the system in a non-degraded condition.

## Analysis Guidelines

A. Certification/validation of hardware design below the system level should be accomplished by test and/or
analysis.

B. Analytical methods may be used in lieu of, in combination with, or in support of tests to satisfy specification

C. Analyses may be used for certification/validation when existing data are available or when test is not
feasible.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 31 of 43**

D. Similarity analysis may be used in lieu of tests where it can be shown that the article is similar in design,
manufacturing process, and quality control to another article that was previously certified/validated in
accordance with equivalent or more stringent criteria. If previous design, history and application are considered
to be similar, but not equal to or more exacting than earlier experiences, the additional or partial certification/
validation tests should concentrate on the areas of changed or increased requirements.

## Analysis Reports

The analysis reports should identify: (1) The basis for the analysis; (2) the hardware or software items
analyzed; (3) conclusions; (4) safety factors; and (5) limit of the analysis. The assumptions made during the
analysis should be clearly stated and a description of the effects of these assumptions on the conclusions and

limits should be included.

Certification/validation by similarity analysis reports should identify, in addition to the above, application of the
part, component or subsystem for which certification/validation is being sought as well as data from previous
usage establishing adequacy of the item. Similarity analysis should not be accepted when the internal and
external stresses on the item being certified/validated are not defined.

Usage experience should also include failure data supporting adequacy of the design.

# Appendix C to § 1910.217—Mandatory Requirements for OSHA Recognition of Third-Party Validation Organizations for the PSDI Standard

This appendix prescribes mandatory requirements and procedures for OSHA recognition of third-party
validation organizations to validate employer and manufacturer certifications that their equipment and
practices meet the requirements of the PSDI standard. The scope of the appendix includes the three categories
of certification/validation required by the PSDI standard: Design Certification/Validation, Installation
Certification/Validation, and Annual Recertification/Revalidation.

If further detailing of these provisions will assist the validation organization or OSHA in this activity, this
detailing will be done through appropriate OSHA Program Directives.

## I. Procedure for OSHA Recognition of Validation Organizations

A. A PPLICATIONS

1. _Eligibility._ a. Any person or organization considering itself capable of conducting a PSDI-related third-party
validation function may apply for OSHA recognition.

b. However, in determining eligibility for a foreign-based third-party validation organization, OSHA shall take
into consideration whether there is reciprocity of treatment by the foreign government after consultation with
relevant U.S. government agencies.

2. _Content of application._ a. The application shall identify the scope of the validation activity for which the
applicant wishes to be recognized, based on one of the following alternatives:

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 32 of 43**

(1) Design Certification/Validation, Installation Certification/Validation, and Annual Recertification/
Revalidation;

(2) Design Certification/Validation only; or

(3) Installation/Certification/Validation and Annual Recertification/Revalidation.

b. The application shall provide information demonstrating that it and any validating laboratory utilized meet
the qualifications set forth in section II of this appendix.

c. The applicant shall provide information demonstrating that it and any validating laboratory utilized meet the
program requirements set forth in section III of this appendix.

d. The applicant shall identify the test methods it or the validating laboratory will use to test or judge the
components and operations of the PSDI safety system required to be tested by the PSDI standard and
appendix A, and shall specify the reasons the test methods are appropriate.

e. The applicant may include whatever enclosures, attachments, or exhibits the applicant deems appropriate.
The application need not be submitted on a Federal form.

f. The applicant shall certify that the information submitted is accurate.

3. _Filing office location._ The application shall be filed with: PSDI Certification/Validation Program, Office of
Variance Determination, Occupational Safety and Health Administration, U.S. Department of Labor, Room
N3653, 200 Constitution Avenue, NW., Washington, DC 20210.

4. _Amendments and withdrawals._ a. An application may be revised by an applicant at any time prior to the
completion of the final staff recommendation.

b. An application may be withdrawn by an applicant, without prejudice, at any time prior to the final decision by
the Assistant Secretary in paragraph I.B.8.b.(4) of this appendix.

B. R EVIEW AND D ECISION P ROCESS

1. _Acceptance and field inspection._ All applications submitted will be accepted by OSHA, and their receipt
acknowledged in writing. After receipt of an application, OSHA may request additional information if it believes
information relevant to the requirements for recognition have been omitted. OSHA may inspect the facilities of
the third-party validation organization and any validating laboratory, and while there shall review any additional
documentation underlying the application. A report shall be made of each field inspection.

2. _Requirements for recognition._ The requirements for OSHA recognition of a third-party validation organization
for the PSDI standard are that the program has fulfilled the requirements of section II of this appendix for
qualifications and of section III of this appendix for program requirements, and the program has identified
appropriate test and analysis methods to meet the requirements of the PSDI standard and appendix A.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 33 of 43**

3. _Preliminary approval._ If, after review of the application, any additional information, and the inspection report,
the applicant and any validating laboratory appear to have met the requirements for recognition, a written
recommendation shall be submitted by the responsible OSHA personnel to the Assistant Secretary to approve
the application with a supporting explanation.

4. _Preliminary disapproval._ If, after review of the application, additional information, and inspection report, the
applicant does not appear to have met the requirements for recognition, the Director of the PSDI certification/
validation program shall notify the applicant in writing, listing the specific requirements of this appendix which
the applicant has not met, and the reasons.

5. _Revision of application._ After receipt of a notification of preliminary disapproval, the applicant may submit a
revised application for further review by OSHA pursuant to subsection I.B. of this appendix or may request that
the original application be submitted to the Assistant Secretary with a statement of reasons supplied by the
applicant as to why the application should be approved.

6. _Preliminary decision by Assistant Secretary._ a. The Assistant Secretary, or a special designee for this purpose,
will make a preliminary decision whether the applicant has met the requirements for recognition based on the
completed application file and the written staff recommendation, as well as the statement of reasons by the
applicant if there is a recommendation of disapproval.

b. This preliminary decision will be sent to the applicant and subsequently published in the F EDERAL R EGISTER .

7. _Public review and comment period._ a. The F EDERAL R EGISTER notice of preliminary decision will provide a
period of not less than 60 calendar days for the written comments on the applicant's fulfillment of the
requirements for recognition. The application, supporting documents, staff recommendation, statement of
applicant's reasons, and any comments received, will be available for public inspection in the OSHA Docket

 statement of reasons supplied by the

Office.

b. If the preliminary decision is in favor of recognition, a member of the public, or if the preliminary decision is
against recognition, the applicant may request a public hearing by the close of the comment period, if it
supplies detailed reasons and evidence challenging the basis of the Assistant Secretary's preliminary decision
and justifying the need for a public hearing to bring out evidence which could not be effectively supplied
through written submissions.

8. _Final decision by Assistant Secretary_ —a. _Without hearing._ If there are no valid requests for a hearing, based on
the application, supporting documents, staff recommendation, evidence and public comment, the Assistant
Secretary shall issue the final decision (including reasons) of the Department of Labor on whether the
applicant has demonstrated by a preponderance of the evidence that it meets the requirements for recognition.

b. _After hearing._ If there is a valid request for a hearing pursuant to paragraph I.B.7.b. of this appendix, the
following procedures will be used:

(1) The Assistant Secretary will issue a notice of hearing before an administrative law judge of the Department
[of Labor pursuant to the rules specified in 29 CFR part 1905, subpart C.](https://www.ecfr.gov/on/2025-07-23/title-29/part-1905/subpart-C/)

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 34 of 43**

(2) After the hearing, pursuant to subpart C, the administrative law judge shall issue a decision (including
reasons) based on the application, the supporting documentation, the staff recommendation, the public
comments and the evidence submitted during the hearing (the record), stating whether it has been
demonstrated, based on a preponderance of evidence, that the applicant meets the requirements for
recognition. If no exceptions are filed, this is the final decision of the Department of Labor.

(3) Upon issuance of the decision, any party to the hearing may file exceptions within 20 days pursuant to
subpart C. If exceptions are filed, the administrative law judge shall forward the decision, exceptions and record
to the Assistant Secretary for the final decision on the application.

(4) The Assistant Secretary shall review the record, the decision by the administrative law judge, and the
exceptions. Based on this, the Assistant Secretary shall issue the final decision (including reasons) of the
Department of Labor stating whether the applicant has demonstrated by a preponderance of evidence that it
meets the requirements for recognition.

b. _Publication._ A notification of the final decision shall be published in the F EDERAL R EGISTER .

C. T ERMS AND C ONDITIONS OF R ECOGNITION, R ENEWAL AND R EVOCATION

1. The following terms and conditions shall be part of every recognition:

a. The recognition of any validation organization will be evidenced by a letter of recognition from OSHA. The
letter will provide the specific details of the scope of the OSHA recognition as well as any conditions imposed
by OSHA, including any Federal monitoring requirements.

b. The recognition of each validation organization will be valid for five years, unless terminated before or
renewed after the expiration of the period. The dates of the period of recognition will be stated in the
recognition letter.

c. The recognized validation organization shall continue to satisfy all the requirements of this appendix and the
letter of recognition during the period of recognition.

2. A recognized validation organization may change a test method of the PSDI safety system certification/
validation program by notifying the Assistant Secretary of the change, certifying that the revised method will be
at least as effective as the prior method, and providing the supporting data upon which its conclusions are

based.

3. A recognized validation organization may renew its recognition by filing a renewal request at the address in
paragraph I.A.3. of this appendix, above, not less than 180 calendar days, nor more than one year, before the
expiration date of its current recognition. When a recognized validation organization has filed such a renewal
request, its current recognition will not expire until a final decision has been made on the request. The renewal
request will be processed in accordance with subsection I.B. of this appendix, above, except that a reinspection
is not required but may be performed by OSHA. A hearing will be granted to an objecting member of the public
if evidence of failure to meet the requirements of this appendix is supplied to OSHA.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 35 of 43**

4. A recognized validation organization may apply to OSHA for an expansion of its current recognition to cover
other categories of PSDI certification/validation in addition to those included in the current recognition. The
application for expansion will be acted upon and processed by OSHA in accordance with subsection I.B. of this
appendix, subject to the possible reinspection exception. If the validation organization has been recognized for
more than one year, meets the requirements for expansion of recognition, and there is no evidence that the
recognized validation organization has not been following the requirements of this appendix and the letter of
recognition, an expansion will normally be granted. A hearing will be granted to an objecting member of the
public only if evidence of failure to meet the requirements of this appendix is supplied to OSHA.

5. A recognized validation organization may voluntarily terminate its recognition, either in its entirety or with
respect to any area covered in its recognition, by giving written notice to OSHA at any time. The written notice
shall indicate the termination date. A validation organization may not terminate its installation certification and
recertification validation functions earlier than either one year from the date of the written notice, or the date on
which another recognized validation organization is able to perform the validation of installation certification
and recertification.

6.a. OSHA may revoke its recognition of a validation organization if its program either has failed to continue to
satisfy the requirements of this appendix or its letter of recognition, has not been performing the validation
functions required by the PSDI standard and appendix A, or has misrepresented itself in its applications. Before
proposing to revoke recognition, the Agency will notify the recognized validation organization of the basis of
the proposed revocation and will allow rebuttal or correction of the alleged deficiencies. If the deficiencies are
not corrected, OSHA may revoke recognition, effective in 60 days, unless the validation organization requests a
hearing within that time.

b. If a hearing is requested, it shall be held before an administrative law judge of the Department of Labor
[pursuant to the rules specified in 29 CFR part 1905, subpart C.](https://www.ecfr.gov/on/2025-07-23/title-29/part-1905/subpart-C/)

c. The parties shall be OSHA and the recognized validation organization. The decision shall be made pursuant
to the procedures specified in paragraphs I.B.8.b.(2) through (4) of this appendix except that the burden of
proof shall be on OSHA to demonstrate by a preponderance of the evidence that the recognition should be
revoked because the validation organization either is not meeting the requirements for recognition, has not
been performing the validation functions required by the PSDI standard and appendix A, or has misrepresented
itself in its applications.

D. P ROVISIONS OF OSHA R ECOGNITION

Each recognized third-party validation organization and its validating laboratories shall:

1. Allow OSHA to conduct unscheduled reviews or on-site audits of it or the validating laboratories on matters
relevant to PSDI, and cooperate in the conduct of these reviews and audits;

2. Agree to terms and conditions established by OSHA in the grant of recognition on matters such as exchange
of data, submission of accident reports, and assistance in studies for improving PSDI or the certification/
validation process.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 36 of 43**

**29 CFR 1910.217 (up to date as of 

 should be

## II. Qualifications

The third-party validation organization, the validating laboratory, and the employees of each shall meet the
requirements set forth in this section of this appendix.

A. E XPERIENCE OF V ALIDATION O RGANIZATION

1. The third-party validation organization shall have legal authority to perform certification/validation activities.

2. The validation organization shall demonstrate competence and experience in either power press design,
manufacture or use, or testing, quality control or certification/validation of equipment comparable to power
presses and associated control systems.

3. The validation organization shall demonstrate a capability for selecting, reviewing, and/or validating
appropriate standards and test methods to be used for validating the certification of PSDI safety systems, as
well as for reviewing judgements on the safety of PSDI safety systems and their conformance with the

4. The validating organization may utilize the competence, experience, and capability of its employees to
demonstrate this competence, experience and capability.

B. I NDEPENDENCE OF V ALIDATION O RGANIZATION

1. The validation organization shall demonstrate that:

a. It is financially capable to conduct the work;

b. It is free of direct influence or control by manufacturers, suppliers, vendors, representatives of employers
and employees, and employer or employee organizations; and

c. Its employees are secure from discharge resulting from pressures from manufacturers, suppliers, vendors,
employers or employee representatives.

2. A validation organization may be considered independent even if it has ties with manufacturers, employers
or employee representatives if these ties are with at least two of these three groups; it has a board of directors
(or equivalent leadership responsible for the certification/validation activities) which includes representatives
of the three groups; and it has a binding commitment of funding for a period of three years or more.

C. V ALIDATING L ABORATORY

The validation organization's laboratory (which organizationally may be a part of the third-party validation
organization):

1. Shall have legal authority to perform the validation of certification;

2. Shall be free of operational control and influence of manufacturers, suppliers, vendors, employers, or
employee representatives that would impair its integrity of performance; and

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 37 of 43**

3. Shall not engage in the design, manufacture, sale, promotion, or use of the certified equipment.

D. F ACILITIES AND E QUIPMENT

The validation organization's validating laboratory shall have available all testing facilities and necessary test
and inspection equipment relevant to the validation of the certification of PSDI safety systems, installations
and operations.

E. P ERSONNEL

The validation organization and the validating laboratory shall be adequately staffed by personnel who are
qualified by technical training and/or experience to conduct the validation of the certification of PSDI safety

systems.

1. The validation organization shall assign overall responsibility for the validation of PSDI certification to an
Administrative Director. Minimum requirements for this position are a Bachelor's degree and five years
professional experience, at least one of which shall have been in responsible charge of a function in the areas
of power press design or manufacture or a broad range of power press use, or in the areas of testing, quality
control, or certification/validation of equipment comparable to power presses or their associated control

systems.

2. The validating laboratory, if a separate organization from the validation organization, shall assign technical
responsibility for the validation of PSDI certification to a Technical Director. Minimum requirements for this
position are a Bachelor's degree in a technical field and five years of professional experience, at least one of
which shall have been in responsible charge of a function in the area of testing, quality control or certification/
validation of equipment comparable to power presses or their associated control systems.

3. If the validation organization and the validating laboratory are the same organization, the administrative and
technical responsibilities may be combined in a single position, with minimum requirements as described in
E.1. and 2. for the combined position.

4. The validation organization and validating laboratory shall have adequate administrative and technical staffs
to conduct the validation of the certification of PSDI safety systems.

F. C ERTIFICATION /V ALIDATION M ARK OR L OGO

1. The validation organization or the validating laboratory shall own a registered certification/validation mark or
logo.

2. The mark or logo shall be suitable for incorporation into the label required by paragraph (h)(11)(iii) of this

section.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 38 of 43**

## III. Program Requirements

A. T EST AND C ERTIFICATION /V ALIDATION P ROCEDURES

1. The validation organization and/or validating laboratory shall have established written procedures for test
and certification/validation of PSDI safety systems. The procedures shall be based on pertinent OSHA
standards and test methods, or other publicly available standards and test methods generally recognized as
appropriate in the field, such as national consensus standards or published standards of professional societies
or trade associations.

2. The written procedures for test and certification/validation of PSDI systems, and the standards and test
methods on which they are based, shall be reproducible and be available to OSHA and to the public upon

request.

B. T EST R EPORTS

1. A test report shall be prepared for each PSDI safety system that is tested. The test report shall be signed by
a technical staff representative and the Technical Director.

2. The test report shall include the following:

a. Name of manufacturer and catalog or model number of each subsystem or major component.

b. Identification and description of test methods or procedures used. (This may be through reference to
published sources which describe the test methods or procedures used.)

c. Results of all tests performed.

d. All safety distance calculations.

3. A copy of the test report shall be maintained on file at the validation organization and/or validating
laboratory, and shall be available to OSHA upon request.

C. C ERTIFICATION /V ALIDATION R EPORTS

1. A certification/validation report shall be prepared for each PSDI safety system for which the certification is
validated. The certification/validation report shall be signed by the Administrative Director and the Technical

Director.

2. The certification/validation report shall include the following:

b. Results of all tests which serve as the basis for the certification.

c. All safety distance calculations.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 39 of 43**

d. Statement that the safety system conforms with all requirements of the PSDI standard and appendix A.

3. A copy of the certification/validation report shall be maintained on file at the validation organization and/or
validating laboratory, and shall be available to the public upon request.

4. A copy of the certification/validation report shall be submitted to OSHA within 30 days of its completion.

D. P UBLICATIONS S YSTEM

The validation organization shall make available upon request a list of PSDI safety systems which have been
certified/validated by the program.

                         E. F OLLOW UP A CTIVITIES

1. The validation organization or validating laboratory shall have a follow-up system for inspecting or testing
manufacturer's production of design certified/validated PSDI safety system components and subassemblies
where deemed appropriate by the validation organization.

2. The validation organization shall notify the appropriate product manufacturer(s) of any reports from
employers of point of operation injuries which occur while a press is operated in a PSDI mode.

F. R ECORDS

The validation organization or validating laboratory shall maintain a record of each certification/validation of a
PS

 organization and/or

F. R ECORDS

PSDI safety system, including manufacturer and/or employer certification documentation, test and working
data, test report, certification/validation report, any follow-up inspections or testing, and reports of equipment
failures, any reports of accidents involving the equipment, and any other pertinent information. These records
shall be available for inspection by OSHA and OSHA State Plan offices.

G. D ISPUTE R ESOLUTION P ROCEDURES

1. The validation organization shall have a reasonable written procedure for acknowledging and processing
appeals or complaints from program participants (manufacturers, producers, suppliers, vendors and
employers) as well as other interested parties (employees or their representatives, safety personnel,
government agencies, etc.), concerning certification or validation.

2. The validation organization may charge any complainant the reasonable charge for repeating tests needed
for the resolution of disputes.

# Appendix D to § 1910.217—Nonmandatory Supplementary Information

This appendix provides nonmandatory supplementary information and guidelines to assist in the
understanding and use of 29 CFR 1910.217(h) to allow presence sensing device initiation (PSDI) of mechanical
power presses. Although this appendix as such is not mandatory, it references sections and requirements
which are made mandatory by other parts of the PSDI standard and appendices.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 40 of 43**

## 1. General

OSHA intends that PSDI continue to be prohibited where present state-of-the-art technology will not allow it to
be done safely. Only _part revolution_ type mechanical power presses are approved for PSDI. Similarly, only
presses with a configuration such that a person's body cannot completely enter the bed area are approved for

PSDI.

## 2. Brake and Clutch

Flexible steel band brakes do not possess a long-term reliability against structural failure as compared to other
types of brakes, and therefore are not acceptable on presses used in the PSDI mode of operation.

Fast and consistent stopping times are important to safety for the PSDI mode of operation. Consistency of
braking action is enhanced by high brake torque. The requirement in paragraph (h)(2)(ii) defines a high torque
capability which should ensure fast and consistent stopping times.

Brake design parameters important to PSDI are high torque, low moment of inertia, low air volume (if
pneumatic) mechanisms, non-interleaving engagement springs, and structural integrity which is enhanced by
over-design. The requirement in paragrpah (h)(2)(iii) reduces the possibility of significantly increased stopping
time if a spring breaks.

As an added precaution to the requirements in paragraph (h)(2)(iii), brake adjustment locking means should be
secured. Where brake springs are externally accessible, lock nuts or other means may be provided to reduce
the possibility of backing off of the compression nut which holds the springs in place.

## 3. Pneumatic Systems

Elevated clutch/brake air pressure results in longer stopping time. The requirement in paragraph (h)(3)(i)( _C_ ) is
intended to prevent degradation in stoping speed from higher air pressure. Higher pressures may be permitted,
however, to increase clutch torque to free “jammed” dies, provided positive measures are provided to prevent
the higher pressure at other times.

## 4. Flywheels and Bearings

Lubrication of bearings is considered the single greatest deterrent to their failure. The manufacturer's
recommended procedures for maintenance and inspection should be closely followed.

## 5. Brake Monitoring

The approval of brake monitor adjustments, as required in paragraph (h)(5)(ii), is not considered a
_recertification,_ and does not necessarily involve an on-site inspection by a representative of the validation
organization. It is expected that the brake monitor adjustment normally could be evaluated on the basis of the
effect on the safety system certification/validation documentation retained by the validation organization.

Use of a brake monitor does not eliminate the need for periodic brake inspection and maintenance to reduce
the possibility of catastrophic failures.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 41 of 43**

## 6. Cycle Control and Control Systems

The PSDI set-up/reset means required by paragraph (h)(6)(iv) may be initiated by the actuation of a special
momentary pushbutton or by the actuation of a special momentary pushbutton and the initiation of a first
stroke with two hand controls.

It would normally be preferable to limit the adjustment of the time required in paragraph (h)(6)(vi) to a
maximum of 15 seconds. However, where an operator must do many operations outside the press, such as
lubricating, trimming, deburring, etc., a longer interval up to 30 seconds is permitted.

When a press is equipped for PSDI operation, it is recommended that the presence sensing device be active as
a guarding device in other production modes. This should enhance the reliability of the device and ensure that
it remains operable.

An acceptable method for interlocking supplemental guards as required by paragraph (h)(6)(xiii) would be to
incorporate the supplemental guard and the PSDI presence sensing device into a hinged arrangement in which
the alignment of the presence sensing device serves, in effect, as the interlock. If the supplemental guards are
moved, the presence sensing device would become misaligned and the press control would be deactivated. No
extra microswitches or interlocking sensors would be required.

Paragraph (h)(6)(xv) of the standard requires that the control system have provisions for an “inch” operating
means; that die-setting not be done in the PSDI mode; and that production not be done in the “inch” mode. It
should be noted that the sensing device would be by-passed in the “inch” mode. For that reason, the
prohibitions against die-setting in the PSDI mode, and against production in the “inch” mode are cited to
emphasize that “inch” operation is of reduced safety and is not compatible with PSDI or other production

modes.

## 7. Environmental Requirements

It is the intent of paragraph (h)(7) that control components be provided with inherent design protection against
operating stresses and environmental factors affecting safety and reliability.

## 8. Safety system

The safety system provision continues the concept of paragraph (b)(13) that the probability of two independent
failures in the length of time required to make one press cycle is so remote as to be a negligible risk factor in
the total array of equipment and human factors. The emphasis is on an integrated total system including all
elements affecting point of operation safety.

It should be noted that this does not require redundancy for press components such as structural elements,
clutch/brake mechanisms, plates, etc., for which adequate reliability may be achieved by proper design,
maintenance, and inspection.

## 9. Safeguarding the Point of Operation

The intent of paragraph (h)(9)(iii) is to prohibit use of mirrors to “bend” a single light curtain sensing field
around corners to cover more than one side of a press. This prohibition is needed to increase the reliability of
the presence sensing device in initiating a stroke only when the desired work motion has been completed.

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 42 of 43**

_Object sensitivity_ describes the capability of a presence sensing device to detect an object in the sensing field,
expressed as the linear measurement of the smallest interruption which can be detected at any point in the
field. Minimum object sensitivity describes the largest acceptable size of the interruption in the sensing field. A
minimum object sensitivity of one and one-fourth inches (31.75 mm) means that a one and one-fourth inch
(31.75 mm) diameter object will be continuously detected at all locations in

 to increase the reliability of

(31.75 mm) diameter object will be continuously detected at all locations in the sensing field.

In deriving the safety distance required in paragraph (h)(9)(v), all stopping time measurements should be made
with clutch/brake air pressure regulated to the press manufacturer's recommended value for full clutch torque
capability. The stopping time measurements should be made with the heaviest upper die that is planned for
use in the press. If the press has a slide counterbalance system, it is important that the counterbalance be
adjusted correctly for upper die weight according to the manufacturer's instructions. While the brake monitor
setting is based on the stopping time it actually measures, i.e., the normal stopping time at the top of the
stroke, it is important that the safety distance be computed from the longest stopping time measured at any of
the indicated three downstroke stopping positions listed in the explanation of Ts. The use in the formula of
twice the stopping time increase, Tm, allowed by the brake monitor for brake wear allows for greater increases
in the downstroke stopping time than occur in normal stopping time at the top of the stroke.

## 10. Inspection and Maintenance. [Reserved] 11. Safety System Certification/Validation

Mandatory requirements for certification/validation of the PSDI safety system are provided in appendix A and
appendix C to this standard. Nonmandatory supplementary information and guidelines relating to certification/
validation of the PSDI safety system are provided to appendix B to this standard.

_[[39 FR 23502, June 27, 1974, as amended at 39 FR 41846, Dec. 3, 1974; 40 FR 3982, Jan. 27, 1975; 43 FR 49750, Oct. 24, 1978; 45](https://www.federalregister.gov/citation/39-FR-23502)_
_[FR 8594, Feb. 8, 1980; 49 FR 18295, Apr. 30, 1984; 51 FR 34561, Sept. 29, 1986; 53 FR 8353, 8358 Mar. 14, 1988; 54 FR 24333,](https://www.federalregister.gov/citation/45-FR-8594)_
_[June 7, 1989; 61 FR 9240, Mar. 7, 1996; 69 FR 31882, June 8, 2004; 76 FR 80739, Dec. 27, 2011; 77 FR 46949, Aug. 7, 2012; 78 FR](https://www.federalregister.gov/citation/61-FR-9240)_
_[69550, Nov. 20, 2013]](https://www.federalregister.gov/citation/78-FR-69550)_

**29 CFR 1910.217(h)(13)(ii) (enhanced display)** **page 43 of 43**

**29 CFR 1910.218 (up to date as of 7/23/2025)**
**29 CFR 1910.218 (July 23, 2025)**
**Forging machines.**

**§ 1910.218 Forging machines.**

(1) _Use of lead._ The safety requirements of this subparagraph apply to lead casts or other use of lead in

the forge shop or die shop.

(i) Thermostatic control of heating elements shall be provided to maintain proper melting

temperature and prevent overheating.

(ii) Fixed or permanent lead pot installations shall be exhausted.

(iii) Portable units shall be used only in areas where good, general room ventilation is provided.

(iv) Personal protective equipment (gloves, goggles, aprons, and other items) shall be worn.

(v) A covered container shall be provided to store dross skimmings.

(vi) Equipment shall be kept clean, particularly from accumulations of yellow lead oxide.

(2) _Inspection and maintenance._ It shall be the responsibility of the employer to maintain all forge shop

equipment in a condition which will insure continued safe operation. This responsibility includes:

(i) Establishing periodic and regular maintenance safety checks and keeping certification records

of these inspections which include the date of inspection, the signature of the person who
performed the inspection and the serial number, or other identifier, for the forging machine
which was inspected.

(ii) Scheduling and recording the inspection of guards and point of operation protection devices at

frequent and regular intervals. Recording of inspections shall be in the form of a certification
record which includes the date the inspection was performed, the signature of the person who
performed the inspection and the serial number, or other identifier, of the equipment inspected.

(iii) Training personnel for the proper inspection and maintenance of forging machinery and

equipment.

(iv) All overhead parts shall be fastened or protected in such a manner that they will not fly off or

fall in event of failure.

**29 CFR 1910.218(a)(2)(iv) (enhanced display)** **page 1 of 5**

**29 CFR 1910.218(a)(3)**

(3) _Hammers and presses._

(i) All hammers shall be positioned or installed in such a manner that they remain on or are

anchored to foundations sufficient to support them according to applicable engineering
standards.

(ii) All presses shall be installed in such a manner that they remain where they are positioned or

they are anchored to foundations sufficient to support them according to applicable
engineering standards.

# **T ABLE O-11—S TRENGTH AND D IMENSIONS FOR W OOD R AM P ROPS**

_1_ _Actual dimension._

_2_ _Adapted from U.S. Department of Agriculture Technical Bulletin 479. Hardwoods recommended are_
_those whose ultimate crushing strengths in compression parallel to grain are 5,000 p.s.i. (pounds per_
_square inch) or greater._

_3_ _Slenderness ratio formula for short columns is L/d = 11, where L = length of timber in inches and d =_

_least dimension in inches; this ratio should not exceed 11._

(iii) Means shall be provided for disconnecting the power to the machine and for locking out or

rendering cycling controls inoperable.

(iv) The ram shall be blocked when dies are being changed or other work is being done on the

hammer. Blocks or wedges shall be made of material the strength and construction of which
should meet or exceed the specifications and dimensions shown in Table O-11.

(v) Tongs shall be of sufficient length to clear the body of the worker in case of kickback, and shall

not have sharp handle ends.

(vi) Oil swabs, or scale removers, or other devices to remove scale shall be provided. These devices

shall be long enough to enable a man to reach the full length of the die without placing his hand

or arm between the dies.

**29 CFR 1910.218(a)(3)(vi) (enhanced display)** **page 2 of 5**

**29 CFR 1910.218(a)(3)(vii)**

(vii) Material handling equipment shall be of adequate strength, size, and dimension to handle

diesetting operations safely.

(viii) A scale guard of substantial construction shall be provided at the back of every hammer, so

arranged as to stop flying scale.

(ix) A scale guard of substantial construction shall be provided at the back of every press, so

(b) _Hammers, general_ —

(1) _Keys._ Die keys and shims shall be made from a grade of material that will not unduly crack or

splinter.

(2) _Foot operated devices._ All foot operated devices (i.e., treadles, pedals, bars, valves, and switches)

shall be substantially and effectively protected from unintended operation.

(c) _Presses._ All manually operated valves and switches shall be clearly identified and readily accessible.

(d) _Power-driven hammers_ —

(1) _Safety cylinder head._ Every steam or airhammer shall have a safety cylinder head to act as a cushion

if the rod should break or pullout of the ram.

(2) _Shutoff valve._ Steam hammers shall be provided with a quick closing emergency valve in the

admission pipeline at a convenient location. This valve shall be closed and locked in the off position
while the hammer is being adjusted, repaired, or serviced, or when the dies are being changed.

(3) _Cylinder draining._ Steam hammers shall be provided with a means of cylinder draining, such as a

self-draining arrangement or a quick-acting drain cock.

(4) _Pressure pipes._ Steam or air piping shall conform to the specifications of American National

Standard ANSI B31.1.0-1967, Power Piping with Addenda issued before April 28, 1971, which is

(e) _Gravity hammers_ —

(1) _Air-lift hammers._

(i) Air-lift hammers

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 the

(i) Air-lift hammers shall have a safety cylinder head as required in paragraph (d)(1) of this section.

(ii) Air-lift hammers shall have an air shutoff valve as required in paragraph (d)(2) of this section.

(iii) Air-lift hammers shall be provided with two drain cocks: one on main head cylinder, and one on

clamp cylinder.

(iv) Air piping shall conform to the specifications of the ANSI B31.1.0-1967, Power Piping with

[Addenda issued before April 28, 1971, which is incorporated by reference as specified in §](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.6/)

[1910.6.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.6/)

(2) _Board drophammers._

(i) A suitable enclosure shall be provided to prevent damaged or detached boards from falling. The

board enclosure shall be securely fastened to the hammer.

(ii) All major assemblies and fittings which can loosen and fall shall be properly secured in place.

(f) _Forging presses_ —

**29 CFR 1910.218(f) (enhanced display)** **page 3 of 5**

**29 CFR 1910.218(f)(1)**

(1) _Mechanical forging presses._ When dies are being changed or maintenance is being performed on the

press, the following shall be accomplished:

(i) The power to the press shall be locked out.

(ii) The flywheel shall be at rest.

(iii) The ram shall be blocked with a material the strength of which shall meet or exceed the

specifications or dimensions shown in Table O-11.

(2) _Hydraulic forging presses._ When dies are being changed or maintenance is being performed on the

(i) The hydraulic pumps and power apparatus shall be locked out.

(ii) The ram shall be blocked with a material the strength of which shall meet or exceed the

(g) _Trimming presses_ —

(1) _Hot trimming presses._ The requirements of paragraph (f)(1) of this section shall also apply to hot

trimming presses.

(2) _Cold trimming presses._ [Cold trimming presses shall be safeguarded in accordance with §](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/?#p-1910.217(c))

[1910.217(c).](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.217/?#p-1910.217(c))

(h) _Upsetters_ —

(1) _General requirements._ All upsetters shall be installed so that they remain on their supporting

foundations.

(2) _Lockouts._ Upsetters shall be provided with a means for locking out the power at its entry point to the

machine and rendering its cycling controls inoperable.

(3) _Manually operated controls._ All manually operated valves and switches shall be clearly identified and

readily accessible.

(4) _Tongs._ Tongs shall be of sufficient length to clear the body of the worker in case of kickback, and

shall not have sharp handle ends.

(5) _Changing dies._ When dies are being changed, maintenance performed, or any work done on the

machine, the power to the upsetter shall be locked out, and the flywheel shall be at rest.

(i) _Other forging equipment_ —

(1) _Boltheading._ The provisions of paragraph (h) of this section shall apply to boltheading.

(2) _Rivet making._ The provisions of paragraph (h) of this section shall apply to rivet making.

(j) _Other forge facility equipment_ —

(1) _Billet shears._ A positive-type lockout device for disconnecting the power to the shear shall be

provided.

(2) _Saws._ Every saw shall be provided with a guard of not less than one-eighth inch sheet metal

positioned to stop flying sparks.

**29 CFR 1910.218(j)(2) (enhanced display)** **page 4 of 5**

**29 CFR 1910.218(j)(3)**

(3) _Conveyors._ Conveyor power transmission equipment shall be guarded in accordance with ANSI

B20.1-1957, Safety Code for Conveyors, Cableways, and Related Equipment, which is incorporated by

(4) _Shot blast._ The cleaning chamber shall have doors or guards to protect operators.

(5) _Grinding._ Personal protective equipment shall be used in grinding operations, and equipment shall be

used and maintained in accordance with ANSI B7.1-1970, Safety Code for the Use, Care, and
[Protection of Abrasive Wheels, which is incorporated by reference as specified in § 1910.6, and with](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.6/)
[§ 1910.215.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.215/)

_[[39 FR 23502, June 27, 1974, as amended at 49 FR 5323, Feb. 10, 1984; 51 FR 34561, Sept. 29, 1986; 61 FR 9240, Mar. 7, 1996]](https://www.federalregister.gov/citation/39-FR-23502)_

**29 CFR 1910.218(j)(5) (enhanced display)** **page 5 of 5**

**29 CFR 1910.219 (up to date as of 7/23/2025)**
**29 CFR 1910.219 (July 23, 2025)**
**Mechanical power-transmission apparatus.**

**§ 1910.219 Mechanical power-transmission apparatus.**

(1) This section covers all types and shapes of power-transmission belts, except the following when

operating at two hundred and fifty (250) feet per minute or less:

(i) Flat belts one (1) inch or less in width,

(ii) flat belts two (2) inches or less in width which are free from metal lacings or fasteners,

(iii) round belts one-half ( [1] ⁄2 ) inch or less in diameter; and

(iv) single strand V-belts, the width of which is thirteen thirty-seconds ( [13] ⁄32 ) inch or less.

(2) Vertical and inclined belts (paragraphs (e) (3) and (4) of this section) if not more than two and one
half (2 [1] ⁄2 ) inches wide and running at a speed of less than one thousand (1,000) feet per minute, and
if free from metal lacings or fastenings may be guarded with a nip-point belt and pulley guard.

(3) For the Textile Industry, because of the presence of excessive deposits of lint, which constitute a

serious fire hazard, the sides and face sections only of nip-point belt and pulley guards are required,
provided the guard shall extend at least six (6) inches beyond the rim of the pulley on the in-running
and off-running sides of the belt and at least two (2) inches away from the rim and face of the pulley
in all other directions.

(4) This section covers the principal features with which power transmission safeguards shall comply.

(b) _Prime-mover guards_ —

(1) _Flywheels._ Flywheels located so that any part is seven (7) feet or less above floor or platform shall be

guarded in accordance with the requirements of this subparagraph:

(i) With an enclosure of sheet, perforated, or expanded metal, or woven wire;

(ii) With guard rails placed not less than fifteen (15) inches nor more than twenty (20) inches from

rim. When flywheel extends into pit or is within 12 inches of floor, a standard toeboard shall
also be provided;

**29 CFR 1910.219(b)(1)(ii) (enhanced display)** **page 1 of 9**

**29 CFR 1910.219(b)(1)(iii)**

(iii) When the upper rim of flywheel protrudes through a working floor, it shall be entirely enclosed or

surrounded by a guardrail and toeboard.

(iv) For flywheels with smooth rims five (5) feet or less in diameter, where the preceding methods

cannot be applied, the following may be used: A disk attached to the flywheel in such manner
as to cover the spokes of the wheel on the exposed side and present a smooth surface and
edge, at the same time providing means for periodic inspection. An open space, not exceeding
four (4) inches in width, may be left between the outside edge of the disk and the rim of the
wheel if desired, to facilitate turning the wheel over. Where a disk is used, the keys or other
dangerous projections not covered by disk shall be cut off or covered. This subdivision does
not apply to flywheels with solid web centers.

(v) Adjustable guard to be used for starting engine or for running adjustment may be provided at

the flywheel of gas or oil engines. A slot opening for jack bar will be permitted.

(vi) Wherever flywheels are above working areas, guards shall be installed having sufficient strength

to hold the weight of the flywheel in the event of a shaft or wheel mounting failure.

(2) _Cranks and connecting rods._ Cranks and connecting rods, when exposed to contact, shall be guarded

in accordance with paragraphs (m) and (n) of this section, or by a guardrail as described in
paragraph (o)(5) of this section.

(3) _Tail rods or extension piston rods._ Tail rods or extension piston rods shall be guarded in accordance

with paragraphs (m) and (o) of this section, or by a guardrail on sides and end, with a clearance of
not less than fifteen (15) nor more than twenty (20) inches when rod is fully extended.

(c) _Shafting_ —

(1) _Installation._

(i) Each continuous line of shafting shall be secured in position against excessive endwise

movement.

(ii) Inclined and vertical shafts, particularly inclined idler shafts, shall be securely held in position

against endwise thrust.

(2) _Guarding horizontal shafting._

(i) All exposed parts of horizontal shafting seven (7) feet or less from floor or working platform,

excepting runways used exclusively for oiling, or running adjustments, shall be protected by a
stationary casing enclosing shafting completely or by a trough enclosing sides and top or sides
and bottom of shafting as location requires.

(ii) Shafting under bench machines shall be enclosed by a stationary casing, or by a trough at sides

and top or sides and bottom, as location requires. The sides of the trough shall come within at
least six (6) inches of the underside of table, or if shafting is located near floor within six (6)
inches of floor. In every case the sides of trough shall extend at least two (2) inches beyond the
shafting or protuberance.

(3) _Guarding vertical and inclined shafting._ Vertical and inclined shafting seven (7) feet or less from floor

or working platform, excepting maintenance runways, shall be enclosed with a stationary casing in
accordance with requirements of paragraphs (m) and (o) of this section.

(4) _Projecting shaft ends._

**29 CFR 1910.219(c)(4) (enhanced display)** **page 2 of 9**

**29 CFR 1910.219(c)(4)(i)**

(i) Projecting shaft ends shall

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, or if shafting is located near floor within six (6)

(i) Projecting shaft ends shall present a smooth edge and end and shall not project more than one
half the diameter of the shaft unless guarded by nonrotating caps or safety sleeves.

(ii) Unused keyways shall be filled up or covered.

(5) _Power-transmission apparatus located in basements._ All mechanical power transmission apparatus

located in basements, towers, and rooms used exclusively for power transmission equipment shall
be guarded in accordance with this section, except that the requirements for safeguarding belts,
pulleys, and shafting need not be complied with when the following requirements are met:

(i) The basement, tower, or room occupied by transmission equipment is locked against

unauthorized entrance.

(ii) The vertical clearance in passageways between the floor and power transmission beams,

ceiling, or any other objects, is not less than five feet six inches (5 ft. 6 in.).

(iii) The intensity of illumination conforms to the requirements of ANSI A11.1-1965 (R-1970), which

[is incorporated by reference as specified in § 1910.6.](https://www.ecfr.gov/on/2025-07-23/title-29/section-1910.6/)

(iv) [Reserved]

(v) The route followed by the oiler is protected in such manner as to prevent accident.

(d) _Pulleys_ —

(1) _Guarding._ Pulleys, any parts of which are seven (7) feet or less from the floor or working platform,

shall be guarded in accordance with the standards specified in paragraphs (m) and (o) of this
section. Pulleys serving as balance wheels (e.g., punch presses) on which the point of contact
between belt and pulley is more than six feet six inches (6 ft. 6 in.) from the floor or platform may be
guarded with a disk covering the spokes.

(2) _Location of pulleys._

(i) Unless the distance to the nearest fixed pulley, clutch, or hanger exceeds the width of the belt

used, a guide shall be provided to prevent the belt from leaving the pulley on the side where
insufficient clearance exists.

(3) _Broken pulleys._ Pulleys with cracks, or pieces broken out of rims, shall not be used.

(4) _Pulley speeds._ Pulleys intended to operate at rim speed in excess of manufacturers normal

recommendations shall be specially designed and carefully balanced for the speed at which they are

to operate.

(e) _Belt, rope, and chain drives_ —

(1) _Horizontal belts and ropes._

(i) Where both runs of horizontal belts are seven (7) feet or less from the floor level, the guard shall

extend to at least fifteen (15) inches above the belt or to a standard height except that where
both runs of a horizontal belt are 42 inches or less from the floor, the belt shall be fully enclosed
in accordance with paragraphs (m) and (o) of this section.

(ii) In powerplants or power-development rooms, a guardrail may be used in lieu of the guard

required by subdivision (i) of this subparagraph.

**29 CFR 1910.219(e)(1)(ii) (enhanced display)** **page 3 of 9**

**29 CFR 1910.219(e)(2)**

(2) _Overhead horizontal belts._

(i) Overhead horizontal belts, with lower parts seven (7) feet or less from the floor or platform,

shall be guarded on sides and bottom in accordance with paragraph (o)(3) of this section.

(ii) Horizontal overhead belts more than seven (7) feet above floor or platform shall be guarded for

their entire length under the following conditions:

( _a_ ) If located over passageways or work places and traveling 1,800 feet or more per minute.

( _b_ ) If center to center distance between pulleys is ten (10) feet or more.

( _c_ ) If belt is eight (8) inches or more in width.

(iii) Where the upper and lower runs of horizontal belts are so located that passage of persons

between them would be possible, the passage shall be either:

( _a_ ) Completely barred by a guardrail or other barrier in accordance with paragraphs (m) and

(o) of this section; or

( _b_ ) Where passage is regarded as necessary, there shall be a platform over the lower run

guarded on either side by a railing completely filled in with wire mesh or other filler, or by a
solid barrier. The upper run shall be so guarded as to prevent contact therewith either by
the worker or by objects carried by him. In powerplants only the lower run of the belt need
be guarded.

(iv) Overhead chain and link belt drives are governed by the same rules as overhead horizontal belts

and shall be guarded in the same manner as belts.

(3) _Vertical and inclined belts._

(i) Vertical and inclined belts shall be enclosed by a guard conforming to standards in paragraphs

(m) and (o) of this section.

(ii) All guards for inclined belts shall be arranged in such a manner that a minimum clearance of

seven (7) feet is maintained between belt and floor at any point outside of guard.

(4) _Vertical belts._ Vertical belts running over a lower pulley more than seven (7) feet above floor or

platform shall be guarded at the bottom in the same manner as horizontal overhead belts, if
conditions are as stated in paragraphs (e)(2)(ii) ( _a_ ) and ( _c_ ) of this section.

(5) _Cone-pulley belts._

(i) The cone belt and pulley shall be equipped with a belt shifter so constructed as to adequately

guard the nip point of the belt and pulley. If the frame of the belt shifter does not adequately
guard the nip point of the belt and pulley, the nip point shall be further protected by means of a
vertical guard placed in front of the pulley and extending at least to the top of the largest step
of the cone.

(ii) If the belt is of the endless type or laced with rawhide laces, and a belt shifter is not desired, the

belt will be considered guarded if the nip point of the belt and pulley is protected by a nip point
guard located in front of the cone extending at least to the top of the largest step of the cone,
and formed to show the contour of the cone in order to give the nip point of the belt and pulley
the maximum protection.

**29 CFR 1910.219(e)(5)(ii) (enhanced display)** **page 4 of 9**

**29 CFR 1910.219(e)(5)(iii)**

(iii) If the cone is located less than 3 feet from the floor or working platform, the cone pulley and

belt shall be guarded to a height of 3 feet regardless of whether the belt is endless or laced with

rawhide.

(6) _Belt tighteners._

(i) Suspended counterbalanced tighteners and all parts thereof shall be of substantial

construction and securely fastened; the bearings shall be securely capped. Means must be
provided to prevent tightener from falling, in case the belt breaks.

(ii) Where suspended counterweights are used and not guarded by location, they shall be so

encased as to prevent accident.

(f) _Gears, sprockets, and chains_ —

(1) _Gears._ Gears shall be guarded in accordance with one of the following methods:

(i) By a complete enclosure; or

(ii) By a standard guard as described in paragraph (o) of this section, at least seven (7) feet high

extending six (6) inches above the mesh point of the gears; or

(iii) By a band guard covering the face of gear and having flanges extended inward beyond the root

of the teeth on the exposed side or sides. Where any portion of the train of gears guarded by a
band guard is less than six (6) feet from the floor a disk guard or a complete enclosure to the
height of six (6) feet shall be required.

(2)

 the belt breaks.

(2) _Hand-operated gears._ Paragraph (f)(1) of this section does not apply to hand-operated gears used

only to adjust machine parts and which do not continue to move after hand power is removed.
However, the guarding of these gears is highly recommended.

(3) _Sprockets and chains._ All sprocket wheels and chains shall be enclosed unless they are more than

seven (7) feet above the floor or platform. Where the drive extends over other machine or working
areas, protection against falling shall be provided. This subparagraph does not apply to manually
operated sprockets.

(4) _Openings for oiling._ When frequent oiling must be done, openings with hinged or sliding self-closing

covers shall be provided. All points not readily accessible shall have oil feed tubes if lubricant is to
be added while machinery is in motion.

(g) _Guarding friction drives._ The driving point of all friction drives when exposed to contact shall be guarded,

all arm or spoke friction drives and all web friction drives with holes in the web shall be entirely enclosed,
and all projecting belts on friction drives where exposed to contact shall be guarded.

(h) _Keys, setscrews, and other projections._

(1) All projecting keys, setscrews, and other projections in revolving parts shall be removed or made

flush or guarded by metal cover. This subparagraph does not apply to keys or setscrews within gear
or sprocket casings or other enclosures, nor to keys, setscrews, or oilcups in hubs of pulleys less
than twenty (20) inches in diameter where they are within the plane of the rim of the pulley.

(2) It is recommended, however, that no projecting setscrews or oilcups be used in any revolving pulley

or part of machinery.

(i) _Collars and couplings_ —

**29 CFR 1910.219(i) (enhanced display)** **page 5 of 9**

**29 CFR 1910.219(i)(1)**

(1) _Collars._ All revolving collars, including split collars, shall be cylindrical, and screws or bolts used in

collars shall not project beyond the largest periphery of the collar.

(2) _Couplings._ Shaft couplings shall be so constructed as to present no hazard from bolts, nuts,

setscrews, or revolving surfaces. Bolts, nuts, and setscrews will, however, be permitted where they
are covered with safety sleeves or where they are used parallel with the shafting and are
countersunk or else do not extend beyond the flange of the coupling.

(j) _Bearings and facilities for oiling._ All drip cups and pans shall be securely fastened.

(k) _Guarding of clutches, cutoff couplings, and clutch pulleys_ —

(1) _Guards._ Clutches, cutoff couplings, or clutch pulleys having projecting parts, where such clutches are

located seven (7) feet or less above the floor or working platform, shall be enclosed by a stationary
guard constructed in accordance with this section. A “U” type guard is permissible.

(2) _Engine rooms._ In engine rooms a guardrail, preferably with toeboard, may be used instead of the

guard required by paragraph (k)(1) of this section, provided such a room is occupied only by engine
room attendants.

(l) _Belt shifters, clutches, shippers, poles, perches, and fasteners_ —

(1) _Belt shifters._

(i) Tight and loose pulleys on all new installations made on or after August 31, 1971, shall be

equipped with a permanent belt shifter provided with mechanical means to prevent belt from
creeping from loose to tight pulley. It is recommended that old installations be changed to
conform to this rule.

(ii) Belt shifter and clutch handles shall be rounded and be located as far as possible from danger

of accidental contact, but within easy reach of the operator. Where belt shifters are not directly
located over a machine or bench, the handles shall be cut off six feet six inches (6 ft. 6 in.)
above floor level.

(2) _Belt shippers and shipper poles._ The use of belt poles as substitutes for mechanical shifters is not

recommended.

(3) _Belt perches._ Where loose pulleys or idlers are not practicable, belt perches in form of brackets,

rollers, etc., shall be used to keep idle belts away from the shafts.

(4) _Belt fasteners._ Belts which of necessity must be shifted by hand and belts within seven (7) feet of the

floor or working platform which are not guarded in accordance with this section shall not be
fastened with metal in any case, nor with any other fastening which by construction or wear will

constitute an accident hazard.

(m) _Standard guards—general requirements_ —

(1) _Materials._

(i) Standard conditions shall be secured by the use of the following materials. Expanded metal,

perforated or solid sheet metal, wire mesh on a frame of angle iron, or iron pipe securely
fastened to floor or to frame of machine.

(ii) All metal should be free from burrs and sharp edges.

(2) _Methods of manufacture._

**29 CFR 1910.219(m)(2) (enhanced display)** **page 6 of 9**

**29 CFR 1910.219(m)(2)(i)**

(i) Expanded metal, sheet or perforated metal, and wire mesh shall be securely fastened to frame.

(n) [Reserved]

(o) _Approved materials_ —

(1) _Minimum requirements._ The materials and dimensions specified in this paragraph shall apply to all

guards, except horizontal overhead belts, rope, cable, or chain guards more than seven (7) feet above
floor, or platform.

(i) [Reserved]

( _a_ ) All guards shall be rigidly braced every three (3) feet or fractional part of their height to

some fixed part of machinery or building structure. Where guard is exposed to contact
with moving equipment additional strength may be necessary.

( _b_ ) [Reserved]

(2) _Wood guards._

(i) Wood guards may be used in the woodworking and chemical industries, in industries where the

presence of fumes or where manufacturing conditions would cause the rapid deterioration of
metal guards; also in construction work and in locations outdoors where extreme cold or
extreme heat make metal guards and railings undesirable. In all other industries, wood guards

shall not be used.

(3) _Guards for horizontal overhead belts._

(i) Guards for horizontal overhead belts shall run the entire length of the belt and follow the line of

the pulley to the ceiling or be carried to the nearest wall, thus enclosing the belt effectively.
Where belts are so located as to make it impracticable to carry the guard to wall or ceiling,
construction of guard shall be such as to enclose completely the top and bottom runs of belt
and the face of pulleys.

(iii) Suitable reinforcement shall be provided for the ceiling rafters or overhead floor beams, where

such is necessary, to sustain safely the weight and stress likely to be imposed by the guard.
The interior surface of all guards, by which is meant the surface of the guard with which a belt
will come in contact, shall be smooth and free from all projections of any character, except
where construction demands it; protruding shallow roundhead rivets may be used. Overhead
belt guards shall be at least one-quarter wider than belt which they protect, except that this
clearance need not in any case exceed six (6) inches on each side. Overhead rope drive and
block and roller-chain-drive guards shall be not less than six (6) inches wider than the drive on
each side. In overhead silent chain-drive guards where the chain is held from lateral
displacement on the sprockets, the side clearances required on drives of twenty (20) inch
centers or under shall be not less

 the ceiling rafters or overhead floor beams, where

centers or under shall be not less than one-fourth inch from the nearest moving chain part, and
on drives of over twenty (20) inch centers a minimum of one-half inch from the nearest moving
chain part.

**29 CFR 1910.219(o)(3)(iii) (enhanced display)** **page 7 of 9**

**29 CFR 1910.219(o)(4)**

(4) _Guards for horizontal overhead rope and chain drives._ Overhead-rope and chain-drive guard

construction shall conform to the rules for overhead-belt guard.

(5) _Guardrails and toeboards._

(i) Guardrail shall be forty-two (42) inches in height, with midrail between top rail and floor.

(ii) Posts shall be not more than eight (8) feet apart; they are to be permanent and substantial,

smooth, and free from protruding nails, bolts, and splinters. If made of pipe, the post shall be
one and one-fourth (1 [1] ⁄4 ) inches inside diameter, or larger. If made of metal shapes or bars,
their section shall be equal in strength to that of one and one-half (1 [1] ⁄2 ) by one and one-half
(1 [1] ⁄2 ) by three-sixteenths ( [3] ⁄16 ) inch angle iron. If made of wood, the posts shall be two by four
(2 × 4) inches or larger. The upper rail shall be two by four (2 × 4) inches, or two one by four (1 ×
4) strips, one at the top and one at the side of posts. The midrail may be one by four (1 × 4)
inches or more. Where panels are fitted with expanded metal or wire mesh the middle rails may
be omitted. Where guard is exposed to contact with moving equipment, additional strength may
be necessary.

(iii) Toeboards shall be four (4) inches or more in height, of wood, metal, or of metal grill not

exceeding one (1) inch mesh.

(p) _Care of equipment_ —

(1) _General._ All power-transmission equipment shall be inspected at intervals not exceeding 60 days and

be kept in good working condition at all times.

(2) _Shafting._

(i) Shafting shall be kept in alignment, free from rust and excess oil or grease.

(ii) Where explosives, explosive dusts, flammable vapors or flammable liquids exist, the hazard of

static sparks from shafting shall be carefully considered.

(3) _Bearings._ Bearings shall be kept in alignment and properly adjusted.

(4) _Hangers._ Hangers shall be inspected to make certain that all supporting bolts and screws are tight

and that supports of hanger boxes are adjusted properly.

(5) _Pulleys._

(i) Pulleys shall be kept in proper alignment to prevent belts from running off.

(6) _Care of belts._

(ii) Inspection shall be made of belts, lacings, and fasteners and such equipment kept in good

repair.

(7) _Lubrication._ The regular oilers shall wear tight-fitting clothing. Machinery shall be oiled when not in

motion, wherever possible.

**29 CFR 1910.219(p)(7) (enhanced display)** **page 8 of 9**

**29 CFR 1910.219(p)(7)**

_[[39 FR 23502, June 27, 1974, as amended at 43 FR 49750, Oct. 24, 1978; 43 FR 51760; Nov. 7, 1978; 49 FR 5323, Feb. 10, 1984; 61](https://www.federalregister.gov/citation/39-FR-23502)_
_[FR 9240, Mar. 7, 1996; 69 FR 31882, June 8, 2004]](https://www.federalregister.gov/citation/61-FR-9240)_

**29 CFR 1910.219(p)(7) (enhanced display)** **page 9 of 9**

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7/24/25, 10:30 AM OSHA Technical Manual (OTM) - Section IV: Chapter 4 | Occupational Safety and Health Administration

**[U.S. DEPARTMENT OF LABOR](https://www.dol.gov/)**

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#### **Occupational Safety and Health Administration**

## OSHA Technical Manual (OTM)

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## Section IV: Chapter 4

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# Industrial Robot Systems and Industrial Robot

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# System Safety

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**Table of Contents:**

I. Introduction

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II. Basic Components of Industrial Robot Systems

A. Manipulator

B. Control System

C. Teach Pendant

D. End-Efector
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III. Structure of Industrial Robots

A. Articulated Robots

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B. Selective Compliance Articulated Robot Arms

C. Cartesian Robots

D. Parallel Robots

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IV. Collaborative, Non-Collaborative, and Mobile Industrial Robot Applications

A. Collaborative Industrial Robot Applications

B. Non-Collaborative Industrial Robot Applications

C. Industrial Mobile Robots

V. Hazards Associated with Industrial Robot Applications

A. Robot Application Hazards

B. Robot Application Hazards by Process

C. Sources of Robot Application Hazards

D. Accidents: Past Studies

VI. Safety Considerations for Employers and Workers

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A. Safety Considerations for Robot Manufacturers

B. Safety Considerations for Robot System Integrators

C. Safety Considerations for Robot System Operators and Maintenance Workers

D. Safety Considerations during Planning of the Robot Application

E. General Safety Requirements

also the end-effector attached to the robot manipulator; computers, processors, and programs

(i.e., the control system); power sources; sensors; and, sequencing or monitoring communication

interfaces (i.e., input/output devices). See the Basic Components of Industrial Robot Systems

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section of this chapter for more information about these parts. See Appendix 1 Glossary for

Robots and Industrial Robot Systems for common acronyms and definitions used in the robotics

industry.

Industrial robot systems have many different uses such as for materials handling, assembly

operations, arc and resistance welding, machine-tool loading and unloading functions, painting,

spraying, inspecting, testing, packaging, labeling. The development and use of robot systems in

industry continues to advance with more and more companies finding more and more uses.

Advances in artificial intelligence 2 have also boosted the abilities and uses of robot systems,

especially in industrial applications.

The International Federation of Robotics (IFR) estimates that as of the end of 2018, there were

more than 2 million robots in workplaces worldwide (more than 40,000 installed in 2018 in the

United States alone), and the numbers continue to increase yearly (with an anticipated growth of

12 percent per year through 2022). 3 As robot systems appear in more workplaces, more workers

are exposed to them, including in industries that historically have not used robot systems, but

where technological advancements have introduced such systems (e.g. restaurants/food services,

agriculture, and delivery services).

This chapter is not an all-inclusive document. Robot systems other than those discussed in this

chapter may be found during inspections. In those cases, and when questions arise, consult with

the area office, regional office, or national office for assistance. The OSHA Health Response Team

(HRT) at Directorate of Technical Support and Emergency Management's Salt Lake Technical

Center is also available as needed.

### II. Basic Components of Industrial Robot Systems

Industrial robot systems have four major components:

B. Control system, or robot controller (includes interfaces for communication and input/output

(I/O); power is supplied to the controller)

C. Teach pendant

D. When an end-effector (such as a gripper, etc.) is added to the industrial robot, the result is an

industrial robot system (Figure IV-1).

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**Figure IV-1. Industrial Robot System: Major Components** (Source: OSHA/ NIOSH/ RIA Alliance)

The industrial robot system is then typically integrated with additional equipment, such as

conveyors, elevators, worktables (with clamps – manual or automated), process equipment (e.g.,

welding, cutting, assembly, inspection) and other machines to comprise an industrial robot

application.

A. **Manipulator**

The robot's physical structure is essentially the manipulator. This manipulator is comprised of

a structural frame with provisions for supporting mechanical linkage and joints, guides,

actuators (linear or rotary), control valves, sensors, and communications within the

manipulator. The physical dimensions, reach, and payload (weight carrying ability) depend on

robot model and application. The application requirements determine the needed

specifications. These specifications can introduce hazards to workers who may be integrating,

operating, and/or maintaining the robot application. See the Hazards Associated with

Industrial Robot Applications section of this chapter for more about these hazards.

B. **Control System**

Industrial robot control systems, or robot controllers, consist of several parts, including a

power source, sensors, input signals from the sensors to a computer or microprocessor (wired

or wireless), programming functions, and output command signals back from the computer or

microprocessor to the manipulator and/or end-effectors (wired or wireless).

1. Power Sources

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Energy is provided to various robot sensors, actuators, and their controllers as electrical,

pneumatic, or hydraulic power. These power sources can be hazardous to workers

depending on the energy infeed(s) and/or the resulting energy produced (e.g. motion,

stored energy). Hazardous energy can exist in internal components such as capacitors,

springs, pressurized cylinders, and other energy sources. See the Hazards Associated with

The robot's drives are usually electrically powered. Selection of the robot system is usually

based upon application requirements. For example, pneumatic power (typically 80-90 psi

air) is often used for end-effectors, and hydraulic power can be used for associated

processes. Consideration should be given to potential hazards of fires from leaks if

flammable materials are used as the hydraulic fluid.

Electrically-powered robots are by far the most prevalent in industry. Either AC or DC

electrical power can be used to supply energy to electromechanical drives, sensors, and

the robot's respective control systems. Electrical motion control is superior compared to

pneumatic and hydraulic. In an emergency, an electrically-powered robot can be stopped

or powered down more safely and faster than those powered pneumatically or

hydraulically.

2. Sensors

Sensors are used in robot systems to sense the location of mechanical portions of the

manipulator and/or the end-effector, as well as to sense the location of objects exterior to

the robot. Advancements in robot systems and in artificial intelligence would not be

possible without advancements in sensor technology. Types of sensors available include

(but are not limited to):

Contact sensors, which require physical contact against an object. These include limit

switches, button switches, bumper switches, touch sensors, etc. These sensors are

easily implemented but require physical contact to actuate.

Light sensors, which detect changes in light. These sensors include photovoltaic

sensors and photoresistor sensors.

Optical sensors, which are camera-based.

Ultrasonic sensors, which emit ultrasonic pulses, that when contacting an object,

bounce the signal back to the sensor.

Proximity sensors, which can detect an object within a given distance. This

functionality can be provided by light sensors, ultrasonic sensors, capacitive sensors,

inductive (magnetic) sensors, etc. These sensors will only actuate when an object is

sensed within a predetermined distance.

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Distance sensors, which can measure the distance the sensor is away from an object.

This technology is similar to proximity sensors, but rather than actuating only when an

object is within a certain distance, these

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resistor sensors.

object is within a certain distance, these provide an output of the distance an object is

from the sensor. These include laser range sensors, light sensors, ultrasonic sensors.

Tilt sensors, which measure the tilt of the robot, end-effector, or object.

Navigation sensors, which can detect the location of the robot, end-effector, or object

by use of a GPS or other localization technology.

Motion sensors (encoders, resolvers), which detect the motion of the robot or object.

Other sensors. Sensors to detect pressure, temperature, acceleration, gyro, inertial

measurement, humidity, or gas.

Sensors or sensor circuits that malfunction can create additional hazards to workers

during interventions to correct or replace parts. Therefore, sensors need to be properly

selected for the environment (long, reliable life) and be properly and routinely maintained.

See the Hazards Associated with Industrial Robot Applications section of this chapter for

more about these hazards.

3. Computers and Microprocessors

Either computers or embedded microprocessors are used for control of industrial robot

systems. These perform the required computational functions as well as interface with and

control associated sensors, end-effectors, and other associated peripheral equipment

(robot, system, and application). The control system performs the necessary sequencing

and memory functions for on-line sensing and integration of other equipment.

Programming of the controllers can be done on-line or optionally at remote off-line control

stations.

Self-diagnostic capability for troubleshooting and maintenance greatly reduces robot

system downtime. Some robot controllers have sufficient capacity, in terms of

computational ability, memory capacity, and input-output capability to serve also as

application controllers and may handle other machines and processes. Programming of

robot controllers and systems has not been standardized by the robotics industry, and

manufacturers often use their own proprietary programming languages or techniques,

which can require special training of the workers.

Advancements in artificial intelligence also make it possible for robot systems to adjust or

change programming functions based on sensory input changes.

These advancements are helping workers and industries in many ways, but can also

introduce additional hazards that need to be recognized and addressed. See the Hazards

Associated with Industrial Robot Applications section of the chapter for more about these

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hazards.

C. **Teach Pendant**

Most robot systems are set up for application by programming using a teach pendant (a

portable control device) while in manual mode. In manual mode, a trained worker

(programmer) typically uses a teach pendant to teach a robot its task(s) manually. During the

manual mode of operation, the programmer performing the teaching must have control of the

robot and associated equipment and should be familiar with the operations to be

programmed, system interfacing, and control functions of the robot system, application, and

other equipment. When systems and/or applications are large and complex, it could be

possible to improperly activate functions. Since the programmer doing the teaching can be

within the restricted space, such mistakes can result in injuries. See the Hazards Associated

with Industrial Robot Applications section of the chapter for more about the hazards.

D.
**End-effectors**

End-effectors are sometimes referred to as End-of-Arm Tooling (EOAT). Many industrial robot

systems use robots that can be equipped with different end-effectors as required for the

application. Common end-effectors include grippers, pickers, welding torches, cutting and

trimming tools, material removal tools, drilling tools, collision sensors, force-torque sensors,

inspection equipment, cameras, and adhesive dispensers.

Hundreds of end-effectors are available on the market. As with other components of the robot

system, end-effectors can introduce hazards to workers. See the

Industrial Robot Applications section of the chapter for more about these hazards.

### III. Structure of Industrial Robots

Industrial robots are available in a wide range of sizes, shapes, and structures for use in different

systems and applications. They can also have different numbers of axes or degrees of freedom.

These factors influence their working space (i.e., the volume of working or reaching space). Four

typical robot structures are shown in Figure IV-2 and discussed below.

A. **Articulating Robots**

Articulated robots are robots with at least three rotary joints. The number of joints on the

robot determines its range of motion, which in most cases is relatively free motion. These

robots can reach any point in their working space, very similar to the motion of a worker's

arm. These can be designed to handle light to heavy loads in industrial applications.

B. **SCARA Robots**

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Selective Compliance Assembly, or Articulated, Robot Arm (SCARA) robots include two parallel

rotary joints to provide compliance in a plane. That is, the arms are flexible in the XY axis, but

are rigid in the Z-axis. These robots are typically used in assembly operations.

C. **Cartesian Robots**

Cartesian robots are designed with joints and axes that allow the robot to operate in a

Cartesian coordinate system (i.e., either two or three dimensional movement). These are also

known as linear robots, XYZ robots, or gantry-style robots. They have a rigid structure that can

carry heavy loads and include pick and place, loading and unloading, material handling,

plotting, molding, and 3D printing.

D. **Parallel Robots**

Parallel robots are designed with chains, cables, rods, or other strands that connect to a single

point or tool. Each chain, cable, rod, or strand is controlled separately. These robots can be

used in a variety of applications including very high-speed pick and place, assembly, platform

movements, etc.

**Figure IV-2. Robot Structures** (Source: OSHA)

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### IV. Collaborative, Non-Collaborative, and Mobile Industrial Robot

Industrial robot systems and applications are further divided into collaborative and non

collaborative, based on the degree of interfacing capability with workers. A relatively new type of

industrial robot is the mobile robot, which can navigate throughout the workplace.

A. **Collaborative Industrial Robot Applications**

Collaborative industrial robot applications, 4 are those that are designed for direct interaction

with workers. 5 Although other definitions are found, which define robot applications that

interact with other robots as collaborative, this chapter uses the definition that requires **direct**

**interaction with workers** . Applications where robots interact with other robots are included

in the non-collaborative group of industrial robot applications.

B. **Non-Collaborative Industrial Robot Application**

Non-collaborative industrial robot applications include all other types and structures of robots

used in industry. They are designed without the need for direct interaction with workers and

are typically separated from workers by means of traditional machine safeguarding.

C. **Industrial Mobile Robots**

Industrial Mobile Robots (IMRs) are introduced here because they can be either collaborative

or non-collaborative. IMRs can navigate autonomously within their operating environment to

reach specified locations, and are designed to automate transport tasks. They are integrated

with other technologies that identify obstacles that can hinder their trajectory, and can use

obstacle avoidance and/or collision avoidance to prevent possible impacts.

In contrast with an industrial truck, an IMR is not intended for a seated or standing driver and

does not transport drivers or passengers.

Industrial robot systems can be mounted to an IMR, enabling a manipulator-based robot

system that is mobile and capable of moving from one application (or use) to another.

IMRs can be used as single units or in IMR fleets.

### V. Hazards Associated with Industrial Robot Applications

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 can be either collaborative

The hazards associated with industrial robot systems are best categorized based on the industrial

robot system's application, or the application for which it was designed, as well with the stage of

the robot application.

A. **Robot Application Hazards**

Hazards can be grouped into the following major types:

Impact, Collision, or other "Struck-by/Caught-between" Hazards

Unpredicted or unexpected movements, component malfunctions, or unexpected

program changes related to the robot manipulator, end-effector, or peripheral equipment

can result in contact injuries. An IMR could also drive into a worker, similar to struck

by/caught-between hazards posed by vehicles.

Crushing and Trapping Hazards

Similar to above, a worker's limb or other body part can be trapped within or between a

robot, end-effector, or workpiece and another robot, or other peripheral equipment,

resulting in potential crushing injuries.

Struck-by Projectiles Hazards

Similar to above, the breakdown of the end-effector, workpiece, peripheral equipment, or

its power source is a mechanical failure. Parts release, gripper mechanism failure, or end
effector power tool failure (e.g., grinding wheels, buffing wheels, deburring tools, power

screwdrivers, and nut runners) are also sources for mechanical failure hazards and injuries.

Breakdown or fatigue failure of the robot manipulator is unlikely when the robot is

maintained and used within its specifications.

Electrical Hazards

A robot system's power supply and cords can present arc flash, shock, fire, and/or other

electrical hazards and injuries.

Hydraulic Hazards

Ruptured hydraulic lines can create dangerous high-pressure cutting streams and injury

hazards from whipping hoses. Ruptures or leaks can also result in fires or worker

exposures if the fluids are flammable, toxic, or otherwise hazardous.

Ruptured or leaking hydraulic lines can also result in pressure losses that could result in

struck-by or crushing hazards if, for example, an arm drops on a worker.

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Pneumatic Hazards

Ruptured pneumatic lines can create injury hazards from whipping hoses.

Slipping, Tripping, and Falling Hazards

Slipping, tripping and falling hazards and injuries are common in almost any workplace.

Spills or leaks can result in slipping hazards. Equipment, power cables, and hoses can

present tripping and falling hazards. General housekeeping is an element that should be

maintained in all workplaces.

Environmental Hazards

Hazards of the environment in which the robot application is operating such as, but not

limited to: exposure to chemicals (including fumes, such as from welding), heat, hot

surfaces, dust, overhead hazards, equipment orientation hazards, radiation or other

potentially hazardous light, sparks, and noise.

B. **Robot Application Hazards by Process**

The hazards of industrial robot applications can occur during any of the stages or processes

associated with the typical lifecycle.

1. Manufacturing the Robot Systems and Applications

The hazards associated with the manufacturing of individual parts for use in robot systems

are specific to those industries. It is typically during the assembly, installation, and testing

of the robot applications where many of the above listed hazards are introduced. The

following hazards must be considered:

Impact, struck-by and caught between hazards, or struck-by projectiles hazards.

Assembly, installation, and testing are where workers are first exposed to the robot

application. These stages are when errors in design, assembly, and installation will

present themselves.

Electrical, hydraulic, or pneumatic hazards. Assembly and installation can also result in

termination or connection errors that may not be discovered until the initial testing.

Other listed hazards are also possible depending on where and how the assembly,

installation, and testing are being performed.

2. Integrating Robot Applications

The total functionality of the robot application often cannot be fully completed until the

robot system is integrated for use in company facilities. The completed robot application

should include any end-effectors, sensors, safeguarding, control equipment, or other

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fixtures needed for the robot application to perform its intended task(s). Some robot

manufacturers and some users (employers) also act as the integrator of their robots by

providing robot integration for specific applications.

This is often the first place where human interaction occurs in accordance with the robot's

application. As a result, any of the hazards listed above are possible during the final

assembly and integration process, and all must be considered.

3. Operating and Maintaining Robot Applications

The operational characteristics of robot applications can be significantly different from

other machines and equipment. Robots are capable of high-energy (fast and/or powerful)

movements through a large volume of space beyond the base dimensions of the robot (see

Figure IV-3). However, even low-energy robots that look harmless (i.e., robots with

payloads as low as 6-1/2 pounds or 3 kilograms) can be used in very dangerous

applications.

The pattern and initiation of movement of the robot application is predictable if the

item(s) being worked and the environment are held constant. However, it is typical for

application programs to be complex with some movements or actions happening

infrequently, such that they might be unexpected. Also, any change to the object being

worked (i.e., a physical model change) or the environment can affect the movements and

activities.

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process sensors could cause reactions that are unexpected, even if everything is working

as designed and validated.

C. **Sources of Robot Application Hazards**

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The list below describes some common source(s) of hazards, of which some or all can be

addressed by the proper design, testing, integration, operation, and maintenance of the robot

and the robot application.

1. Human Errors of Integration and/or Programming

A common misunderstanding with the robot is "direction of movement". The worker could

be looking at the robot and tell it to move left but it moves right from the perspective of

the worker. This situation is because the robot pose could be different from the worker's

perspective of the pose, e.g. robot mounted overhead.

Existing programming, interfacing peripheral equipment, or processing of live inputs

outputs by the robot controller or a peripheral controller can cause dangerous,

unpredicted movement or action. The incorrect activation of the teach pendant or control

panel is a frequent worker error. The most common problem, however, is over familiarity

with the application so that a worker places themselves in a hazardous position while

programming, integrating, troubleshooting, or performing maintenance.

2. Control Errors

Faults within the control system of the robot application, errors in software,

electromagnetic interference, and/or radio frequency interference are control errors or

faults. In addition, these can occur due to faults in the hydraulic, pneumatic, or electrical

sub-controls associated with the robot, robot system, or application.

While current robot systems are designed to minimize faults and to tolerate interference, it

can happen. For safety-related parts of the control system, which include all safety

functions, there are more stringent requirements for design, implementation, and testing

such that these attributes are assured to the extent of the functional safety performance.

3. Unauthorized Access

Entry into the restricted space is hazardous because the worker involved may not be

familiar with the hazards, the safeguards in place, or their activation status.

4. Mechanical Failures

Operating programs do not account for cumulative mechanical part failure

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 a hazardous position while

Operating programs do not account for cumulative mechanical part failure, resulting in

potentially faulty or unexpected operation occurring. Inspection and maintenance

activities should be performed in accordance with the manufacturer's requirements and in

accordance with industrial standards.

5. Time Pressure

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Often employers and sometimes the workers themselves can impose pressure to resume

operations as soon as possible. When workers feel rushed to resume operations as quickly

as possible, critical safety functions can be overlooked, maintenance steps can be missed,

shutdown and/or startup steps can be neglected, the position of other workers can be

unnoticed, and other critical steps could be overlooked resulting in hazards and injuries.

6. Environmental Sources

Exposure to water, heat, dust, combustible or flammable atmospheres, and/or other

environmental sources in the area can adversely affect robot operation or result in failure

of the robot application. If not designed for the environment, a robot's exposure to these

sources can result in electrical shock, fire, or explosion, and can increase the potential for

injury to workers in the area.

Electromagnetic or radio-frequency interference (transient signals) should be considered

to exert an undesirable influence on robot operation and increase the potential for injury

to any workers in the area. Solutions to environmental hazards should be documented

prior to equipment start-up. Current designs should also be sufficiently robust, and

consider that the environment can introduce unique and/or extreme conditions on

occasion.

7. Power System Failures or Malfunctions

Pneumatic, hydraulic, or electrical power sources that have malfunctioning control or

transmission elements in the robot power system can disrupt electrical signals to the

control and/or power source lines. Fire risks are increased by electrical overloads or by use

of flammable hydraulic oil. Electric shock and release of stored energy from accumulating

devices can also be hazardous to workers.

8. Improper Assembly and Installation

The design requirements, and layout of equipment, utilities, and facilities of a robot

application, if inadequately done per applicable safety codes and standards, can lead to

hazards and injuries.

D. **Accidents: Past Studies**

Studies in Sweden and Japan indicated that many robot accidents do not occur under normal

operating conditions, but instead during assembly, installation, and testing where workers are

first exposed to the robot application. These stages are when errors in design, assembly, and

installation will present themselves – during initial programming (and program touch-up or

refinement) and maintenance (repair, testing, setup, or adjustment). [6]

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During many of these activities, the workers can be within the robot application's reach, as

well as within hazard zones of other machines and/or components.

Examples of accidents have included the following:

1. A robot application functioned as integrated, but the motion was unexpected during a

programming sequence and struck a worker.

**Possible causes:**

The worker did not know the program or expected motions of the program.

The application did not have pre-determined task locations for programming such that

the worker was positioned with poor visibility.

The worker did not have a teach pendant with an enabling device while programming.

2. A worker entered a restricted space during automatic operation of a material handling and

robot application. The worker was pinned between the back end of the manipulator and a

post (called a "safety pole" in the report).

Inadequate perimeter guarding such that a worker could enter the safeguarded space

and not cause a protective stop.

The "safety pole" was not well positioned and introduced a crushing hazard.

3. A fellow worker accidentally tripped the power switch while another maintenance worker

was servicing an assembly robot. The manipulator struck the maintenance worker's hand.

Lockout/tagout was not applied or was not properly applied, which would have

prevented repowering the assembly robot.

The application did not meet applicable electrical safety standards because turning on

power is not to cause operation or movement of the robot application.

The power switch accessibility (location and ease of changing power state) was

inappropriate.

4. A service company worker cleaned the optical surface of a photobeam reflector (sensor)

while in automatic mode. Once cleaned, the sensor provided a signal for the robot system

to resume the programmed path in auto mode, and the worker was struck.

There is no servicing allowed during automatic operation unless there is safeguarding

that will prevent operation or cause a stop (and not allow restart).

Insufficient safeguarding was provided.

Lockout/tagout was not considered for the operation.

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### VI. Safety Considerations for Employers and Workers

In order to protect workers involved in robotic industries, employers should implement a

safeguarding strategy as follows, using a hierarchy of controls (Figure IV-4).

**Figure IV-4: Hierarchy of Controls** (Source: NIOSH)

It should be noted that the term, "hierarchy of controls" is not used in current robot

system/application industry standards. Instead of the hierarchy above, a "3-step approach" is

used as outlined in Figure IV-5.

With this 3-Step process, the safeguarding requirements are placed primarily on the machine

manufacturer and the robot application integrator (see Designer Impact and Integrator Impact in

the figure), and finally on the employer (see User, i.e. employer, Impact in the figure).

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**Figure IV-5: Hierarchy of Controls 3-Step Method** (Source: RIA)

While administrative controls and PPE are listed as least effective in the two hierarchy of controls

figures above (Figures IV-4 and IV-5), there can be situations where they are effective and best to

use (e.g., for thermal hazards and protective gear). The above User (employer) requirements

include the typical requirements for all machinery in workplaces, including:

1. Organizational measures (e.g. administrative controls)

Safe working procedures

Supervision

Permit-to-work systems

2. Provision and use of additional administrative safeguards

3. Use of PPE

4. Training

A. **Safety Considerations for Robot Manufacturers**

Employers and the workers involved in developing robots should understand, design, and

implement robot applications that comply with applicable safety regulations and standards.

The safety standard for robots is Part-1 and Part-2 of American National Standards Institute

(ANSI)/Robotic Industries Association (RIA) R15.06-2012, Industrial Robots and Robot Systems

– Safety Consideration. Among other things, ANSI/RIA R15.06-2012 requires that relevant, safe

operating and maintenance information be provided with the robot (Part 1) and the robot

system/application (Part 2).

B. **Safety Considerations for Robot System Integrators**

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Integrators and other workers involved in integrating robotic systems (to meet customer

needs) should comply with relevant regulations and standards. The safety standard for

integrating robot systems into robot applications is Part-2 of ANSI/RIA R15.06-2012. Other

standards can also apply depending on the specific application or task of the robot. For

compliance with ANSI/RIA R15.06-2012, and for collaborative application also, RIA Technical

Report (TR

OSHA Technical Manual (OTM) - Section IV_ Chapter 4 _ Occupational Safety and Health Administration.pdf_dpr_chunk_4

Report (TR) R15.606-2016, Robots and Robotic Devices – Safety Requirements for

Collaborative Robots, requires that integrators must conduct comprehensive hazard analyses

and risk assessments for each application, ideally with participation from the employer and

workers. For example, a company under contract to integrate systems for an employer should

explain the risk assessment process to the employer’s management and any workers who will

work with or near the robot applications. In addition, RIA TR R15.306-2016, Task-Based RA

Methodology, offers a risk assessment methodology that complies with the requirements of

ANSI/RIA R15.06-2012. See Appendix 2 Example RA.

Employers should ensure that the integrator has designed and implemented a safe robot

application. This requirement is typically accomplished by including the ANSI/RIA R15.06-2012

and RIA TR R15.606-2016, Collaborative Robot Safety, compliance requirements in the

Statement of Work (SOW) for a robotic integration contract. It must then be verified that

compliance has been achieved (usually during site acceptance).

C. **Safety Considerations for Robot System Operators and Maintenance Workers**

Employers and workers involved in operating and maintaining systems should understand

and have general working knowledge of robot system and application safety standards, as

well as specific understanding and knowledge of regulations and standards that apply to their

specific robotic application(s). The safety standard for robot systems and applications is Part-2

of ANSI/RIA R15.06-2012. Other standards can also apply depending on the robot application

or task. Some employers integrate robot systems themselves. When this situation is the case,

employers are acting as integrators and should meet the integration requirements, as

discussed above.

Site acceptance testing (SAT) confirms that the equipment performs as expected with the sites

utilities, services, machine interfaces and environmental characteristics. These tests should be

performed by the integrator and verified by the user. Employers should ensure that site

acceptance is performed before initial startup of a robot application. Then, even after the

application has undergone site acceptance, employers have a responsibility to maintain the

application in a compliant state. This can be done through periodic robot system performance

testing to verify that conditions of use are unchanged from the original installation. Stopping

ability performance, and the appropriateness of the application's safety distances, should also

be checked as well as safety function settings to ensure that they are properly set. The

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employer, or often companies, can be used to check and monitor the checksums 7 of safety

parameters, as this is a quick way to see if the safety settings have changed since the last

inspection.

Testing and verification services are often provided by third-party companies who must also

comply with the applicable requirements. ANSI/RIA R15.06-2012, lists requirements for

performance testing, how often to do them, and how to interpret the results of the tests.

RIA TR R15.706, User Responsibilities, provides user responsibilities guidance for robot

Maintaining records of the testing performed and the results is an effective way to track

robotic system safety. Users may also consult these records during safety and/or other checks

and inspections.

D. **Safety Considerations during Planning of the Robot Application**

For the planning stage, prior to the beginning of assembly, installation, integration, and

subsequent operation of a robot or robot application, the following should be considered:

1. Risk Assessment(s)

At each stage of development of the robot application (design, manufacturing, integrating,

operating, and maintaining), a risk assessment should be performed. There are different

system and worker safety requirements to be considered at each stage. The appropriate

level of safety and safeguarding determined by the risk assessment(s) should also be

applied. In addition, the risk assessment for each stage of development should be

documented for future reference. See the Risk Assessments (RAs) and Risk Reduction

Measures sections, as well as Appendix 2 Example RA.

2. Safeguarding Devices

Workers should be safeguarded from hazards associated with the restricted space through

the use of one or more safeguarding devices such as:

Presence-sensing safeguarding devices

Fixed barrier/perimeter guards (which prevent access and contact with moving parts)

Interlocked barrier guards

Limiting the space requirements of a robot application can also be accomplished with:

Mechanical limiting devices

Non-mechanical limiting devices, which can include soft-axis and space-limiting safety

function(s).

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3. Awareness Devices

Typical awareness devices include chain or rope barriers with supporting stanchions or

flashing lights, signs, whistles, and horns. They are used in conjunction with other

safeguarding devices. The effectiveness of these devices must be evaluated with the level

of risk for each hazard.

4. Safeguarding the Teacher (Programmer)

Special consideration must be given to the teacher or worker who is programming the

robot. In manual mode, a trained programmer programs the robot, typically using a

portable control station (a teach pendant). Robot speeds during these programming

sessions are at a reduced speed, less than 10 inches (250 mm) per second.

While in manual mode, the teacher must have control of the robot and associated

equipment. The teacher should be familiar with what needs to be programmed, system

interfacing, and control functions of the robot and other equipment in the application.

When systems are large and complex, it could be possible to improperly activate functions.

Since the teacher can be within the restricted space, mistakes can result in injuries.

Mistakes in programming can result in unintended movement or actions with similar

results. For this reason, robot speeds should be placed at a reduced speed of 10 inches per

second (250 mm/second) or less on any part of the application during teaching to decrease

the likelihood of contact and minimize the potential of injuries.

5. Operator Safeguards

The operator should be protected from all hazards during automatic operation. When in

automatic mode, all safeguarding devices should be activated, and at no time should the

operator have access to or be exposed to hazards. For additional operator safeguarding

information, see the ANSI/RIA R15.06-2012 Part 2 standard, Section 5.10.

6. Safeguarding Maintenance, Repair, and Troubleshooting Workers

Safeguarding maintenance, repair, and troubleshooting workers can be difficult to detail

because their job tasks are so varied. Troubleshooting faults or problems with the robot,

controller, tooling, or other associated equipment is part of these workers' job. Program

touchup is another task as are scheduled maintenance, adjustments of tooling, gauges,

recalibration, and much more.

[Power and other hazardous energy sources should be controlled in accordance with 29](https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.147)

[CFR 1910.147, The Control of Hazardous Energy (Lockout/Tagout), or 29 CFR 1910.333,](https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.147)

Selection and Use of Work Practices.

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When maintenance, repairs, and/or troubleshooting must be performed with power on

and with maintenance workers performing their work within the safeguarded space, the

robot should be in manual mode. Additional hazards can be present during this manual

mode because some of the robot application safeguards may not be active and

functioning as during automatic mode. To protect maintenance and repair workers,

safeguarding techniques and procedures as stated in the ANSI/RIA R15.06-2012 Part 2,

Sections 5.9

OSHA Technical Manual (OTM) - Section IV_ Chapter 4 _ Occupational Safety and Health Administration.pdf_dpr_chunk_5

0.333,](https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.147)

Sections 5.9.7, 5.10.2, 5.12.1, 7.2.7 are recommended.

7. Maintenance Activities

Maintenance can occur during the regular and periodic inspection program for a robot or

robot system. An inspection program should include, but not be limited to, the

recommendations of the robot manufacturer and manufacturer of other associated robot

system equipment such as conveyor mechanisms, parts feeders, end-effectors, fixtures,

gauges, sensors, and the like. These inspection and maintenance programs are essential

for minimizing the hazards from component malfunction, wear, breakage, changes

(documented and undocumented), and unexpected movements or actions by the robot or

other system equipment. To ensure proper maintenance, periodic maintenance and

inspections should be documented along with the identity and/or skill profile of workers

performing these tasks. Many computerized maintenance management systems (CMMSs)

are available that can perform these documentation functions.

8. Procedures

Specific procedures should be considered during the risk assessment(s). At a minimum,

procedures should be written for:

Activities that must be done in specific sequences or order.

Activities that create unique, unusual, or significant hazards (beyond the ordinary)

such as for collaborative tasks, startups, shutdowns, and emergency events.

Complex jobs, tasks, or activities such as equipment replacements or overhauls.

Procedures also should be considered for integrating, operating, and maintaining activities

and should be written. See the Risk Assessments (RAs) and Risk Reduction Measures

sections, as well as Appendix 2 Example RA.

In addition, workers should be trained to the procedures prior to job assignment(s), as

follows.

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9. Procedure and Safety Training

Workers who assemble, install, program, integrate, operate, maintain, or repair robots,

robot systems, or robot applications should receive adequate safety training, and they

should be able to demonstrate their competency to perform their jobs safely. A safety

training program should be developed and provided to the workers prior to their

assignment(s) on robot applications. Employers can refer to OSHA's homepage under

["Help and Resources", "Training", "OSHA Training Requirements and Resources".](https://www.osha.gov/training/library/)

E. **General Safety Requirements**

The proper selection of an effective robot safety system should be based upon risk

assessments of the robot application(s) considering its design, use, programming, operation,

and maintenance. See the Risk Assessments (RAs) and Risk Reduction Measures sections, as

well as Appendix 2 Example RA. Among the factors to be considered are:

Tasks that will be programmed

Start-up and command or programming procedures

Environmental conditions

Location and installation requirements

Possible worker errors

Scheduled and unscheduled maintenance

Possible robot and system malfunctions

Normal mode of operation and procedures

Emergency conditions and procedures

All worker functions and duties

Hazards typical of the specific robot application

Integrators, robot application operators, maintenance workers, and others working near robot

applications need to have an understanding not only of the nature and severity of the hazard,

but also of how these hazards are addressed and safeguarded. With this understanding,

integrators and workers are likely to choose controls and safeguards, and implement systems

that work well with their specific applications and processes.

Controls and safeguards selected during the risk assessment(s), including alternative risk

reduction methods selected (e.g., procedures, training, daily toolbox talks) for each stage or

process (e.g., assembling, integrating, operating, and maintaining), should be reviewed and

approved by employers, and should be fully implemented to protect workers.

To ensure safe operating controls and safeguards are adequately evaluated and selected for

industrial robots and robot applications, refer to ANSI, ANSI/RIA, and RIA Standards,which

contain specific information about robot system safety.

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Robot applications shall also comply with the applicable OSHA regulations, including those

listed in Section IX Applicable OSHA and Industry Standards Regarding Industrial Robot

System Safety.

A combination of controls and safeguarding should be used. Reliable systems and timely

maintenance, performed to industry standards and manufacturer recommendations, are

especially important, particularly if a robot application is operating in hazardous conditions or

handling hazardous materials/chemicals. The safeguarding devices should not themselves

constitute or act as a hazard or curtail necessary vision or viewing by workers. However,

sometimes a view can be obstructed by equipment and objects. If viewing is important, there

is an increased use of camera systems to enable a view yet keep a distance.

An effective control and safeguarding strategy protects not only operators and maintenance

workers, but also engineers, programmers, and any others who work on or with robot system

applications and/or could be exposed to hazards associated with an application.

F. **Additional Safety Requirements for Collaborative Robot Applications**

A collaborative robot application uses one or more of the following technologies while

operating in automatic mode:

8

Speed and Separation Monitoring (SSM)

A protective device (i.e., presence-sensing safeguarding device) is integrated with the robot

application such that intrusion of workers is detected. At a minimum, the robot application

stops during the intrusion and then operation can resume after all workers have left the

area and no further intrusion is detected. Even now, there are integrations that cause the

robot application to slow down upon initial intrusion detection, but if the worker(s) get

closer to another detection zone, the robot stops before contact by the robot application

can happen. For example, a robot may change to a lower speed based on how close it is to

a worker, or change direction to move away from workers. Using the same example as

above, the robot application's motion of the nozzles would slow if the worker's hand

approached within a certain distance and then stop completely before the hand can access

the hazard. It is important to note that when speed is being used for safety purposes, the

speed should have an associated safety function that monitors that the needed speed will

not be exceeded.

Hand-Guided Controls (HGC)

The robot system moves under a worker's direct control while in automatic mode and

executing its program. The worker controls the motion for the collaborative portion of the

task (similar to powered-assist tools/machinery). With HGC, a worker can guide a robot

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system to grasp a heavy box. The worker may then guide the robot system to place the box

onto a truck. The robot application in this case is doing all the heavy lifting, but will not

move without the worker physically directing it while the worker presses (or actuates) a

hold-to-run control device.

Power and Force Limited (PFL)

Physical contact between a robot application (i.e., robot, end-effector, and workpiece) and

a worker is expected and permitted in this mode. It is permitted when the forces and

pressures of contact are limited such that there will be no injury to the worker(s). PFL

robots limit the incurred forces and pressures when such contact is made from the robot

application to the worker.

There are two ways that PFL capability can be provided. One is by inherently safe design of

the robot (e.g., low energy potential due to very low payload and/or speed capability).

Another is by control means, which is described

OSHA Technical Manual (OTM) - Section IV_ Chapter 4 _ Occupational Safety and Health Administration.pdf_dpr_chunk_6

 a heavy box. The worker may then guide the robot system to place the box

Another is by control means, which is described as by safety functions using sensors and

safety-related parts of the control system (SRP/CS) (e.g., torque sensors on all joints to

safety logic that will slow or stop the robot). PFL robots that have the capability to limit

energy transfer have safety functions that are configured, so contact pressures and forces

do not exceed acceptable limits. The typical safety functions are speed limiting, force

limiting, and power limiting. Collaborative applications using PFL robots usually operate

at much lower speeds and payloads than they are physically capable. This is so that when

the robot contacts a worker, not only does the robot stop quickly, but also the robot is not

moving with enough energy to cause injury. [Note: robot contact with sensitive body

regions (e.g., the face, temples, and throat) is to be prevented or avoided per RIA TR

R15.606-2016.]

ISO 10218-2:2011, and RIA 15.06 Clause 5.11.5.5, requires that parameters of power, force,

and ergonomics pertaining to power and force limited robot systems are to be determined

by a risk assessment. Limits for quasi-static and transient contact must be evaluated as

part of the risk assessment, and by determining pressure and force threshold limit values

on the collaborative robot system utilizing Tables A.1 and A.2 in Annex A of RIA TR15.606.

SSM/PFL

It is common to see SSM combined with PFL for collaborative applications so that the

application can run at high speed when no workers are nearby, but then slow such that

contacts would be permissible according to PFL above.

Safety-rated Monitored Stop

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The concept of Safety-rated Monitored Stop (SMS) is included in ANSI/RIA R15.06-2012,

where it is referred to as a fourth type of collaborative technology. However, this mode is

not used alone but must be used in conjunction with SSM, HGC and/or PFL. This type of

stop is also called a monitored standstill and is a stop which is activated when the system

detects an intrusion. This type of stop is also called a "Category 2 Stop" according to

National Fire Protection Association (NFPA) 79-2017, Electrical Standard for Industrial

Machinery.

With SMS, power to the actuators is retained, which enables a quicker resumption of

operation and less wear on contactors and other hardware. For SMS to work, continued

detection of the worker(s) is requires in the safeguarded space (e.g., usually by motion

sensors). The robot application is permitted to automatically resume operation if assured

that no workers are within the space without the need for the worker(s) to press a restart

button. When an SMS is activated, the power to the robot system remains on, but the stop

is automatically held in a monitored standstill state. While in the standstill state, any

movement from within the safeguarded space will result in an immediate stop (similar to

an emergency stop).

### VII. Risk Assessments (RAs)

Preparation and implementation of thorough risk assessments (RAs) with workers are critical for

worker safety. RAs identify the hazards, potential exposures, potential risks, likelihood of risks,

risk avoidance, and the risk-reduction protective measures needed to safely control and/or

safeguard a robot application.

A provision of ANSI/RIA R15.06-2012 is that each robot application should have an RA performed

and documented prior to commissioning. However, the presence of an RA is not by itself sufficient

to ensure that the application meets the intended purpose of ANSI/RIA R15.06-2012, which is to

protect workers from injury. Refer to ANSI/RIA R15.06-2012 and to RIA TR R15.306-2016 for

guidance on the RA process.

It is the responsibility of integrator to ensure that an RA is completed and documented prior to

commissioning. It is also their responsibility to provide the results of the RA to the employer

(user). Further, it is recommended that the integrator and user include the affected workers in the

RA process. It is also recommended that RAs be completed for hazardous tasks within each stage

of the robot application process (i.e., assembly, integration, operation, and maintenance).

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Further, since it is the employer's responsibility under OSHA to maintain a safe work place for

their employees, the employer should require the integrator to provide and train the integrator's

RA to the employees prior to commissioning. If not provided by the integrator, the employer

should provide these functions.

A. **Robot Application RA General Process**

An effective RA process starts with including knowledgeable employees in the process.

1. A leader with expertise in process operations, the specific robotic application, and with

knowledge of the RA process should be selected.

2. Employees with specific or specialized expertize should also be invited to participated on

the team. Meetings of the RA team should be arranged so that all of the team members can

attend.

3. The team should identify all of the tasks to be performed as part of the job, including any

tasks that may be particularly hazardous or complicated. In order to keep RAs from

becoming overly long and/or burdensome to the team, splitting some jobs into separate

RAs may be advisable.

4. The specific tasks that are important to safely complete the job or that present hazards to

the workers should be listed on the RA. For example, "collecting tools" may not need to be

listed as a task on the RA.

5. Once the tasks have been listed, the RA team should identify the hazards of each task and

list each identified hazard next to the task(s) to which the hazard(s) apply.

6. Once the hazards have been identified, the team should consider the risks associated with

each task and hazard.

7. For each task/hazard, the most appropriate risk reduction techniques (controls and/or

safeguards) should be identified for implementation.

8. The team should welcome open discussion during preparation of the RA, and the final RA

should be documented in writing.

9. Each team member and the team leader should sign the RA as acceptable to them. If

signing presents a challenge, then the risk assessment document should include the

statement that agreement was reached.

[See Appendix 2 Example RA. See also OSHA's Job Hazard Analysis Guide.](https://www.osha.gov/sites/default/files/publications/osha3071.pdf)

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After the RA is completed and accepted by the team, it should be distributed and made

available to all affected employees, and to other affected employers. The documentation

should also be retained for future reference and reviewed if any changes are made to the

robot application.

B. **Robot Application RA Additional Requirements**

Similar applications in the same plant should each have their own individual RAs. Though the

equipment may be identical, the robot applications may be working on different parts or

processes, so the robot's path, pose, and possibly end-effector(s) may be different from

another one that appears otherwise identical. Additionally, their physical placement in the

facility may introduce unique hazards (e.g., a particular application may be next to a wall,

while another otherwise-identical application is next to a walkway).

RIA TR R15.306-2016 provides detailed steps for conducting a task-based RA for each robot

application. See Appendix 2 Example RA.

The Annexes of ANSI/RIA R15.06-2012 also include examples of hazards, risks, controls, and

safeguards that could apply to many common robot applications.

C. **RA Implementation

OSHA Technical Manual (OTM) - Section IV_ Chapter 4 _ Occupational Safety and Health Administration.pdf_dpr_chunk_7

 any changes are made to the

C. **RA Implementation, Validation, and Review**

As discussed above, RAs should periodically be reviewed and validated per ANSI/RIA R15.06

2012 once the required risk-reduction measures (e.g., controls, guards, protective devices,

safety procedures, training, signs, PPE) identified in the RA have been implemented. This will

ensure the measures are effective and the robot application safety functions are correct for

the application. It is not enough to simply trust the integrator or to perform a simple visual

inspection alone. A formal and thorough verification and validation is crucial to ensure all

requirements of the RA have been implemented and function as intended. Effective periodic

validations should include review of:

The documented RA(s)

Electrical and mechanical drawings

Manuals and training documentation

Safety-related parts of control system (SRP/CS) reviews, which include checking safety

function settings as well as other safeguards and their integration

In the case of PFL, contact event testing results (e.g., pressures and other forces)

Sensor operation testing

Keeping validation assessments and reviewing documentation provides several benefits,

including:

Allowing more efficient internal and external checks and inspections

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Ensuring that workers stay current on technical information by involving them in the

process

Driving continuous improvement for both safety and performance

### VIII. Risk Reduction Measures

As discussed above, comprehensive, task-based RAs will identify potential hazards and risks, and

will then prioritize risk reduction measures for each robot application in a workplace. A critical

part of the process is then to implement the risk reduction measures selected.

The risk reduction measures will vary based on industry, robot application type, process, and

work practices. Each risk reduction measure has its own strengths and limitations. Users

(employers) must be able to demonstrate that they understand the implemented measure(s). This

demonstration should extend to understanding what hazard is mitigated by which risk reduction

measure. Effective risk reduction, based on task-based RAs, will align with the standard hierarchy

of controls. In general, elimination, substitution, and engineering controls are preferred over

administrative controls and PPE.

Risk reduction measures can vary between collaborative and non-collaborative robot

applications, and between the different processes each robot application is performing. Some risk

reduction measures can be external to the robot application and will need to be verified visually,

validated, and documented that they are present and functioning correctly (e.g., interlocked

guards, light curtains, and laser scanners). Some risk reduction measures can be internal to the

robot itself and not readily apparent, requiring a view of the safety configuration on the display.

For example, some robots have built-in safety functions providing capabilities or software that are

not visible (e.g., safety functions for PFL). The configuration and settings of safety functions

should be verified by trained professionals.

A. **Non-Collaborative Robot Application Risk Reduction**

Risks are reduced by physically separating workers from robot applications during automatic

operation (in automatic mode). This risk reduction is achieved through safeguards such as

guards (fences, barriers), interlocked guards, and presence-sensing devices (e.g., light

curtains, safety mats, safety scanners, and safety vision systems) (Figure IV-6).

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**Figure IV-6: Enclosed Robot Application with an Overhead Observation Station** (Source: iStock)

In most circumstances, the robot application automatically achieves a safe state when a

worker enters the safeguarded space (Figure IV-7). However, there are some circumstances in

which a worker needs to perform a task that will require them to interact with a robot

application that is still active (e.g., programming or teaching the system). In an industrial

robot application, worker safety while within the safeguarded space is based on the

application being in manual mode while using an enabling device (often integrated into the

teach pendant) with the robot operating at a reduced speed. The application layout design

needs to provide adequate clearance. Because the enabling device is typically a 3-position

device, the worker must hold it in the center-ON position, otherwise the robot system's

motion will be inhibited. If the enabling device is interconnected with other equipment in the

application, then the other equipment will be similarly inhibited from operation.

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**Figure IV-7: Inside a Robot Application Safeguarded Space** (Source: iStock)

As already explained, enabling devices are used during manual mode, sometimes also known

as teach or T1 mode. In this mode, the robot system operates at a reduced speed, slow enough

for a person to avoid hazardous contact, but not greater than 10 inches/second

(250mm/second).

In addition to physical safeguards, protective devices, and other engineering controls, risk can

be further reduced through administrative controls such as:

1. Written robot application entry and exit procedures and training

2. Lockout/tagout standard operating procedures (SOPs) and training

3. Signs

PPE may include:

Hardhats

Hand protection for the intended use (sharp edges, heat, cold)

Safety glasses

Protective footwear

Hearing protection

Arc-flash protection

Respirators

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[OSHA's PPE standards (29 CFR 1910 Subpart I) require employers to provide workers with](https://www.osha.gov/laws-regs/regulations/standardnumber/1910)

appropriate PPE, and train them on how to properly don, use, doff, clean, maintain, and

dispose of such equipment.

Administrative controls and PPE should be implemented after attempts to design out (i.e.,

eliminate) the hazard and safeguards have been exhausted as required by the RA process.

Once all of the above risk reduction measures have been implemented, the question should

be asked, "Does this robot application have sufficient measures in place to adequately protect

workers?"

B. **Collaborative Robot Application Risk Reduction**

Collaborative robot applications operate with workers in shared, safeguarded spaces. The

following questions should be answered to determine if collaborative operation is necessary,

and to what extent:

Is the presence of a person integral to the application?

Do the robot and person have to share a workstation?

Do the robot system and person have to work on the same workpiece simultaneously?

Have task locations been identified and made known?

Is there safe access to the task location(s)?

Does the person need to be in physical contact with the robot, end-effector, or workpiece

while the robot system is in motion?

Due to the expectation of possible worker interaction, collaborative applications can require

specific risk reduction measures. Some key questions to ask before using a robot in a

collaborative application include:

1. Is the robot system and end-effector designed for use in a collaborative application?

2. Does the robot application have the needed safety functions?

3. Does this robot application have adequate risk reduction measures in place?

4. Has this collaborative robot application considered contact events?

These questions are expanded with further discussion, below.

1. Is this robot application designed for use as a collaborative application?

Typically, the manufacturer's manual will list the safety functions provided that can be

used to enable the implementation of collaborative application (e.g. safety functions that

limit speed, force, positions, and momentum which would be needed for PFL).

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 measures. Some key questions to ask before using a robot in a

Additionally, a third-party can certify the safety functions that are provided with a robot

and robot application. A robot application can use one or more safety functions to achieve

a SSM, HGC, PFL or SSM/PFL application, or a combination of these.

2. Does this robot application have the needed safety functions?

When a robot and end-effector are confirmed to be designed for collaborative use, the next

step in safe operation is confirming and using its safety functions. Additional safety

functions can also be provided in the overall robot control system.The appropriate safety

functions required for a given collaborative robot application depend on the potential

contact situations. For example, if the collaboration expects contact to occur with the

robot moving then the robot selected for use in this application should have PFL

capabilities. On the other hand, if the type of collaboration is intended to have no contact

while the robot is moving, then SSM or SSM/PFL capabilities can be used. Other safety

functions could also be required, including:

Protective stop

Force limiting

Speed limiting

Soft axis-limiting

Space limiting

Position limiting

These safety functions can have safety inputs and/or safety outputs. The specific safety

functions selected for a given collaborative application can differ according to the

collaborative technique(s) used in the application. That is, most of the safety functions

required for SSM are different than those for PFL. If a given application utilizes both

collaborative SSM and PFL techniques, then all of the safety functions above would be

required.

The required safety functions should be determined during the RA. Then, for each safety

function, the RA establishes the functional risk reduction measures for each function. See

Appendix 2 Example RA for more details about this process.

3. Does this robot application need additional risk reduction measures?

Beyond the active safety functions listed above, a collaborative robot application typically

requires both active and passive protective measures to provide added protection. These

may include:

Passive:

Rounded corners and edges on the end-effector and fixture

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Padding on sharp corners and edges

Eliminating projections on surfaces

Compliant elements such as springs that limit force

Smooth protective covers

Active:

Presence-sensing interlocked coverings around the robot manipulator and/or end
effector that initiate a protective stop

Similarly, as with non-collaborative robot applications, administrative controls and PPE

can add protection to further reduce risk to workers. Appropriate administrative controls

Written application entry and exit procedures and training

Lockout/tagout SOPs and training

Collaborative space delineation (i.e., where can the robot system and application

move?) [Delineation may be a diagram on the wall, painted lines on the floor, or

something else that conveys the information]

Safety signs that warn workers that this is a collaborative robot application [Signs

should be designed and mounted per OSHA 29 CFR 1910.145]

Post signs stating mandatory PPE [The RA should identify required PPE]

4. Have contact events been considered in collaborative robot applications?

Contact events can be either transient or quasi-static. Transient contact occurs when the

worker's movement is not restricted at the time of contact (e.g., the worker's body part can

move in free-space at the time of contact). Quasi-static contact occurs when a worker’s

body part is unable to move at the time of contact due to being restricted by a fixed object

(e.g., trapped or pinched between the robot and a fixture).

Contact events are usually expected in collaborative operations utilizing PFL safety

functions, but can occur during other collaborative operation types, especially during non

routine tasks. During the RA, determine the expected contact areas on the worker body,

possible contact types (i.e., transient or quasi-static), and the allowable force (see RIA TR

R15.606-2016) for that body part and type of contact. Measure the pressure and/or other

forces for each contact event prior to factory acceptance testing. Compare the measured

pressure/force with the allowable pressure/force. For example, if the worker leans into the

manipulator, would they be struck? If yes, then where on the body would the worker be

contacted (e.g., hand, shoulder, or thigh)?

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For each of these combinations (type of contact event and body region contacted), RIA TR

R15.606-2016 provides the permissible biomechanical limits for force and contact pressure

based on the location of the body being contacted. These limits are intended to avoid pain

during contact events. [Note: robot contact with sensitive body regions (e.g., the face,

temples, and throat) is to be prevented or avoided per RIA TR R15.606-2016.]

RIA TR R15.606-2016 also provides guidance on the allowable speed to stay within the

biomechanical limits during a transient contact event. See also RIA TR R15.806-2018,

Testing Methods for Power & Force Limited Collaborative Applications, for specific

guidance on how to measure pressure and forces. Then use this guidance to compare the

pressures and other forces to the permissible biomechanical limits. The integrator should

use the robot manufacturer's information (i.e., moving mass of the manipulator, speed

capabilities) combined with the payload mass of the end-effector and/or workpiece to

determine the maximum allowable speed for contact events.

For PFL applications, the integrator should confirm that contact events do not exceed the

force and pressure biomechanical limits. The user should periodically verify that the

safety-function settings are still valid (e.g., speed limit has not increased or workpiece

attributes changed). These measurements are performed by a competent worker and the

results documented. If a biomechanical limit is exceeded, safety function settings should

be adjusted by adding risk reduction measures and/or by modifying or replacing the

### IX. Applicable OSHA and Industry Standards Regarding Industrial

The following OSHA and industry standards are identified as most likely to be relevant to current

industrial robot applications. However, industrial robot applications continue to grow and, as a

result, other standards may apply.

A. **OSHA Standards**

[1. 29 CFR 1910 Subpart D – Walking Working Surfaces](https://www.osha.gov/laws-regs/regulations/standardnumber/1910#1910_Subpart_D)

[29 CFR 1910.22, General Requirements. Requires employers to adequately protect](https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.22)

walking and working surfaces from hazards such as slips, trips, falls, and other hazards.

[Related Information](https://www.osha.gov/laws-regs/interlinking/standards/1910.22)

[2. 29 CFR 1910 Subpart G – Occupational Health and Environmental Control](https://www.osha.gov/laws-regs/regulations/standardnumber/1910#1910_Subpart_G)

[29 CFR 1910.95, Occupational Noise Exposure. Requires that employers evaluate and](https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.95)

[Related Information](https://www.osha.gov/laws-regs/interlinking/standards/1910.95)
protect against the effects of noise exposure in the workplace.

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[3. 29 CFR 1910 Subpart I – Personal Protective Equipment. Requires that employers perform](https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.132)

a PPE

OSHA Technical Manual (OTM) - Section IV_ Chapter 4 _ Occupational Safety and Health Administration.pdf_dpr_chunk_9

/1910#1910_Subpart_G)

a PPE hazard assessment, establish PPE requirements as a result of the hazard

assessment, and use PPE as required.

[4. 29 CFR 1910 Subpart J - General Environmental Controls](https://www.osha.gov/laws-regs/regulations/standardnumber/1910#1910_Subpart_J)

[29 CFR 1910.147, The Control of Hazardous Energy (Lockout/Tagout). Requires the use](https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.147)

[1910.147(a)(2)(ii)(A) & (B). Related Information](https://www.osha.gov/laws-regs/interlinking/standards/1910.147)

[5. 29 CFR 1910 Subpart O - Machinery and Machine Guarding](https://www.osha.gov/laws-regs/regulations/standardnumber/1910#1910_Subpart_O)

[29 CFR 1910.211, Definitions. Related Information](https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.211)

[Information](https://www.osha.gov/laws-regs/interlinking/standards/1910.216)

voltages and other hazards.

B. **ANSI, ANSI/RIA, ANDI/ISO, RIA and ISO Standards**

revision of ISO 10218-1 and ISO 10218-2, which is in progress.

advancements.

ANSI/RIA R15.06-2012, Industrial Robots and Robot Systems - Safety Requirements.

Provides safety requirements for industrial robot manufacture, remanufacture, and rebuild

(Part 1); and robot system integration/installation (Part 2). This standard is the U.S.

National Adoption of ISO 10218-1:2011 and ISO 10218-2:2011.

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ANSI B11.0, Safety of Machinery – General Requirements and Risk Assessment. Applies to

new, existing, modified, or rebuilt power-driven machines, not portable by hand while

working, used to shape and/or form metal or other materials by cutting, impact, pressure,

electrical, or other processing techniques, or a combination of these processes. This can

be a single machine, a machine tool, or a machine tool system(s), and may include

industrial robot(s) and robot system(s). Also contains guidance on performing risk

assessments.

ANSI B11.20, Safety Requirements for Integrated Manufacturing Systems. Specifies the

safety requirements for the design, construction, set-up, operation, and maintenance

(including installation, dismantling and transport) of integrated manufacturing systems,

which may include industrial robot(s) and robot system(s).

RIA TR R15.306-2016, Task-Based RA Methodology. Describes one method of performing an

RA that would comply with the R15.06-2012 requirements.

RIA TR R15.506-2014, Applicability of R15.06-2012 for Existing Industrial Robot

Applications. The R15.06-2012 standard is forward-looking; that is, its primary topic is the

installation of an all-new robot systems and applications. Explains how to take the R15.06

2012 standard into account for existing robot systems and applications.

RIA TR R15.606-2016, Collaborative Robot Safety. Explains safety requirements specific to

collaborative robot systems and applications, and is supplemental to the guidance in

ANSI/RIA R15.06-2012. This standard is the U.S. National Adoption of ISO/TS 15066:2016.

RIA TR R15.706-2019, User Responsibilities. Describes the responsibilities of the user

(employer) that are in the other standards. Describes requirements for RA and training of

workers. Offers suggestions for interaction with integrators and the supply chain.

RIA TR R15.806-2018, Testing Methods for Power & Force Limited Collaborative

Applications. Describes methods to test and verify that the pressure and other forces

exerted by a collaborative robot application remain within the allowable limits described

in TR R15.606-2016.

C. **International Organization for Standardization (ISO) Standards**

ISO TC 299, Robotics. Develops high quality standards for the safety of industrial robots

and service robots to enable innovative robotic products to be brought onto the market. In

addition, ISO TC 299 develops non-safety standards in fields like terminology, performance

measurement, and modularity.

ISO 10218-1:2011, Robots for industrial environments - Safety requirements - Part 1:

Robots. Specifies requirements and guidelines for inherently safe design, safeguards and

other protective measures, and information for use of industrial robots. It describes basic

hazards associated with robots, and provides requirements to eliminate or adequately

reduce the risks associated with these hazards.

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ISO 10218-2:2011, Robots for industrial environments – Safety requirements – Part 2:

Robot systems and integration. Specifies requirements and guidelines for the safe

integration of an industrial robot system into a complete robot application, which includes

end-effectors and other related equipment. This document describes basic hazards

associated with robot systems, and provides requirements to eliminate or adequately

ISO/TS 15066:2016, Collaborative Robot Safety. Gives information about how to

implement a collaborative robot application so that safety for the worker is provided.

ISO/TR 20218-1:2018, Safety Design for End-effectors. Provides guidance on the design and

implementation of end-effectors (EOATs) and end-effector exchange systems for safety of

workers, in both collaborative and non-collaborative applications.

ISO/TR 20218-2:2017, Safety Design for Manual Load/ Unload Stations. Provides guidance

on the design of manual load/unload stations that will be safe for workers.

D. **American Welding Society (AWS)**

AWS D16.1M/D16.1, Specification for Robotic Arc Welding Safety. Identifies hazards

involved in maintaining, operating, integrating, and setting up arc welding robot

### X. Considerations for Evaluating Robotic Safety Systems

The following is a summary of the content found in this chapter that may be useful when

evaluating robotic safety systems and associated safety and health programs elements.

A. Review the Robot Application Hazards by Process section of this chapter for lists of the

common hazards found in each process.

B. Obtain and review the applicable robot system risk assessment(s) prior to robot system

evaluation(s).

C. Review and evaluate relevant OSHA standards as listed in Section IX Applicable OSHA and

Industry Standards Regarding Industrial Robot System Safety.

D. Evaluate that all robots, end-effectors, and the completed robot applications meet the

requirements necessary to ensure safe operation by operators and workers. Refer to ANSI/RIA

R15.06-2012.

E. Evaluate if older or obsolete robots, robot systems, and/or applications are rebuilt or

remanufactured to determine if they should be upgraded to conform to current industry

standards. Refer to RIA TR R15.506-2014.

F. Review and evaluate assembly, installation, and testing procedures.

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G. Review work areas to assure that assembly, installation, and testing are, or have been

performed safely and per established procedures.

H. Review that robot systems and robot applications are installed in accordance with the

manufacturer's requirements, industry standards, and applicable OSHA general industry

and/or construction standards.

O. Review that the RA(s) received from the integrator have been reviewed, modified as necessary,

and followed by

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, and/or applications are rebuilt or

and followed by the users. Review that additional task-based risk assessments have been

prepared for any new or modified operating or maintenance tasks before they are performed.

See Section VII Risk Assessments (RAs).

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P. Based on the results of the RA and manufacturer's information, review that maintenance

plans which include identifying critical components and the frequency of inspections and

testing have been developed.

Q. Review that safeguards and other controls are not disabled or removed and that they are

functioning properly before any worker exposure to the robot application is permitted.

**ANSI**

ANSI/ISO 12100-2012, Safety of Machinery – General Principles for Design, RA and Risk

Reduction

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ANSI/RIA R15.06-2012, Industrial Robots and Robot Systems - Safety Requirements

ANSI/UL1740-2019, Standard for Safety: Robots and Robotic Equipment

**RIA**

RIA TR R15.306-2016, Technical Report for Industrial Robots and Robot Systems — Safety

Requirements — Task-Based RA Methodology

RIA TR R15.406-2012, Technical Report for Industrial Robots and Robot Systems — Safety

Requirements — Safeguarding

RIA TR R15.506-2014, Technical Report for Industrial Robots and Robot Systems — Safety

Requirements — Applicability of R15.06-2012 for Existing Industrial Robot Applications

RIA TR R15.606-2016, Technical Report for Industrial Robots and Robot Systems — Safety

Requirements — Collaborative Robots

RIA TR R15.706-2019, Technical Report for Industrial Robots and Robot Systems — Safety

Requirements — User Responsibilities

RIA TR R15.806-2018, Technical Report for Industrial Robots and Robot Systems — Safety

Requirements — Testing Methods for Power & Force Limited Collaborative Applications

[Robotics Industries Association Resource Page](https://www.nist.gov/robotics-manufacturing)

**ISO**

ISO TC 299, Robotics

ISO 10218-1:2011, Robots and robotic devices — Safety requirements for industrial robots —

Part 1: Robots

ISO 10218-2:2011, Robots and robotic devices — Safety requirements for industrial robots —

Part 2: Robot systems and integration

ISO 13849-1:2015, Safety of Machinery, Safety-related parts of control systems, Part 1: General

Principles of Design

ISO 13849-2:2015, Safety of Machinery, Safety-related parts of control systems, Part 2:

Validation

ISO/TS 15066:2016, Robots and robotic devices — Collaborative robots

ISO/TR 20218-1:2018,Robotics — Safety design for industrial robot systems — Part 1: End
effectors

ISO/TR 20218-2:2017, Robotics — Safety design for industrial robot systems — Part 2: Manual

load/unload stations

**Other**

AWS D16.1M/D16.1, Specification for Robotic Arc Welding Safety.

CSA Z434-14, Industrial Robots and Robot Systems.

https://www.osha.gov/otm/section-4-safety-hazards/chapter-4 41/56

NFPA 79, Electrical Standard for Industrial Machinery

[National Institute of Standards and Technology Robotics in Manufacturing Page](https://www.nist.gov/robotics-manufacturing)

[National Institute of Standards and Technology Robotics Test Facility](https://www.nist.gov/laboratories/tools-instruments/robotics-test-facility)

[National Science Foundation – Robotics](https://www.nsf.gov/news/special_reports/robotics/)

[NIOSH Robotics Workplace Safety and Health Topics Page](https://www.cdc.gov/niosh/topics/robotics/default.html)

### Appendix 1. Glossary for Industrial Robot Systems and Applications

**Application Program** – The set of instructions that defines the specific intended tasks of robots

and robot systems. This program may be originated and modified by the robot user.

**Attended Program Verification** – The time when a person within the restricted envelope (space)

verifies the robot's programmed tasks at programmed speed.

**Automatic Guided Vehicle (AGV) systems** – Advanced material-handling or conveying systems

that involve a driverless vehicle which follows a guide-path.

**Axis** – A direction that is used to state the motion of a robot in a linear or rotary mode; the line

about which a rotating body (such as a tool) turns.

**Coordinated Straight Line Motion** – Control wherein the axes of the robot arrive at their

respective end points simultaneously, giving a smooth appearance to the motion wherein the

motions of the tool center point moves along a pre-specified linear path.

**Enabling Device** – A manually operated device that permits motion when continuously activated.

ANSI/RIA R15.06-2012 requires a 3-position enabling device where release of, or compression of,

the device stops robot system motion and motion of associated equipment that may present a

hazard.

**End-effector** – An accessory device or tool specifically designed for attachment to the robot wrist

or tool mounting plate to enable the robot to perform its intended task. Examples may include

gripper, spot-weld gun, arc-weld gun, spray-paint gun, inspection camera, adhesive dispenser, or

any other application tools.

**End-effector Manufacturer** – A company or business involved in the design, fabrication and

assembly of end-effectors (EOAT) and/or end-effector exchange systems.

**Industrial Robot** – A reprogrammable, multifunctional manipulator designed to move material,

parts, tools, or specialized devices through variable programmed motions for the performance of

a variety of tasks.

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**Industrial Robot Application** – An application that includes industrial robot systems, the end
effector, the workpiece, and safeguards.

**Industrial Robot System** – A system that includes industrial robots, the end-effectors, and the

devices and sensors required for the robots to be taught or programmed, or for the robots to

perform the intended automatic operations, as well as the communication interfaces required for

interlocking, sequencing, or monitoring the robots.

**Joint Motion** – A method for coordinating the movement of the joints such that all joints arrive at

the desired location simultaneously wherein the motion of the tool center point travels along a

curved path.

**Kinematics** – The actual arrangement of rigid members and joints in the robot, which determines

the robot's possible motions. Classes of robot kinematics include articulated, Cartesian, parallel,

and SCARA.

**Limiting Device** – A device that restricts the maximum envelope (space) by stopping or causing to

stop all robot motion and is independent of the control program and the application programs.

**Manual Mode** – A mode of operating the robot in which a trained operator (programmer; teacher)

typically uses a portable control device (a teach pendant) to teach a robot its task(s) manually.

Robot speeds during manual mode are limited to less than 10 inches (250 mm) per second, to

reduce hazards to the teacher.

**Maximum Space** – The volume of space encompassing the maximum designed movements of all

robot parts including the end-effector, workpiece, and attachments.

**Mobile Robot** – A self-propelled and self-contained robot that navigates autonomously within its

operating environment to reach specified locations; designed to automate transport tasks.

**Muting** – The deactivation of a presence-sensing safeguarding device during a portion of the

robot cycle.

**Numerically Controlled Machine Tools** – Operated by a series of coded instructions comprised of

numbers, letters of the

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 motion and is independent of the control program and the application programs.

numbers, letters of the alphabet, and other symbols. These are translated into pulses of electrical

current or other output signals that activate motors and other devices to run the machine.

**Operating Space** – That portion of the restricted envelope (space) that is actually used by the

robot while performing its programmed motions.

**Presence-Sensing Safeguarding Device** – A device designed, constructed, and installed to create

a sensing field or area to detect an intrusion into the field or area by workers, robots, or other

objects.

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**Repeatability** – How well the robot will return to a programmed position.

**Restricted Space** – That portion of the maximum envelope (space) to which a robot is restricted

by limiting devices. The maximum distance that the robot can travel after the limiting device is

actuated defines the boundaries of the restricted envelope of the robot. (Note: the safeguarding

interlocking logic and robot program may redefine the restricted envelope as the robot performs

its application program. See Part 2, Clause 5.4.4 of the ANSI/RIA R15.06-2012 standard).

**Robot Manufacturer** – A company or business involved in the design, fabrication, and/or

assembly of robot systems.

**Robot Integrator** – A company or business who either directly or through a subcontractor will

assume responsibility for the design, fabrication, and integration of the required robot, robotic

peripheral equipment, and other required ancillary equipment for a particular robot application.

**Single Point of Control** – The ability to operate the robot such that initiation or robot motion

from one source of control is possible only from that source and cannot be overridden from

another source.

**Tele-operators** – Robotic devices comprised of sensors and actuators for mobility and/or

manipulation and are controlled remotely by a worker operator.

**Teach**
– The generation and storage of a series of positional data points effected by moving the

robot arm through a path of intended motions.

**Tool Center Point (TCP)** – The origin of the tool coordinate system.

### Appendix 2. Example Risk Assessment (RA)

**Purpose**

This appendix outlines key steps to perform during a RA with examples of how to determine the

necessary risk reduction measures needed to adequately reduce risk. This appendix is based on

RIA TR R15.306-2016 and does not necessarily cover all RA aspects that may be needed for a robot

system and/or application. See the Risk Assessments (RAs) and Risk Reduction Measures sections.

**RA**

A. Analyzes the tasks, usage, and hazards associated with a robot application and the area in

which it is installed and used (or to be installed and used). For example, the robot application

can be installed under overhead lighting that requires periodic lamp replacement. This task

would also be included.

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B. Provides a method to understand, rate (estimate the risk), and eliminate or reduce risk(s)

associated with the hazards.

C. Identifies all activities of workers exposed to, operating, or maintaining the robotic

application. It should include expected activities within the application workspace, even if the

activities are not associated with the robot application, e.g. changing the overhead light.

D. Results in risk reduction measures that need to be implemented to comply with applicable

standards and regulations.

**Figure IV-A2.1: RA Key Steps** (Source: RIA)

**RA - 7 Key Steps (Figure IV-A2.1)**

1. Intended Use

Define the operation, including normal sequence(s) and alternate (non-typical) sequences.

Define the expected worker interaction required for the operation, reasonably expected

misuse and maintenance, repair, cleaning, emergency conditions, etc.

Determine and document the operating space and restricted space.

Determine the desired restricted space, considering possible limits such as hard stops,

travel limit sensors, safety-rated soft-axis limits, etc.

2. Task Determination Based On Intended Use

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Define and document all the tasks that each worker will perform. Workers may perform

assembly, testing, integration, material infeed and take-away, quality control, operations,

observation, maintenance, etc. related to the robot system and application. And there can

be other nearby workers who are bystanders or passers-by. Example task can include:

Path teaching

Observing

Debugging, troubleshooting, or adjusting

Repairing or replacing components

3. Hazard Determination for Each Task

With the tasks identified, define and document the hazards related to each task (Figure IV

A2.2). Examples include:

Mechanical: Crushing, caught-between, struck-by, shearing, cutting, projectiles, etc.

Electrical: Shock, spark/arc flash, electrostatic, etc.

Thermal: Heat, cold, burns, etc.

Ergonomic: Reach, weight, posture, motion, etc.

Slips, trips, and falls: Objects on floors or in pathways, wet surfaces, etc.

Machinery instability: Falling equipment, tools, etc.

Environmental: Chemicals (including as fumes, such as from welding), heat, dust,

radiation or other potentially hazardous sources such as light, sparks, noise, etc.

Note: ANSI/RIA R15.06-2012 Part 1, Annex A, Table A.1 — List of significant hazards,

provides additional information on hazards typically associated with robots and robot

systems.

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RA Task List

https://www.osha.gov/otm/section-4-safety-hazards/chapter-4 47/56

RA Hazard List

**Figure IV-A2.2: Example Task and Associated Hazard Sheets** (Source: RIA)

4. Risk Estimation for Each Task & Hazard

For each task/hazard combination estimate and document the risk factors:

Possible injury severity (Figure IV-A2.3)

Exposure frequency (Figure IV-A2.4)

Possibility for avoidance (Figure IV-A2.5)

These factors determine the risk level for each task/hazard combination:

The risk level is used in the risk reduction step and drives what safeguarding measures

need to be applied to the system.

The risk levels are also used to determine the required performance level (PLr) of each

safety function.

RIA TR R15.306-2016 section 6.4.1.1 describes injury severity as the degree of estimated

harm due to each hazard while the operator is performing the associated task.

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**Figure IV-A2.3: Possible Injury Severity Chart** (Source: RIA)

RIA TR R15.306-2016 section 6.4.1.2 describes exposure as a function of the estimated

incidence of operator exposure (frequency or duration), and takes into consideration the

following:

How frequently the operator would be in the hazard zone

The duration in which the operator would be in the hazard zone

Whether the task is routine or non-routine or other task frequency considerations

**Figure IV-A2.4: Exposure Frequency Chart** (Source: RIA)

RIA TR R15.306-2016 section 6.4.1.3 describes

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RIA TR R15.306-2016 section 6.4.1.3 describes avoidance as an assessment of the

operator's ability to sense and elude a hazardous situation.

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**Figure IV-A2.5: Possibility for Avoidance Chart** (Source: RIA)

Use the risk factors (severity, exposure, and avoidance) to derive the risk level using RIA TR

R15.306-2016 Table 2 (Figure IV-A2.6).

**Figure IV-A2.6: Risk Level Decision Matrix** (Source: RIA)

Using the determined risk level for each task from Figure IV-A2.6, identify the performance

level for each task using RIA TR R15.306-2016 Table 5 (Figure IV-A2.7).

https://www.osha.gov/otm/section-4-safety-hazards/chapter-4 50/56

**Figure IV-A2.7: Performance Level Chart** (Source RIA)

Note: For a detailed explanation of Performance Level and Structure Categories see ISO 13849

1:2015

5. Risk Reduction Measure Determination for Each Task

The hierarchy of risk reduction measures should comply with RIA TR R15.306-2016 Table 3

(Figure IV-A2.8).

**Figure IV-A2.8: Hierarchy of Risk Reduction Measures**

https://www.osha.gov/otm/section-4-safety-hazards/chapter-4 51/56

Select risk reduction measures for each task based on the determined risk level for the

task.

Risk reduction measures should comply with risk level requirements shown in RIA TR

R15.306-2016 Table 4 (Figure IV-A2.9).

**Figure IV-A2.9: Minimum Risk Reduction Measures as a Function of Risk Level** (Source: RIA)

For all risks with a very high, high or medium initial risk level, inherently safe design

(elimination, substitution, or limiting interaction) or safeguarding should be used as a

primary means to reduce risks. Complementary protective measures or information for

use should not be used as the primary risk reduction measure for very high, high or

medium initial risk levels.

After the risk reduction measures are selected for each of the tasks, determine the

performance level that has been achieved as the result of the risk reduction measures

selected using RIA TR R15.306-2016 Table 5 (Figure IV-A2.10).

**Figure IV-A2.10: Minimum Functional Safety Performance Chart** (Source RIA)

https://www.osha.gov/otm/section-4-safety-hazards/chapter-4 52/56

Now compare the task-risk performance level (Step 4) to the reduction-risk performance

level (this Step 5).

Modify risk reduction measures as necessary until the risk-reduction performance levels

are at least as high as the task-risk performance levels.

This is often an iterative process that must be continued until reduction-risk

performance levels are at least as high as the task-risk performance levels.

6. Evaluation of Risk Reduction Measures

First, each member who participated in development of the RA should evaluate that the

right risk levels and performance levels have been assigned to each task (Step 4).

Second, each member who participated in development of the RA should evaluate that the

right risk reduction measures have been selected for each task (Step 5).

Members should ensure that the hierarchy of risk reduction measures has been

followed (Figure IV-A2.8). For example, if the risk cannot be eliminated by design, then

measures to mitigate the risk by less preferred measures should be applied in order of

hierarchy.

Members should then evaluate each risk reduction measure to ensure that the

measure selected in each case is in line with the task risk level (Figure IV-A2.9).

Finally, members should ensure that the selected performance levels are in line with

the risk reduction measures selected (Figure IV-A2.10).

Once each member has evaluated the RA, the team should meet and discuss each issue

found with the RA.

Each issue should be resolved with the team to ensure that residual risk is acceptable and

that the RA will provide the highest degree of safety and protection for the workers.

7. Validate the RA, Train Workers, Review RA Effectiveness, and Update the RA as Needed.

The completed RA should be documented in writing. See Examples 1 and 2 below of

completed RAs (Figures IV-A2.11 and 12).

Once the RA is acceptable to the team, team members should sign the RA as evidence of

Validated RAs should be provided to all affected workers and also made accessible for their

future reference.

Employers should train workers on the tasks, the hazards and risks associated with each

tasks, and the risk reduction measures that have been put in place and that the workers

must follow.

No work should be performed for any hazardous task(s), until an RA has been validated,

issued and trained to.

https://www.osha.gov/otm/section-4-safety-hazards/chapter-4 53/56

Once work begins, employers should ensure that the risk reduction measures are effective

and continually practiced.

Field observations are required while tasks are being performed.

When risk reduction measures are found to be ineffective or not continually practiced, the

work should be immediately stopped.

**Figure IV-A2.12:RA Example 2 – Safeguarded using PFL Collaborative Technologies**

1

[See Robotics Industries Association (RIA): https://www.automate.org/robotics.](https://www.automate.org/robotics)

https://www.osha.gov/otm/section-4-safety-hazards/chapter-4 54/56

2 Artificial intelligence in robotics refers to programming functions that can "learn" and adjust

outputs based on inputs received from the robot or from workers.

3 See:

[https://ifr.org/downloads/press2018/Executive%20Summary%20WR%202019%20Industrial%20Robo](https://ifr.org/downloads/press2018/Executive%20Summary%20WR%202019%20Industrial%20Robots.pdf)

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# **Control of** **Hazardous Energy**
#### **Lockout/Tagout**

**OSHA 3120**
**2002 (Revised)**

## Control of Hazardous Energy
### Lockout/ Tagout

U.S. Department of Labor
Elaine L. Chao, Secretary

Occupational Safety and Health Administration
John L. Henshaw, Assistant Secretary

OSHA 3120
2002 (Revised)

**Contents**

Page

**Background ............................................................................... 1**

How should I use this booklet? ............................................ 1

What is “lockout/tagout”? .................................................... 1

Why do I need to be concerned
about lockout/tagout? ........................................................... 2

**OSHA Coverage ........................................................................ 3**

How do I know if the OSHA standard
applies to me? ....................................................................... 3

When does the standard not apply to
service and maintenance activities performed
in industries covered by Part 1910? ..................................... 3

How does the standard apply to general
industry service and maintenance operations? .................... 4

**Requirements of the Standard................................................. 6**

What are OSHA’s requirements? ......................................... 6

What must an energy-control procedure include? ............... 7

What must workers do before they
begin service or maintenance activities? ............................. 8

remove their lockout or tagout device
and reenergize the machine? ................................................ 8

When do I use lockout and how do I do it?

......................... 9

How can I determine if the energy-isolating

device can be locked out? .................................................. 10

What do I do if I cannot lock out
the equipment? ................................................................... 10

Contents i

What other options do I have? ............................................11

When can tagout devices be used
instead of lockout devices? .................................................11

What are the limitations of tagout devices?

What are the requirements for

....................... 12

lockout/tagout devices? ...................................................... 12

What do employees need to know
about lockout/tagout programs?......................................... 13

When is training necessary?

............................................... 14

What if I need power to test or position

machines, equipment, or components? .............................. 15

What if I use outside contractors for
service or maintenance procedures? .................................. 16

What if a group performs service
or maintenance activities? .................................................. 16

What if a shift changes during
machine service or maintenance? ...................................... 16

How often do I need to review
my lockout/tagout procedures? .......................................... 17

What does a review entail? ................................................ 17

What additional information does OSHA
provide about lockout/tagout?............................................ 18

**Commonly Used Terms .......................................................... 20**

**OSHA Assistance, Programs, and Services .......................... 22**

How can OSHA help me? .................................................. 22

How does safety and health program management
assistance help employers and employees? ....................... 22

ii Control of Hazardous Energy (Lockout/Tagout)

What are state plans?.......................................................... 23

How can consultation assistance
help employers? ................................................................. 23

Who can get consultation assistance
and what does it cost? ........................................................ 24

Can OSHA assure privacy to an employer
who asks for consultation assistance? ................................ 24

Can an employer be cited for violations
after receiving consultation assistance? ............................. 24

What incentives does OSHA provide for
seeking consultation assistance? ........................................ 24

What are the Voluntary Protection Programs? ................... 25

How does the VPP work? ................................................... 25

How does VPP help employers and employees? ............... 26

How does OSHA monitor VPP sites? ................................ 26

Can OSHA inspect an employer

who is participating in the VPP? ........................................ 26

How can a partnership with OSHA
improve worker safety and health? .................................... 27

What is OSHA’s Strategic Partnership
Program (OSPP)? ............................................................... 27

What do OSPPs do? ........................................................... 27

What are the different kinds of OSPPs? ............................ 28

What are the benefits of participation in the OSPP? ......... 28

Does OSHA have occupational safety and
health training for employers and employees? .................. 29

Does OSHA give money to organizations
for training and education? ................................................ 29

Contents iii

Does OSHA have other assistance

materials available? ............................................................ 30

What do I do in case of an emergency
or to file a complaint? ........................................................ 31

**OSHA Regional and Area Offices ......................................... 32**

**OSHA Consultation Projects ................................................. 36**

**OSHA-Approved Safety and Health Plans .......................... 38**

iv Control of Hazardous Energy (Lockout/Tagout)

**Background**

How should I use this booklet? 1

positive restraints that no one can remove without a key or other
unlocking mechanism, or through extraordinary means, such as
bolt cutters. Tagout devices, by contrast, are prominent warning
devices that an authorized employee fastens to energy-isolating
devices to warn employees not to reenergize the machine while
he or she services or maintains it. Tagout devices are easier to
remove and, by themselves, provide employees with less
protection than do lockout devices.

**Why do I need to be concerned about lockout/tagout?**

Employees can be seriously or fatally injured if machinery
they service or maintain unexpectedly energizes, starts up, or
releases stored energy. OSHA’s standard on the Control of
Hazardous Energy (Lockout/Tagout), found in _Title 29 of the_
_Code of Federal Regulations_ ( _CFR_ ) Part 1910.147, spells out
the steps employers must take to prevent accidents associated
with hazardous energy. The standard addresses practices and
procedures necessary to disable machinery and prevent the
release of potentially hazardous energy while maintenance or
servicing activities are performed.

Two other OSHA standards also contain energy control
provisions: _29 CFR_ 1910.269 and 1910.333. In addition,
some standards relating to specific types of machinery contain
deenergization requirements—such as _29 CFR_ 1910.179(l)(2)(i)(c)
(requiring the switches to be “open and locked in the open position”
before performing preventive maintenance on overhead and gantry
cranes). [2] The provisions of Part 1910.147 apply in conjunction
with these machine-specific standards to assure that employees will
be adequately protected against hazardous energy.

2 The standard provides a limited exception to the requirement that energy

control procedures be documented. If an employer can demonstrate the
existence of EACH of the eight elements listed in 1910.147(c)(4)(i),
the employer is not required to document the energy control procedure.
However, the exception terminates if circumstances change and ANY
of the elements no longer exist.

2 Control of Hazardous Energy (Lockout/Tagout)

**OSHA Coverage**

**How do I know if the OSHA standard applies to me?**

If your employees service or maintain machines where
the unexpected startup, energization, or the release of stored
energy could cause injury, the standard likely applies to you.
The standard applies to all sources of energy, including, but
not limited to: mechanical, electrical, hydraulic, pneumatic,
chemical, and thermal energy.

The standard does not cover electrical hazards from work
on, near, or with conductors or equipment in electric utilization
(premise wiring) installations, which are outlined by Subpart S
of _29 CFR_ Part 1910. You can find the specific lockout and
tagout provisions for electrical shock and burn hazards in
_29 CFR_ Part 1910.333. Controlling hazardous energy in
installations for the exclusive purpose of power generation,
transmission, and distribution, including related equipment for
communication or metering, is covered by _29 CFR_ 1910.269.

The standard also does not cover the agriculture, construction,
and maritime industries or oil and gas well drilling and servicing.
Other standards concerning the control of hazardous energy,
however, apply in many of these industries/situations.

**When does the standard not apply to service and maintenance**
**activities performed in industries covered by Part 1910?**

The standard does not apply to general industry service
and maintenance activities in the following situations, when:

  - Exposure to hazardous energy is controlled completely
by unplugging the equipment from an electric outlet and
where the employee doing the service or maintenance has
exclusive control of the plug. This applies only if electricity
is the only form of hazardous energy to which employees
may be exposed. This exception encompasses many
portable hand tools and some cord and plug connected
machinery and equipment.

How do I know if the OSHA standard applies to me? 3

4 Control of Hazardous Energy (Lockout/Tagout)

  - Place any part of their bodies in a danger zone associated
with machine operations.

Work involving minor tool changes and adjustments or
other minor servicing activities that are routine, repetitive, and
integral to the use of the production equipment and that occur
during normal production

 service and maintenance**

during normal production operations are not covered by the
lockout/tagout standard. This exception is limited, however, and
applies only when economic considerations prevent the use of
prescribed energy-isolation measures and when the employer
provides and requires alternative measures to ensure effective,
alternative protection.

Whenever the standard is applicable, the machinery must
be shut off and isolated from its energy sources, and lockout or
tagout devices must be applied to the energy-isolation devices.
In addition, the authorized employee(s) must take steps to verify
that he or she has effectively isolated the energy. When there
is stored or residual energy, the authorized employee(s) must
take steps to render that energy safe. If the possibility exists
for reaccumulation of stored energy to hazardous levels, the
employer must ensure that the worker(s) perform verification
steps regularly to detect such reaccumulation before it has the
potential to cause injury.

How does the standard apply to general industry operations? 5

**Requirements of the Standard**

**What are OSHA’s requirements?**

OSHA’s standard establishes minimum performance
requirements for controlling hazardous energy. The standard
specifies that employers must establish an energy-control
program to ensure that employees isolate machines from
their energy sources and render them inoperative before
any employee services or maintains them.

As part of an energy-control program, employers must:

  - Establish energy-control procedures for removing the
energy supply from machines and for putting appropriate
lockout or tagout devices on the energy-isolating devices
to prevent unexpected reenergization. When appropriate,
the procedure also must address stored or potentially
reaccumulated energy;

  - Train employees on the energy-control program, including
the safe application, use, and removal of energy controls;
and

  - Inspect these procedures periodically (at least annually)
to ensure that they are being followed and that they remain
effective in preventing employee exposure to hazardous

energy.

If employers use tagout devices on machinery that can be
locked out, they must adopt additional measures to provide the
same level of employee protection that lockout devices would
provide. Within the broad boundaries of the standard, employers
have the flexibility to develop programs and procedures that
meet the needs of their individual workplaces and the particular
types of machines being maintained or serviced.

6 Control of Hazardous Energy (Lockout/Tagout)

**What must an energy-control procedure include?**

Employers must develop, document, and use procedures
to control potentially hazardous energy. [3 ] The procedures
explain what employees must know and do to control hazardous
energy effectively when they service or maintain machinery.
If this information is the same for the various machines used at
a workplace, then a single energy-control procedure may suffice.
For example, similar machines (those using the same type and
magnitude of energy) that have the same or similar types of
control measures can be covered by a single procedure.
Employers must develop separate energy-control procedures
if their workplaces have more variable conditions such as
multiple energy sources, different power connections, or
different control sequences that workers must follow to shut
down various pieces of machinery.

The energy-control procedures must outline the scope,
purpose, authorization, rules, and techniques that employees
will use to control hazardous energy sources, as well as
the means that will be used to enforce compliance. These
procedures must provide employees at least the following
information:

  - A statement on how to use the procedures;

  - Specific procedural steps to shut down, isolate, block,
and secure machines;

  - Specific steps designating the safe placement, removal,
and transfer of lockout/tagout devices and identifying
who has responsibility for the lockout/tagout devices; and

  - Specific requirements for testing machines to determine
and verify the effectiveness of lockout devices, tagout
devices, and other energy-control measures.

3 The standard provides a limited exception to the requirement that energy

What must an energy-control procedure include? 7

8 Control of Hazardous Energy (Lockout/Tagout)

Before removing lockout or tagout devices, the employees
must take the following steps in accordance with the specific
provisions of the employer’s energy-control procedure:

  - Inspect machines or their components to assure that they
are operationally intact and that nonessential items are
removed from the area; and

  - Check to assure that everyone is positioned safely and
away from machines.

After removing the lockout or tagout devices but before
reenergizing the machine, the employer must assure that all
employees who operate or work with the machine, as well as
those in the area where service or maintenance is performed,
know that the devices have been removed and that the machine
is capable of being reenergized. (See Sections 6(e) and (f) of
_29 CFR_ Part 1910.147 for specific requirements.) In the rare
situation in which the employee who placed the lockout/tagout
device is unable to remove that device, another person may
remove it under the direction of the employer, provided that the
employer strictly adheres to the specific procedures outlined in
the standard. (See _29 CFR_ 1910.147(e)(3).)

**When do I use lockout and how do I do it?**

You must use a lockout program (or tagout program that
provides a level of protection equal to that achieved through
lockout) whenever your employees engage in service or
maintenance operations on machines that are capable of being
locked out and that expose them to hazardous energy from
unexpected energization, startup, or release of stored energy.

The primary way to prevent the release of hazardous
energy during service and maintenance activities is by using
energy-isolating devices such as manually operated circuit
breakers, disconnect switches, and line valves and safety
blocks. Lockout requires use of a lock or other lockout device
to hold the energy-isolating device in a safe position to prevent
machinery from becoming reenergized. Lockout also requires

What must workers do before they remove their lockout or tagout device? 9

10 Control of Hazardous Energy (Lockout/Tagout)

**What other options do I have?**

If it is possible to lock out an energy-isolating device,
employers must use lockout devices unless they develop,
document, and use a tagout procedure that provides
employees with a level of protection equal to that provided
by a lockout device. In a tagout program, an employer can
attain an equal level of protection by complying with all
tagout-related provisions of the standard and using at least one
added safety measure that prevents unexpected reenergization.
Such measures might include removing an isolating circuit
element, blocking a controlling switch, opening an extra
disconnecting device, or removing a valve handle to minimize
the possibility that machines might inadvertently be reenergized
while employees perform service and maintenance activities.

**When can tagout devices be used instead of lockout devices?**

When an energy-isolating device cannot be locked out, the
employer must modify or replace the energy-isolating device
to make it capable of being locked out or use a tagout system.
Whenever employers significantly repair, renovate, or modify
machinery or install new or replacement machinery, however,
they must ensure that the energy-isolating devices for the
machinery are capable of being locked out.

Tagout devices may be used on energy-isolating devices
that are capable of being locked out if the employer develops
and implements the tagout in a way that provides employees
with a level of protection equal to that achieved through a
lockout system.

When using a tagout system, the employer must comply
with all tagout-related provisions of the standard and train
employees in the limitations of tags, in addition to providing
normal hazardous energy control training for all employees.

What other options do I have? 11

**What are the limitations of tagout devices?**

A tagout device is a prominent warning that clearly states
that the machinery being controlled must not be operated until
the tag is removed in accordance with an established procedure.
Tags are essentially warning devices and do not provide the
physical restraint of a lock. Tags may evoke a false sense of
security. For

 the energy-isolating devices for the

security. For these reasons, OSHA considers lockout devices
to be more secure and more effective than tagout devices in
protecting employees from hazardous energy.

**What are the requirements for lockout/tagout devices?**

Whether lockout or tagout devices are used, they must
be the only devices the employer uses in conjunction with
energy-isolating devices to control hazardous energy.
The employer must provide these devices and they must
be singularly identified and not used for other purposes.
In addition, they must have the following characteristics:

  - Durable enough to withstand workplace conditions.
Tagout devices must not deteriorate or become illegible
even when used with corrosive components such as acid
or alkali chemicals or in wet environments.

  - Standardized according to color, shape, or size. Tagout
devices also must be standardized according to print and
format. Tags must be legible and understandable by all
employees. They must warn employees about the hazards
if the machine is energized, and offer employees clear
instruction such as: “Do Not Start,” “Do Not Open,”
“Do Not Close,” “Do Not Energize,” or “Do Not Operate.”

  - Substantial enough to minimize the likelihood of
premature or accidental removal. Employees should be
able to remove locks only by using excessive force with
special tools such as bolt cutters or other metal-cutting
tools. Tag attachments must be non-reusable, self-locking,
and non-releasable, with a minimum unlocking strength

12 Control of Hazardous Energy (Lockout/Tagout)

of 50 pounds. Tags must be attachable by hand, and
the device for attaching the tag should be a one-piece
nylon cable tie or its equivalent so it can withstand all
environments and conditions.

  - Labeled to identify the specific employees authorized to
apply and remove them.

**What do employees need to know about lockout/tagout programs?**

Training must ensure that employees understand the
purpose, function, and restrictions of the energy-control
program. Employers must provide training specific to the
needs of “authorized,” “affected,” and “other” employees.

“Authorized” employees are those responsible for
implementing the energy-control procedures or performing
the service or maintenance activities. They need the
knowledge and skills necessary for the safe application,
use, and removal of energy-isolating devices. They also
need training in the following:

  - Hazardous energy source recognition;

  - The type and magnitude of the hazardous energy
sources in the workplace; and

  - Energy-control procedures, including the methods and
means to isolate and control those energy sources.

“Affected” employees (usually machine operators or users)
are employees who operate the relevant machinery or whose
jobs require them to be in the area where service or maintenance
is performed. These employees do not service or maintain
machinery or perform lockout/tagout activities. Affected
employees must receive training in the purpose and use of
energy-control procedures. They also need to be able to do
the following:

  - Recognize when the energy-control procedure is being
used,

What are the requirements for lockout/tagout devices? 13

  - Understand the purpose of the procedure, and

  - Understand the importance of not tampering with lockout
or tagout devices and not starting or using equipment
that has been locked or tagged out.

All other employees whose work operations are or may
be in an area where energy-control procedures are used must
receive instruction regarding the energy-control procedure
and the prohibition against removing a lockout or tagout
device and attempting to restart, reenergize, or operate
the machinery.

In addition, if tagout devices are used, all employees
must receive training regarding the limitations of tags.
(See _29 CFR_ 1910.147(c)(7)(ii).)

**When is training necessary?**

The employer must provide initial training before starting
service and maintenance activities and must provide retraining
as necessary. In addition, the employer must certify that
the training has been given to all employees covered by the
standard. The certification must contain each employee’s name
and dates of training.

Employers must provide retraining for all authorized and
affected employees whenever there is a change in the following:

  - Job assignments,

  - Machinery or processes that present a new hazard, or

  - Energy-control procedures.

Retraining also is necessary whenever a periodic inspection
reveals, or an employer has reason to believe, that shortcomings
exist in an employee’s knowledge or use of the energy-control

14 Control of Hazardous Energy (Lockout/Tagout)

**What if I need power to test or position machines, equipment,**
**or components?**

OSHA allows the temporary removal of lockout or tagout
devices and the reenergization of the machine only in limited
situations for particular tasks that require energization—for
example, when power is needed to test or position machines,
equipment, or components. However, this temporary exception
applies only for the limited time required to perform the
particular task requiring energization. Employers must provide
effective protection from hazardous energy when employees
perform these operations. The following steps must be
performed in sequence before reenergization:

1. Clear tools and materials from machines.

2. Clear employees from the area around the machines.

3. Remove the lockout or tagout devices as specified in
the standard.

4. Energize the machine and proceed with testing or
positioning.

5. Deenergize all systems, isolate the machine from the
energy source, and reapply energy-control measures
if additional service or maintenance is required.

The employer must develop, document, and use energy-control
procedures that establish a sequence of actions to follow whenever
reenergization is required as a part of a service or maintenance
activity, since employees may be exposed to significant risks
during these transition periods.

What if I need power to test or position machines? 15

16 Control of Hazardous Energy (Lockout/Tagout)

**How often do I need to review my lockout/tagout procedures?**

Employees are required to review their procedures at least
once a year to ensure that they provide adequate worker
protection. As part of the review, employers must correct any
deviations and inadequacies identified in the energy-control
procedure or its application.

**What does a review entail?**

The periodic inspection is intended to assure that employees
are familiar with their responsibilities under the procedure and
continue to implement energy-control procedures properly.
The inspector, who must be an authorized person not involved
in using the particular control procedure being inspected, must
be able to determine the following:

  - Employees are following steps in the energy-control
procedure;

  - Employees involved know their responsibilities under
the procedure; and

  - The procedure is adequate to provide the necessary
protection, and what changes, if any, are needed.

For a lockout procedure, the periodic inspection must
include a review of each authorized employee’s responsibilities
under the energy-control procedure being inspected. Where
tagout is used, the inspector’s review also extends to affected
employees because of the increased importance of their role in
avoiding accidental or inadvertent activation of the machinery.
In addition, the employer must certify that the designated
inspectors perform periodic inspections. The certification
must specify the following:

  - Machine or equipment on which the energy-control
procedure was used,

  - Date of the inspection,

  - Names of employees included in the inspection, and

  - Name of the person who performed the inspection.

How often do I need to review my lockout/tagout procedures? 17

**What additional information does OSHA provide**
**about lockout/tagout?**

To gain a more comprehensive understanding of the
requirements for controlling hazardous energy, employers
and other interested persons should review the following:

  - OSHA standards with provisions regarding the control of
hazardous energy such as _29 CFR_ 1910.147, The control
of hazardous energy (lockout/tagout); _29 CFR_ 1910.269,
Electric power generation, transmission, and distribution;
and _29 CFR_ 1910.333, Selection and use of work practices.
Employers in the maritime, agriculture, and construction
industries are urged to review the provisions for the control
of hazardous energy contained in _29 CFR_ Parts 1915, 1917,
1918, 1925, and 1926.

  - The regulatory preamb

 inspection.

  - The regulatory preambles to _29 CFR_ 1910.147
( _54 Federal Register_ 36644 (September 1, 1989)) and
1910.269 ( _59 Federal Register_ 4320 (January 31, 1994)),
which contain comments from interested parties and
OSHA’s explanation for the provisions of the standards.

  - OSHA instructions concerning the control of hazardous
energy—Directive CPL 2-1.18A, Enforcement of the
Electrical Power Generation, Transmission, and Distribution
Standard (October 20, 1997) and OSHA Directive
STD 1-7.3, _29 CFR_ 1910.147, the Control of Hazardous
Energy (Lockout/Tagout)-Inspection Procedures and
Interpretive Guidance, (September 11, 1990).

  - OSHA letters of interpretation regarding the application
of standards concerning the control of hazardous energy.

Most of these documents are available on the OSHA
website at www.osha.gov.

18 Control of Hazardous Energy (Lockout/Tagout)

Additionally, OSHA offers a variety of web-based tools to
help educate employers and employees about the lockout/tagout
standard and how to apply it in their workplace. These include

  - The Lockout/Tagout Interactive Training Program, which
includes a tutorial, five abstracts with a detailed discussion
of major lockout/tagout issues involved, and interactive
case studies;

  - The Lockout/Tagout Plus Expert Advisor, an interactive,
expert, diagnostic software package to help users
understand and apply OSHA standards that protect workers
from the release of hazardous energy; and

  - The Lockout/Tagout electronic Compliance Assistant Tool
(eCAT), an illustrated tool to help businesses identify and
correct workplace hazards.

These tools are available on the OSHA website at
www.osha.gov. For the Lockout/Tagout Interactive Training
Program, click on **Technical Links** . For the Expert Advisor and
eCAT, click on **eTools** .

What additional information does OSHA provide about lockout/tagout? 19

**Commonly Used Terms**

**Affected employee.** An employee whose job requires
him/her to operate or use a machine or equipment on which
servicing or maintenance is being performed under lockout
or tagout, or whose job requires him/her to work in an area
in which such servicing or maintenance is being performed.

**Authorized employee.** A person who locks out or tags
out machines or equipment in order to perform servicing
or maintenance on that machine or equipment. An affected
employee becomes an authorized employee when that
employee’s duties include performing servicing or
maintenance covered under the standard.

**Capable of being locked out.** An energy-isolating device is
capable of being locked out if it has a hasp or other means of
attachment to which, or through which, a lock can be affixed, or
it has a locking mechanism built into it. Other energy-isolating
devices are capable of being locked out, if lockout can be achieved,
without the need to dismantle, rebuild, or replace the energyisolating device or permanently alter its energy control capability.

**Energized.** Connected to an energy source or containing
residual or stored energy.

**Energy-isolating device.** A mechanical device that physically
prevents the transmission or release of energy, including but not
limited to the following: a manually operated electrical circuit
breaker; a disconnect switch; a manually operated switch by
which the conductors of a circuit can be disconnected from
all ungrounded supply conductors, and in addition, no pole
can be operated independently; a line valve; a block; and any
similar device used to block or isolate energy. Push buttons,
selector switches and other control circuit-type devices are
not energy-isolating devices.

**Energy source.** Any source of electrical, mechanical,
hydraulic, pneumatic, chemical, thermal, or other energy.

**Hot tap.** A procedure used in the repair, maintenance,
and services activities, which involve welding on a piece of
equipment (pipelines, vessels, or tanks) under pressure, in order
to install connections or appurtenances. It is commonly used

20 Control of Hazardous Energy (Lockout/Tagout)

to replace or add sections of pipeline without the interruption
of service for air, gas, water, steam, and petrochemical
distribution systems.

**Lockout.** The placement of a lockout device on an
energy-isolating device, in accordance with an established
procedure, ensuring that the energy-isolating device and the
equipment being controlled cannot be operated until the
lockout device is removed.

**Lockout device.** A device that uses a positive means such
as a lock, either key or combination type, to hold an energyisolating device in the safe position and prevent the energizing
of a machine or equipment. Included are blank flanges and
bolted slip blinds.

**Normal production operations.** The utilization of a machine
or equipment to perform its intended production function.

**Servicing and/or maintenance.** Workplace activities such
as constructing, installing, setting up, adjusting, inspecting,
modifying, and maintaining and/or servicing machines or
equipment. These activities include lubricating, cleaning or
unjamming machines or equipment and making adjustments
or tool changes where the employee may be exposed to the
unexpected energization or startup of the equipment or release
of hazardous energy.

**Setting up.** Any work performed to prepare a machine or
equipment to perform its normal production operation.

**Tagout.** The placement of a tagout device on an energyisolating device, in accordance with an established procedure,
to indicate that the energy-isolating device and the equipment
being controlled may not be operated until the tagout device
is removed.

**Tagout device.** A prominent warning device, such as a tag
and a means of attachment, which can be securely fastened to
an energy-isolating device in accordance with an established
procedure, to indicate that the energy-isolating device and
the equipment being controlled may not be operated until the
tagout device is removed.

Commonly Used Terms 21

**OSHA Assistance, Programs, and Services**

**How can OSHA help me?**

OSHA can provide extensive help through a variety of
programs, including assistance about safety and health
programs, state plans, workplace consultations, voluntary
protection programs, strategic partnerships, training and
education, and more.

**How does safety and health program management assistance**
**help employers and employees?**

Effective management of worker safety and health
protection is a decisive factor in reducing the extent and
severity of work-related injuries and illnesses and their related
costs. In fact, an effective safety and health program forms the
basis of good worker protection and can save time and money
—about $4 for every dollar spent—and increase productivity.

To assist employers and employees in developing effective
safety and health programs, OSHA published recommended
_Safety and Health Program Management Guidelines (Federal_
_Register_ 54(18):3908-3916, January 26, 1989). These voluntary
guidelines can be applied to all worksites covered by OSHA.

The guidelines identify four general elements that are
critical to the development of a successful safety and health
management program:

  - Management leadership and employee involvement,

  - Worksite analysis,

  - Hazard prevention and control, and

  - Safety and health training.

The guidelines recommend specific actions under each of
these general elements to achieve an effective safety and health
program. The _Federal Register_ notice is available online at
www.osha.gov.

22 Control of Hazardous Energy (Lockout/Tagout)

**What are state plans?**

State plans are OSHA-approved job safety and health
programs operated by individual states or territories instead
of Federal OSHA. The _Occupational Safety and Health Act_
_of 1970 (OSH Act)_ encourages states to develop and operate
their own job safety and health plans and permits state
enforcement of OSHA standards if the state has an approved
plan. Once OSHA approves a state plan, it funds 50 percent
of the program’s operating costs. State plans must provide
standards and enforcement programs, as well as voluntary
compliance activities that are at least as effective as those
of Federal OSHA.

There are 26 state plans: 23 cover both private and public
(state and local

 each of

(state and local governments) employment, and 3 (Connecticut,
New Jersey, and New York) cover only the public sector.
For more information on state plans, see the listing at the end
of this publication, or visit OSHA’s website at www.osha.gov.

**How can consultation assistance help employers?**

In addition to helping employers identify and correct
specific hazards, OSHA’s consultation service provides free,
onsite assistance in developing and implementing effective
workplace safety and health management systems that
emphasize the prevention of worker injuries and illnesses.

Comprehensive consultation assistance provided by OSHA
includes a hazard survey of the worksite and an appraisal of all
aspects of the employer’s existing safety and health management
system. In addition, the service offers assistance to employers
in developing and implementing an effective safety and health
management system. Employers also may receive training and
education services, as well as limited assistance away from the
worksite.

What are state plans? 23

24 Control of Hazardous Energy (Lockout/Tagout)

What incentives does OSHA provide for seeking consultation assistance? 25

26 Control of Hazardous Energy (Lockout/Tagout)

Additional information on VPP is available from OSHA
national, regional, and area offices, listed beginning on page 34.
Also, see Outreach at OSHA’s website at www.osha.gov.

**How can a partnership with OSHA improve worker safety and health?**

OSHA has learned firsthand that voluntary, cooperative
partnerships with employers, employees, and unions can be a
useful alternative to traditional enforcement and an effective
way to reduce worker deaths, injuries, and illnesses. This is
especially true when a partnership leads to the development and
implementation of a comprehensive workplace safety and health
management system.

**What is OSHA’s Strategic Partnership Program (OSPP)?**

OSHA Strategic Partnerships are alliances among labor,
management, and government to foster improvements in
workplace safety and health. These partnerships are voluntary,
cooperative relationships between OSHA, employers, employee
representatives, and others such as trade unions, trade and
professional associations, universities, and other government
agencies. OSPPs are the newest member of OSHA’s family of
cooperative programs.

**What do OSPPs do?**

These partnerships encourage, assist, and recognize the
efforts of the partners to eliminate serious workplace hazards
and achieve a high level of worker safety and health. Whereas
OSHA’s Consultation Program and VPP entail one-on-one
relationships between OSHA and individual worksites, most
strategic partnerships seek to have a broader impact by
building cooperative relationships with groups of employers
and employees.

Can OSHA inspect an employer who is participating in the VPP? 27

**What are the different kinds of OSPPs?**

There are two major types:

  - Comprehensive, which focuses on establishing
comprehensive safety and health management systems
at partnering worksites; and

  - Limited, which helps identify and eliminate hazards
associated with worker deaths, injuries, and illnesses, or
have goals other than establishing comprehensive worksite
safety and health programs.

OSHA is interested in creating new OSPPs at the national,
regional, and local levels. OSHA also has found limited
partnerships to be valuable. Limited partnerships might address
the elimination or control of a specific industry hazard.

**What are the benefits of participation in the OSPP?**

Like VPP, OSPP can mean the following:

  - Fewer worker fatalities, injuries, and illnesses;

  - Lower workers’ compensation and other injury- and

illness-related costs;

  - Improved employee motivation to work safely, leading to

a better quality of life at work and enhanced productivity;

  - Positive community recognition and interaction;

  - Development of or improvement in safety and health

management systems; and

  - Positive interaction with OSHA.

For more information about this program, contact your nearest
OSHA office or go to the agency website at www.osha.gov.

28 Control of Hazardous Energy (Lockout/Tagout)

**Does OSHA have occupational safety and health training for**
**employers and employees?**

Yes. The OSHA Training Institute in Des Plaines, IL,
provides basic and advanced training and education in safety
and health for federal and state compliance officers, state
consultants, other federal agency personnel, and private-sector
employers, employees, and their representatives.

Institute courses cover diverse safety and health topics
including electrical hazards, machine guarding, personal
protective equipment, ventilation, and ergonomics. The facility
includes classrooms, laboratories, a library, and an audiovisual
unit. The laboratories contain various demonstrations and
equipment, such as power presses, woodworking and welding
shops, a complete industrial ventilation unit, and a sound
demonstration laboratory. More than 57 courses dealing with
subjects such as safety and health in the construction industry
and methods of compliance with OSHA standards are available
for personnel in the private sector.

In addition, OSHA’s 73 area offices are full-service centers
offering a variety of informational services such as personnel
for speaking engagements, publications, audiovisual aids on
workplace hazards, and technical advice.

**Does OSHA give money to organizations for training and education?**

OSHA awards grants through its Susan Harwood Training
Grant Program to nonprofit organizations to provide safety and
health training and education to employers and workers in the
workplace. The grants focus on programs that will educate
workers and employers in small business (fewer than 250
employees), train workers and employers about new OSHA
standards, or a high-risk activities or hazards. Grants are
awarded for 1 year and may be renewed for an additional 12 months
depending on whether the grantee has performed satisfactorily.

Does OSHA have occupational safety and health training? 29

OSHA expects each organization awarded a grant to develop
a training and/or education program that addresses a safety and
health topic named by OSHA, recruit workers and employers
for the training, and conduct the training. Grantees are also
expected to follow up with people who have been trained to
find out what changes were made to reduce the hazards in their
workplaces as a result of the training.

Each year OSHA has a national competition that is announced
in the _Federal Register_ and on the Internet at www.osha-slc.gov/
Training/sharwood/sharwood.html. If you do not have access
to the Internet, you can contact the OSHA Office of Training
and Education, 1555 Times Drive, Des Plaines, IL 60018,
(847) 297–4810, for more information.

**Does OSHA have other assistance materials available?**

Yes. OSHA has a variety of materials and tools available
on its website at www.osha.gov. These include eTools, Expert
Advisors, Electronic Compliance Assistance Tools (eCATS),
Technical Links, regulations, directives, publications, videos,
and other information for employers and employees. OSHA’s
software programs and compliance assistance tools walk you
through challenging safety and health issues and common
problems to find the best solutions for your workplace. OSHA’s
comprehensive publications program includes more than 100
titles to help you understand OSHA requirements and programs.

OSHA’s CD-ROM includes standards, interpretations,
directives, and more and can be purchased on CD-ROM from
the U.S. Government Printing Office. To order, write to the
Superintendent of Documents, U.S. Government Printing Office,
Washington, DC 20402, or phone (202) 512–1800. Specify
_OSHA Regulations, Documents and Technical Information on_
_CD-ROM (ORDT)_, GPO Order No. S/N 729-013-00000-5.

30 Control of Hazardous Energy (Lockout/Tagout)

**What do I do in case of an emergency or to file a complaint?**

To report an emergency, file a complaint, or seek OSHA
advice, assistance, or products, call (800) 321–OSHA or
contact your nearest OSHA regional or area office listed at the
end of this publication. The teletypewriter (TTY) number is
(877) 889–5627.

You can also file a complaint online and obtain more
information on OSHA federal and state programs by visiting
OSHA’s website at www.osha.gov.

For more information on grants, training, and education,
write: OSHA Training Institute, Office

 or phone (202) 512–1800. Specify

write: OSHA Training Institute, Office of Training and
Education, 1555 Times Drive, Des Plaines, IL 60018;
call (847) 297-4810; or see **Outreach** on OSHA’s website
at www.osha.gov.

What do I do in case of an emergency or to file a complaint? 31

**OSHA Regional and Area Offices**

**OSHA Regional Offices**

**Region I**
(CT,* MA, ME, NH, RI, VT*)
JFK Federal Building
Room E-340
Boston, MA 02203
Telephone: (617) 565 _–_ 9860

**Region II**
(NJ,* NY,* PR,* VI*)
201 Varick Street
Room 670
New York, NY 10014
Telephone: (212) 337 _–_ 2378

**Region III**
(DC, DE, MD,* PA, VA,* WV)
The Curtis Center—Suite 740 West
170 S. Independence Mall West
Philadelphia, PA 19106-3309
Telephone: (215) 861 _–_ 4900

**Region IV**
(AL, FL, GA, KY,* MS, NC,*
SC,* TN*)
Atlanta Federal Center
61 Forsyth Street, SW, Room 6T50
Atlanta, GA 30303
Telephone: (404) 562 _–_ 2300

**Region V**
(IL, IN,* MI,* MN,* OH, WI)
230 South Dearborn Street

Room 3244
Chicago, IL 60604
Telephone: (312) 353 _–_ 2220

**Region VI**
(AR, LA, MN,* OK, TX)
525 Griffin Street
Room 602
Dallas, TX 75202
Telephone: (214) 767 _–_ 4731

**Region VII**
(IA,* KS, MO, NE)
City Center Square
1100 Main Street, Suite 800
Kansas City, MO 64105
Telephone: (816) 426 _–_ 5861

**Region VIII**
(CO, MT, ND, SD, UT,* WY*)
1999 Broadway
Suite 1690
Denver, CO 80802-5716
Telephone: (303) 844 _–_ 1600

**Region IX**
(American Samoa, AZ,* CA,*
Guam, HI,* NV,*
Commonwealth of the
Northern Mariana Islands)
71 Stevenson Street

4th Floor
San Francisco, CA 94105
Telephone: (415) 975 _–_ 4310

**Region X**
(AK,* ID, OR,* WA*)
1111 Third Avenue
Suite 715
Seattle, WA 98101 _-_ 3212
Telephone: (206) 553 _–_ 5930

- These states and territories operate their own OSHA-approved job safety
and health programs (Connecticut, New Jersey, and New York plans cover
public employees only). States with approved programs must have a
standard that is identical to, or at least as effective as, the federal standard.

32 Control of Hazardous Energy (Lockout/Tagout)

**OSHA Area Offices**

Anchorage, AK
(907) 271 _–_ 5152

Birmingham, AL
(205) 731 _–_ 1534

Mobile, AL
(334) 441 _–_ 6131

Little Rock, AR

_–_
(501) 324 6291 (5818)

Phoenix, AZ
(602) 640 _–_ 2348

Sacramento, CA
(916) 566 _–_ 7471

San Diego, CA
(619) 557 _–_ 5909

Denver, CO
(303) 844 _–_ 5285

Englewood, CO
(303) 843 _–_ 4500
Bridgeport, CT
(203) 579 _–_ 5581

Hartford, CT
(860) 240 _–_ 3152

Wilmington, DE
(302) 573 _–_ 6518

Fort Lauderdale, FL
(954) 424 _–_ 0242

Jacksonville, FL
(904) 232 _–_ 2895

Tampa, FL
(813) 626 _–_ 1177

Savannah, GA
(912) 652 _–_ 4393

Smyrna, GA
(770) 984 _–_ 8700

Tucker, GA
(770) 493 _–_ 6644/6742/8419

Des Moines, IA
(515) 284 _–_ 4794

Boise, ID
(208) 321 _–_ 2960

Calumet City, IL
(708) 891 _–_ 3800

Des Plaines, IL
(847) 803 _–_ 4800

Fairview Heights, IL
(618) 632 _–_ 8612

North Aurora, IL
(630) 896 _–_ 8700

Peoria, IL
(309) 671 _–_ 7033

Indianapolis, IN
(317) 226 _–_ 7290

Wichita, KS
(316) 269 _–_ 6644

Frankfort, KY
(502) 227 _–_ 7024

Baton Rouge, LA

_–_
(225) 389 0474 (0431)

Braintree, MA
(617) 565 _–_ 6924

Methuen, MA
(617) 565 _–_ 8110

Springfield, MA
(413) 785 _–_ 0123

Linthicum, MD
(410) 865 _–_ 2055/2056

Augusta, ME
(207) 622 _–_ 8417

OSHA Regional and Area Offices 33

Bangor, ME
(207) 941 _–_ 8177

Portland, ME
(207) 780 _–_ 3178

Lansing, MI
(517) 327 _–_ 0904

Minneapolis, MN
(612) 664 _–_ 5460

Kansas City, MO
(816) 483 _–_ 9531

St. Louis, MO
(314) 425 _–_ 4289

Jackson, MS
(601) 965 _–_ 4606

Billings, MT
(406) 247 _–_ 7494

Raleigh, NC
(919) 856 _–_ 4770

Bismark, ND
(701) 250 _–_ 4521

Omaha, NE
(402) 221 _–_ 3182

Concord, NH
(603) 225 _–_ 1629

Avenel, NJ
(732) 750 _–_ 3270

Hasbrouck Heights, NJ
(201) 288 _–_ 1700

Marlton, NJ
(609) 757 _–_ 5181

Parsippany, NJ
(973) 263 _–_ 1003

Albuquerque, NM
(505) 248 _–_ 5302

Carson City, NV
(775) 885 _–_ 6963

Albany, NY
(518) 464 _–_ 4338
Bayside, NY
(718) 279 _–_ 9060

Bowmansville, NY
(716) 684 _–_ 3891

New York, NY
(212) 466 _–_ 2482

North Syracuse, NY
(315) 451 _–_ 0808

Tarrytown, NY
(914) 524 _–_ 7510

Westbury, NY
(516) 334 _–_ 3344

Cincinnati, OH
(513) 841 _–_ 4132

Cleveland, OH
(216) 522 _–_ 3818

Columbus, OH
(614) 469 _–_ 5582

Toledo, OH
(419) 259 _–_ 7542

Oklahoma City, OK

_–_

any, NY

Toledo, OH

_–_
(405) 231 5351 (5389)

Portland, OR
(503) 326 _–_ 2251

Allentown, PA
(610) 776 _–_ 0592

Erie, PA
(814) 833 _–_ 5758

Harrisburg, PA
(717) 782 _–_ 3902

34 Control of Hazardous Energy (Lockout/Tagout)

Philadelphia, PA
(215) 597 _–_ 4955

Pittsburgh, PA
(412) 395 _–_ 4903

Wilkes _–_ Barre, PA
(570) 826 _–_ 6538

Guaynabo, PR
(787) 277 _–_ 1560

Providence, RI
(401) 528 _–_ 4669

Columbia, SC
(803) 765 _–_ 5904

Nashville, TN
(615) 781 _–_ 5423

Austin, TX

_–_
(512) 916 5783 (5788)

Corpus Christi, TX
(512) 888 _–_ 3420

Dallas, TX

_–_
(214) 320 2400 (2558)

El Paso, TX
(915) 534 _–_ 6251

Fort Worth, TX

_–_ _–_
(817) 428 2470 (485 7647)

Houston, TX

_–_
(281) 591 2438 (2787)

_–_
(281) 286 0583/0584 (5922)

Lubbock, TX

_–_
(806) 472 7681 (7685)

Salt Lake City, UT
(801) 530 _–_ 6901

Norfolk, VA
(757) 441 _–_ 3820

Bellevue, WA
(206) 553 _–_ 7520

Appleton, WI
(920) 734 _–_ 4521

Eau Claire, WI
(715) 832 _–_ 9019

Madison, WI
(608) 264 _–_ 5388

Milwaukee, WI
(414) 297 _–_ 3315

Charleston, WV
(304) 347 _–_ 5937

OSHA Regional and Area Offices 35

**OSHA Consultation Projects**

(907) 269 _–_ 4957

Tuscaloosa, AL
(205) 348 _–_ 3033

(501) 682 _–_ 4522

(602) 542 _–_ 1695

(916) 574 _–_ 2555

Fort Collins, CO
(970) 491 _–_ 6151

Wethersfield, CT
(860) 566 _–_ 4550

Washington, DC
(202) 541 _–_ 3727

(302) 761 _–_ 8219

Tampa, FL
(813) 974 _–_ 9962

Atlanta, GA
(404) 894 _–_ 2643

Tiyam, GU
9 _–_ 1 _–_ (671) 475 _–_ 1101

Honolulu, HI
(808) 586 _–_ 9100

(515) 281 _–_ 7629

Boise, ID
(208) 426 _–_ 3283

Chicago, IL
(312) 814 _–_ 2337

(317) 232 _–_ 2688

Topeka, KS
(785) 296 _–_ 7476

(502) 564 _–_ 6895

(225) 342 _–_ 9601

West Newton, MA
(617) 727 _–_ 3982

Laurel, MD
(410) 880 _–_ 4970

(207) 624 _–_ 6460

(517) 322 _–_ 1809

Saint Paul, MN
(651) 297 _–_ 2393

Jefferson City, MO
(573) 751 _–_ 3403

(601) 987 _–_ 3981

Helena, MT
(406) 444 _–_ 6418

(919) 807 _–_ 2905

Bismarck, ND
(701) 328 _–_ 5188

Lincoln, NE
(402) 471 _–_ 4717

(603) 271 _–_ 2024

Trenton, NJ
(609) 292 _–_ 3923

Santa Fe, NM
(505) 827 _–_ 4230

36 Control of Hazardous Energy (Lockout/Tagout)

Albany, NY
(518) 457 _–_ 2238

Henderson, NV
(702) 486 _–_ 9140

(614) 644 _–_ 2631

(405) 528 _–_ 1500

Salem, OR
(503) 378 _–_ 3272

Indiana, PA
(724) 357 _–_ 2396

Hato Rey, PR
(787) 754 _–_ 2171

(401) 222 _–_ 2438

(803) 734 _–_ 9614

Brookings, SD
(605) 688 _–_ 4101

(615) 741 _–_ 7036

Austin, TX
(512) 804 _–_ 4640

Richmond, VA
(804) 786 _–_ 6359

Christiansted St. Croix, VI
(809) 772 _–_ 1315

Montepilier, VT
(802) 828 _–_ 2765

Olympia, WA
(360) 902 _–_ 5638

(608) 266 _–_ 9383

Waukesha, WI
(262) 523 _–_ 3044

(304) 558 _–_ 7890

Cheyenne, WY
(307) 777 _–_ 7786

OSHA Consultation Projects 37

**OSHA-Approved Safety and Health Plans**

Juneau, AK
(907) 465–2700

(602) 542–5795

San Francisco, CA
(415) 703–5050

(860) 263–6505

(808) 586–8844

(515) 281–3447

Indianapolis, ID
(317) 232–2378

(317) 232–3325

(502) 564–3070

Baltimore, MD
(410) 767–2215

(517) 322–1814

St. Paul, MN
(651) 284–5010

(919) 807–2900

(609) 292–2975

(505) 827–2850

(775) 684–7260

Salem, OR
**(** 503) 378–3272

(787) 754–211

olulu, HI

Salem, OR

(787) 754–2119

(803) 896–4300

(615) 741–2582

(801) 530–6901

(804) 786–2377

Christiansted, St. Croix, VI
(340) 773–1990

Montpelier VT
(802) 828–2288

(360) 902–4200
(360) 902–5430

(307) 777–7786

38 Control of Hazardous Energy (Lockout/Tagout)

### **www.osha.gov**

# **Safeguarding Equipment and** **Protecting Employees from** **Amputations**

**Small Business Safety and**
**Health Management Series**

**OSHA 3170-02R 2007**

Employers are responsible for providing a safe and
healthful workplace for their employees. OSHA’s
role is to assure the safety and health of America’s
employees by setting and enforcing standards; providing training, outreach, and education; establishing partnerships; and encouraging continual improvement in workplace safety and health.

This publication is in the public domain and may be
reproduced, fully or partially, without permission.
Source credit is requested, but not required.

This information is available to sensory impaired
individuals upon request. Voice phone: (202) 6931999; teletypewriter (TTY) number: (877) 889-5627.

Edwin G. Foulke, Jr.
Assistant Secretary of Labor for
Occupational Safety and Health

## **Safeguarding Equipment** **and Protecting Employees** **from Amputations**

###### **Occupational Safety and Health Administration** **U.S. Department of Labor**

**OSHA 3170-02R**

**2007**

**2**

This OSHA publication is not a standard or regulation, and it creates no new legal obligations. The
publication is advisory in nature, informational in content, and is intended to assist employers in
providing a safe and healthful workplace. _The Occupational Safety and Health Act_ requires employers
to comply with hazard-specific safety and health standards. In addition, pursuant to Section 5(a)(1),
the General Duty Clause of the Act, employers must provide their employees with a workplace free
from recognized hazards likely to cause death or serious physical harm. Employers can be cited for
violating the General Duty Clause if there is a recognized hazard and they do not take reasonable
steps to prevent or abate the hazard. However, failure to implement these recommendations is not,
in itself, a violation of the General Duty Clause. Citations can only be based on standards, regulations, and the General Duty Clause.

**Occupational Safety and**
**Health Administration**

#### **Contents**

**Introduction** **5**

**OSHA Standards** **5**

**National Consensus Standards** **6**

**Recognizing Amputation Hazards** **7**

**Hazardous Mechanical Components** **7**

**Hazardous Mechanical Motions** **7**

**Hazardous Activities** **9**

**Hazard Analysis** **9**

**Controlling Amputation Hazards** **9**

**Safeguarding Machinery** **9**

**Primary Safeguarding Methods** **10**

**Guards** **10**

**Safeguarding Devices** **13**

**Secondary Safeguarding Methods** **16**

**Probe Detection and Safety Edge Devices** **16**

**Awareness Devices** **17**

**Safeguarding Methods** **17**

**Safe Work Procedures** **18**

**Complementary Equipment** **18**

**Administrative Issues** **19**

**Inspection and Maintenance** **19**

**Lockout/Tagout** **20**

**Specific Machine Hazards and**
**Safeguarding Methods** **20**

**Hazards of Mechanical Power Presses** **20**

**Safeguarding Mechanical Power Presses** **22**

**Other Controls for Mechanical Power Press**

**Servicing and Maintenance** **23**

**Training** **24**

**Additional Requirements** **24**

**Power Press Brakes** **25**

**Hazards of Power Press Brakes** **25**

**Safeguarding Power Press Brakes** **25**

**Other Controls for Power Press Brakes** **26**

**Hazards of Conveyors** **26**

**Safeguarding Conveyors** **28**

**Other Controls for Conveyors** **29**

**Hazards of Printing Presses** **30**

**Safeguarding Printing Presses** **31**

**Other Controls for Printing Presses** **32**

**Hazards of Roll-Forming and**

**Roll-Bending Machines** **33**

**Safeguarding Roll-Forming and**

**Other Controls for Roll-Forming and**

**Roll-Bending Machines** **34**

**Hazards of Shearing Machines** **35**

**Safeguarding Shearing Machines** **36**

**Other Controls for Shearing Machines** **36**

**Hazards of Food Slicers** **37**

**Safeguarding and Other Controls for**

**Food Slicers** **38**

**Hazards of Meat Grinders** **38**

**Meat Grinders** **39**

**Hazards of Meat-Cutting Band Saws** **39**

**Meat-Cutting Band Saws** **40**

**Hazards of Drill Presses** **41**

**Drill Presses** **42**

**Hazards of Milling Machines** **43**

**Milling Machines** **44**

**Hazards of Grinding Machines** **45**

**Grinding Machines** **46**

**Hazards of Slitters** **46**

**Slitters** **47**

**OSHA Assistance** **49**

**References** **51**

**Appendix A.**
**Amputation Hazards Not Covered**
**in this Guide** **53**

**Appendix B.**
**Amputation Hazards Associated**
**with Other Equipment and Activities** **54**

**Appendix C.**
**OSHA Regional Offices** **55**

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **3**

**List of Tables**

**Table** **1.** **Commonly Used Machine Guards** **12**

**Table** **2.** **Types of Safeguarding Devices** **13**

**List of Figures**

**Figure** **1.** **Rotating Motion** **7**

**Figure** **2.** **Reciprocating Motion** **7**

**Figure** **3.** **Transversing Motion** **7**

**Figure 4.** **Cutting Action** **7**

**Figure 5.** **Punching Action** **8**

**Figure** **6.** **Shearing Action** **8**

**Figure** **7.** **Bending Action** **8**

**Figure 8.** **In-Running Nip Points** **8**

**Figure 9.** **Fixed Guard on a Power Press** **11**

**Figure 10.** **Power Press with an Adjustable**

**Barrier Guard** **11**

**Figure 11.** **Self-Adjusting Guard on a**

**Radial Saw** **11**

**Figure 12.** **Interlocked Guard on a Roll**

**Make-up Machine** **11**

**Figure 13.** **Pullback Device on a Power Press 13**

**Figure 14.** **Restraint Device on a Power Press 16**

**Figure 15.** **Presence-Sensing Device on a**

**Power Press** **16**

**Figure 16.** **Two-Hand Control** **16**

**Figure 17.** **Power Press with a Gate** **16**

**Figure 18.** **Power Press with a Plunger Feed** **17**

**Figure 19.** **Shuttle Ejection Mechanism** **18**

**Figure 20.** **Safety Tripod on a Rubber Mill** **18**

**Figure 21.** **Typical Hand-Feeding Tools** **19**

**Figure 22.** **Properly Guarded Foot Control** **19**

**Figure 23.** **Part Revolution Mechanical Power**

**Press with a Two-Hand Control** **21**

**Figure 24.** **Hand-Feeding Tools Used in**

**Conjunction with Pullbacks**

**on a Power Press** **23**

**Figure 25.** **Power Press Brake Bending Metal** **25**

**Figure 26.** **Two-Person Power Press Brake**

**Operation with Pullbacks** **26**

**Figure 27.** **Belt Conveyor** **27**

**Figure 28.** **Screw Conveyor** **27**

**Figure 29.** **Chain Driven Live Roller Conveyor 27**

**Figure 30.** **Slat Conveyor** **28**

**

.** **Typical Hand-Feeding Tools** **19**

**Figure 31.** **Roll-to-Roll Offset Printing Press** **31**

**Figure 32.** **Sheet-Fed Offset Printing Press** **31**

**Figure 33.** **Roll-Forming Machine** **33**

**Figure 34.** **In-Feed Area of a Roll-Forming**

**Machine** **33**

**Figure 35.** **Hydraulic Alligator Shear** **35**

**Figure 36.** **Power Squaring Shear** **35**

**Figure 37. Meat Slicer** **37**

**Figure 38.** **Stainless Steel Meat Grinder** **38**

**Figure 39.** **Stainless Steel Meat-Cutting**

**Band Saw** **40**

**Figure 40.** **Drill Press with a Transparent**

**Drill Shield** **41**

**Figure 41. Bed Mill** **43**

**Figure 42.** **Horizontal Surface Grinder** **45**

**Figure 43.** **Paper Slitter** **47**

**4**

#### **Introduction**

Amputations are among the most severe and disabling workplace injuries that often result in permanent disability. They are widespread and involve
various activities and equipment. (The U.S. Bureau
of Labor Statistics 2005 annual survey data indicated that there were 8,450 non-fatal amputation cases
– involving days away from work – for all private
industry. Approximately forty-four percent (44%) of
all workplace amputations occurred in the manufacturing sector and the rest occurred across the
construction, agriculture, wholesale and retail trade,
and service industries.) These injuries result from
the use and care of machines such as saws, presses, conveyors, and bending, rolling or shaping
machines as well as from powered and non-powered hand tools, forklifts, doors, trash compactors
and during materials handling activities.
Anyone responsible for the operation, servicing,
and maintenance (also known as use and care) of
machines (which, for purposes of this publication
includes equipment) — employers, employees,
safety professionals, and industrial hygienists—
should read this publication. Primary safeguarding,
as used in this publication, includes control methods that protect (e.g., prevent employee contact
with hazardous machine areas) employees from
machine hazards through effective machine guarding techniques. In addition, a hazardous energy
control (lockout/tagout) program needs to complement machine safeguarding methods in order to
protect employees during potentially hazardous
servicing and maintenance work activities.
This guide can help you, the small business
employer, identify and manage common amputation hazards associated with the operation and care
of machines. The first two sections of the document,
_Recognizing Amputation Hazards_ and _Controlling_
_Amputation Hazards_, look at sources of amputations and how to safeguard machinery and control
employee exposure to hazardous energy (lockout/
tagout) during machine servicing and maintenance
activities. The section on _Specific Machinery_
_Hazards and Safeguarding Methods_ identifies the
hazards and various control methods for machinery
associated with workplace amputations, such as:
mechanical power presses, press brakes, conveyors, printing presses, roll-forming and roll-bending
machines, shears, food slicers, meat grinders, meatcutting band saws, drill presses, milling machines,
grinding machines, and slitting machines.
The information in this booklet does not specifically address amputation hazards on all types of

machinery in general industry, construction, maritime and agricultural operations; however, many
of the described safeguarding techniques may be
used to prevent other amputation injuries. Additionally, while this manual concentrates attention
on concepts and techniques for safeguarding
mechanical motion, machines obviously present a
variety of other types of energy hazards that cannot
be ignored. For example, pressure system failure
could cause fires and explosions. Machine electrical sources also pose electrical hazards that are
addressed by other OSHA standards, such as the
electrical standards contained in Subpart S. Full
discussion of these matters is beyond the scope of
this publication. For compliance assistance purposes, references and the appendices are provided on
applicable OSHA standards, additional information
sources, and ways you may obtain OSHA assistance.

**OSHA Standards**

Although this guide recommends ways to safeguard
and lockout/tagout energy sources associated with
machinery hazards, there are legal requirements in
OSHA standards that you need to know about and
comply with. The following OSHA standards are a
few of the regulations that protect employees from
amputation hazards.

_**Machinery and Machine Guarding:**_
**29 CFR Part 1910, Subpart O**

 - 1910.211 – _Definitions_

 - 1910.212 – _General requirements for all_
_machines_

 - 1910.213 – _Woodworking machinery require-_

_ments_

 - 1910.215 – _Abrasive wheel machinery_

 - 1910.216 – _Mills and calenders in the rubber_

_and plastics industries_

 - 1910.217 – _Mechanical power presses_

 - 1910.218 – _Forging machines_

 - 1910.219 – _Mechanical power-transmission_
_apparatus_

_**Control of Hazardous Energy (Lockout/Tagout):**_
**29 CFR 1910.147**

_**Hand and Power Tools:**_

**29 CFR Part 1926, Subpart I**

 - 1926.300 – _General requirements_

 - 1926.303 – _Abrasive wheels and tools_

 - 1926.307 – _Mechanical power-transmission_

_**Conveyors:**_
**29 CFR 1926.555**

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **5**

_**Concrete and Masonry Construction**_
**29 CFR Part 1926, Subpart Q**

 - 1926.702 – _Requirements for equipment and_
_tools_

Consult these standards directly to ensure full
compliance with the provisions as this publication
is not a substitute for the standards. States with

OSHA-approved plans have at least equivalent
standards. For detailed information about machine

guarding and lockout/tagout, see the following

resources:

- Machine Guarding Safety and Health Topics
Page (http://www.osha.gov/SLTC/machine
guarding/index.html)

-  Machine Guarding eTool (http://www.osha.gov/
SLTC/etools/machineguarding/index.html)

- OSHA Publication 3067, Concepts and Techniques
of Machine Safeguarding (http://www.osha.gov/
Publications/Mach_Safeguarding/toc.html)

- OSHA Directive STD 01-05-019 [STD 1-7.3],
Control of Hazardous Energy (Lockout/Tagout)—
Inspection Procedures and Interpretive Guidance

- Control of Hazardous Energy (Lockout/Tagout)
Safety and Health Topics Page (http://www.osha.
gov/SLTC/controlhazardousenergy/index.html)

- OSHA’s Lockout Tagout Interactive Training
Program (http://www.osha.gov/dts/osta/
lototraining/index.htm)

- OSHA Publication 3120, Control of Hazardous
Energy (Lockout/Tagout)

OSHA standards, directives, publications,
and other resources are available online at

**National Consensus Standards**

OSHA recognizes the valuable contributions of
national consensus standards and these voluntary
standards may be used as guidance and recognition
of industry accepted practices. For example, the
American National Standards Institute (ANSI) publishes numerous voluntary national consensus standards on the safe care and use of specific machinery.
These consensus standards provide you with useful
guidance on how to protect your em-ployees from
machine amputation hazards and the control
methods described may assist you in complying
with OSHA performance-based standards.
Furthermore, OSHA encourages employers to
abide by the more current industry consensus standards since those standards are more likely to be
ab

 Interactive Training

abreast of the state of the art than an applicable
OSHA standard may be. However, when a consensus standard addresses safety considerations, OSHA

may determine that the safety practices described
by that consensus standard are less protective than
the requirement(s) set forth by the pertinent OSHA
regulations. OSHA enforcement policy regarding
the use of consensus standards is that a violation

of an OSHA standard may be deemed _de minimis_
in nature if the employer complies with a consensus standard (that is not incorporated by reference)
rather than the OSHA standard in effect and if the

employer’s action clearly provides equal or greater
employee protection. (Such _de minimis_ violations
require no corrective action and result in no penalty.)
For example, the OSHA point-of-operation
guarding provisions, contained in paragraph
1910.212(a)(3), require the guarding device to… _be_
_in conformance with any appropriate standards_
_thereof, or in the absence of applicable specific_
_standards, shall be so designed and constructed as_
_to prevent the operator from having any part of his_
_body in the danger zone during the operating cycle._
The terms applicable standards or appropriate standards, as used in the context of 29 CFR 1910.212,
are references to those private consensus standards that were adopted (source standards) or
incorporated by reference in the OSHA standards.
In some instances, a specific national consensus
standard (that is not incorporated by reference or a
source standard), such as an ANSI standard for a
particular machine, may be used for guidance purposes to assist employers in preventing an operator from having any body part in the machine danger zone during the operating cycle. Also, OSHA
may, in appropriate cases, use these consensus
standards as evidence that machine hazards are rec
ognized and that there are feasible means of correcting the hazard. On the other hand, some national consensus standards may sanction practices that
provide less employee protection than that provided
by compliance with the relevant OSHA provisions.
In these cases, compliance with the specific consensus standard provision would not constitute compliance with the relevant OSHA requirement.

Under the _Fair Labor Standards Act_ (FLSA), the
Secretary of Labor has designated certain nonfarm jobs as particularly hazardous for employees younger than 18. Generally, these employees are prohibited from operating:

 - Band saws • Circular saws • Guillotine

shears • Punching and shearing machines

 - Meatpacking or meat-processing machines

 - Certain power-driven machines: Paper products
machines, Woodworking machines, Metal
forming machines, and Meat slicers.

**6**

#### **Recognizing Amputation** **Hazards**

To prevent employee amputations, you and your
employees must first be able to recognize the contributing factors, such as the hazardous energy associated with your machinery and the specific employee
activities performed with the mechanical operation.
Understanding the mechanical components of
machinery, the hazardous mechanical motion that
occurs at or near these components and specific
employee activities performed in conjunction with
machinery operation will help employees avoid injury.

**Hazardous Mechanical Components**
Three types of mechanical components present
amputation hazards:

**Point of Operation** is the area of the machine
where the machine performs work – i.e., mechanical actions that occur at the point of operation,
such as cutting, shaping, boring, and forming.

**Power-Transmission Apparatus** is all components
of the mechanical system that transmit energy,
such as flywheels, pulleys, belts, chains, couplings,
connecting rods, spindles, cams, and gears.

**Other Moving Parts** are the parts of the machine
that move while the machine is operating, such
as reciprocating, rotating, and transverse moving parts as well as lead mechanisms and auxiliary parts of the machine.

**Hazardous Mechanical Motions**

A wide variety of mechanical motion is potentially
hazardous. Here are the basic types of hazardous
mechanical motions:

**Rotating Motion** ( _Figure 1_ ) is circular motion such
as action generated by rotating collars, couplings,
cams, clutches, flywheels, shaft ends, and spindles that may grip clothing or otherwise force a
body part into a dangerous location. Even smooth
surfaced rotating machine parts can be hazardous.
Projections such as screws or burrs on the rotating part increase the hazard potential.

_**Figure 1**_ **Rotating Motion**

**Reciprocating Motion** ( _Figure 2_ ) is back-and-forth
or up-and-down motion that may strike or entrap
an employee between a moving part and a fixed
object.

_**Figure 2**_ **Reciprocating Motion**

**Transversing Motion** ( _Figure 3_ ) is motion in a
straight, continuous line that may strike or catch
an employee in a pinch or shear point created by
the moving part and a fixed object.

_**Figure 3**_ **Transversing Motion**

**Cutting Action** ( _Figure 4_ ) is the action that cuts
material and the associated machine motion may
be rotating, reciprocating, or transverse.

_**Figure 4**_ **Cutting Action**

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**Punching Action** ( _Figure 5_ ) begins when power
causes the machine to hit a slide (ram) to stamp
or blank metal or other material. The hazard

occurs at the point of operation where the
employee typically inserts, holds, or withdraws
the stock by hand.

_**Figure 5**_ **Punching Action**

**Shearing Action** ( _Figure 6_ ) involves applying
power to a slide or knife in order to trim or shear
metal or other materials. The hazard occurs at the

point of operation where the employee typically
inserts, holds, or withdraws the stock by hand.

_**Figure 6**_ **Shearing Action**

**Bending Action** ( _Figure 7_ ) is power applied to a
slide to draw or stamp metal or other materials in
a bending motion. The hazard occurs at the point
of operation where the employee typically inserts,
holds, or withdraws the stock by hand.

_**Figure 7**_ **Bending Action**

**In-Running Nip Points** ( _Figure 8_ ), also known as
“pinch points,” develop when two parts move
together and at least one moves in rotary or circular motion. In-running nip points occur whenever
machine parts move toward each other or when
one part moves past a stationary object. Typical
nip points include gears, rollers, belt drives, and
pulleys.

_**Figure 8**_ **In-Running Nip Points**

**Nip**
**Point**

**8**

**Hazardous Activities**

Employees operating and caring for machinery
perform various activities that present potential

Machine set-up/threading/preparation,*
Machine inspection,*
Normal production operations,
Clearing jams,*
Machine adjustments,*
Cleaning of machine,*
Lubricating of machine parts,* and
Scheduled and unscheduled maintenance.*

 - These activities are servicing and/or maintenance activities.

**Hazard Analysis**
You can help prevent workplace amputations by
looking at your workplace operations and identifying the hazards associated with the use and care of
the machine. A hazard analysis is a technique that
focuses on the relationship between the employee,
the task, the tools, and the environment. When
evaluating work activities for potential amputation
hazards, you need to consider the entire machine
operation production process, the machine modes
of operation, individual activities associated with
the operation, servicing and maintenance of the
machine, and the potential for injury to employees.
The results from the analysis may then be used
as a basis to design machine safeguarding and an
overall energy control (lockout/tagout) program.
This is likely to result in fewer employee amputations; safer, more effective work methods; reduced
workers’ compensation costs; and increased employee productivity and

workers’ compensation costs; and increased employee productivity and morale.

##### **Controlling Amputation** **Hazards**

Safeguarding is essential for protecting employees
from needless and preventable injury. A good rule
to remember is:

_Any machine part, function, or process that may_
_cause injury must be safeguarded._

In this booklet, the term _primary safeguarding_
_methods_ refers to machine guarding techniques
that are intended to prevent or greatly reduce the
chance that an employee will have an amputation
injury. Refer to the OSHA general industry (e.g.,
Subpart O) and construction (e.g., Subparts I and
N) standards for specific guarding requirements.
Many of these standards address preventive methods (such as using barrier guards or two-hand tripping devices) as primary control measures; while
other OSHA standards allow guarding techniques
(such as a self-adjustable table saw guard) that
reduce the likelihood of injury. Other less protective
safeguarding methods (such as safe work methods)
that do not satisfactorily protect employees from
the machine hazard areas are considered second
ary control methods.
Machine safeguarding must be supplemented
by an effective energy control (lockout/tagout)
program that ensures that employees are protected
from hazardous energy sources during machine
Lockout/tagout plays an essential role in the prevention and control of workplace amputations. In
terms of controlling amputation hazards, employees are protected from hazardous machine work
activities either by: 1) effective machine safeguarding, or 2) lockout/tagout where safeguards are rendered ineffective or do not protect employees from
hazardous energy during servicing and maintenance operations.
Additionally, there are some servicing activities,
such as lubricating, cleaning, releasing jams and
making machine adjustments that are minor in
nature and are performed during normal production operations. It is not necessary to lockout/
tagout a machine if the activity is routine, repetitive
and integral to the production operation provided
that you use an alternative control method that
affords effective protection from the machine’s
hazardous energy sources.

**Safeguarding Machinery**
The employer is responsible for safeguarding
machines and should consider this need when purchasing machinery. Almost all new machinery is

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available with safeguards installed by the manufacturer, but used equipment may not be.
If machinery has no safeguards, you may be
able to purchase safeguards from the original
machine manufacturer or from an after-market

manufacturer. You can also build and install the

safeguards in-house. Safeguarding equipment
should be designed and installed only by technically qualified professionals. If possible, the original
equipment manufacturer should review the safeguard design to ensure that it will protect employees without interfering with the operation of the
machine or creating additional hazards.
Regardless of the source of safeguards, the
guards and devices used need to be compatible
with a machine’s operation and designed to ensure
safe operator use. The type of operation, size, and
shape of stock, method of feeding, physical layout
of the work area, and production requirements all
affect the selection of safeguards. Also, safeguards
should be designed with the machine operator in
mind as a guarding method that interferes with the
operation of the machine may cause employees to
override them. To ensure effective and safe operator
use, guards and devices should suit the operation.
The Performance Criteria for Safeguarding

[ANSI B11.19-2003] national consensus standard
provides valuable guidance as the standard
addresses the design, construction, installation,
operation and maintenance of the safeguarding
used to protect employees from machine hazards.
The following safeguarding method descriptions
are, in part, structured like and, in many ways are
similar to this national consensus standard.

The _Performance Criteria for Safeguarding_ [ANSI
B11.19-2003] defines safeguarding as the _protec-_
_tion of personnel from hazards by the use of_
_guards, safeguarding devices awareness devices,_
_safeguarding methods, or safe work procedures._
The following ANSI B11.19 definitions describe
the various types of safeguarding:

**Guard:** A barrier that prevents exposure to an
identified hazard.

**Safeguarding device:** A device that detects or
prevents inadvertent access to a hazard.

NOTE: The 1990 ANSI B11.19 term _Safeguarding_
_device_ was modified to _Safeguarding (Protective)_
_Device_ in the revised 2003 ANSI standard and the

new term includes a detection component. Devices that detect, but do not prevent employee

exposure to machine hazards are not considered
by OSHA to be primary safeguarding methods.

**Awareness device:** A barrier, signal or sign that
warns individuals of an impending, approaching
or present hazard.

**Safeguarding method:** Safeguarding implemented to protect individuals from hazards by the
physical arrangement of distance, holding, openings, or positioning of the machine or machine
production system to ensure that the operator
cannot reach the hazard.

**Safe work procedures:** Formal written instructions developed by the user which describe how
a task is to be performed.

**Primary Safeguarding Methods**
Two primary methods are used to safeguard
machines: guards and some types of safeguarding
devices. Guards provide physical barriers that prevent access to danger areas. Safeguarding devices
either prevent or detect operator contact with the
point of operation or stop potentially hazardous
machine motion if any part of an individual’s body
is within the hazardous portion of the machine.
Both types of safeguards need to be properly
designed, constructed, installed, used and maintained in good operating condition to ensure
employee protection.

**Criteria for Machine Safeguarding**

 - Prevents employee contact with the hazard
area during machine operation.

 - Avoids creating additional hazards.

 - Is secure, tamper-resistant, and durable.

 - Avoids interfering with normal operation of
the machine.

 - Allows for safe lubrication and maintenance.

**Guards**

Guards usually are preferable to other control
methods because they are physical barriers that
enclose dangerous machine parts and prevent
employee contact with them. To be effective,
guards must be strong and fastened by any secure
method that prevents the guard from being inadvertently dislodged or removed. Guards typically
are designed with screws, bolts and lock fasteners
and usually a tool is necessary to unfasten and

**1 0**

remove them. Generally, guards are designed not
to obstruct the operator’s view or to prevent
employees from doing a job.
In some cases, guarding may be used as an
alternative to lockout/tagout because employees
can safely service or maintain machines with a
guard in place. For example, polycarbonate and
wire-mesh guards provide greater visibility and can
be used to allow maintenance employees to safely
observe system components. In other instances,
employees may safely access machine areas, without locking or tagging out, to perform maintenance
work (such as machine cleaning or oiling tasks)
because the hazardous machine components
remain effectively guarded.
Guards must not create additional hazards such

as pinch points or shear points between guards
and other machine parts. Guard openings should
be small enough to prevent employees from
accessing danger areas. (See _Table 1_ and _Figures_
_9 through 12_ for commonly used machine guards.)

_**Figure 9**_ **Fixed Guard on a Power Press**

_**Figure 10**_ **Power Press with an Adjustable Barrier Guard**

_**Figure 11**_ **Self-Adjusting Guard on a Radial Saw**

_**Figure 12**_ **Interlocked Guard on a Roll Make-up Machine**

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_**Table 1.**_ **Commonly Used Machine Guards**

|Types of Machine Guards|Col2|Col3|

See _Table 1_ and _Figures_

|Types of Machine Guards|Col2|Col3|Col4|
|---|---|---|---|
|**Type**|**Method of**<br>**Safeguarding**|**Advantages**|**Limitations**|
|Fixed|Barrier that allows for<br>stock feeding but does not<br>permit operator to reach<br>the danger area.|• Can be constructed to suit<br>many applications.<br>• Permanently encloses<br>the point of operation or<br>hazard area.<br>• Provides protection<br>against machine repeat.<br>• Allows simple, in-plant<br>construction, with mini-<br>mal maintenance.|• Sometimes not practical<br>for changing production<br>runs involving different<br>size stock or feeding<br>methods.<br>• Machine adjustment and<br>repair often require guard<br>removal.<br>• Other means of protecting<br>maintenance personnel<br>often required<br>(lockout/tagout).|
|Adjustable|Barrier that adjusts for<br>a variety of production<br>operations.|• Can be constructed to<br>suit many applications.<br>• Can be adjusted to admit<br>varying stock sizes.|• May require frequent<br>maintenance or<br>adjustment.<br>• Operator may make<br>guard ineffective.|
|Self-<br>Adjusting|Barrier that moves<br>according to the size of the<br>stock entering point of<br>operation. Guard is in place<br>when machine is at rest<br>and pushes away when<br>stock enters the point of<br>operation.|• Off-the-shelf guards are<br>often commercially avail-<br>able.|• Does not provide<br>maximum protection.<br>• May require frequent<br>maintenance and<br>adjustment.|
|Interlocking<br>Barrier<br>Guards|Shuts off or disengages<br>power and prevents<br>machine start-up when<br>guard is open. Should<br>allow for inching of<br>machine.|• Allows access for some<br>minor servicing work, in<br>accordance with the lock-<br>out/tagout exception,<br>without time-consuming<br>removal of fixed guards.|• May require periodic<br>maintenance or adjust-<br>ment.<br>• Movable sections cannot<br>be used for manual feed-<br>ing.<br>• Some designs may be<br>easy to defeat.<br>• Interlock control circuitry<br>may not be used for all<br>maintenance and servic-<br>ing work.|

**1 2**

**Safeguarding Devices**
Safeguarding devices are controls or attachments
that, when properly designed, applied and used,
usually prevent inadvertent access by employees to
hazardous machine areas by:

- Preventing hazardous machine component operation if your hand or body part is inadvertently
placed in the danger area;

- Restraining or withdrawing your hands from the
danger area during machine operation;

- Requiring the use of both of your hands on
machine controls (or the use of one hand if the
control is mounted at a safe distance from the

danger area) that are mounted at a predetermined safety distance; or

- Providing a barrier which is synchronized with
the operating cycle in order to prevent entry to
the danger area during the hazardous part of the
cycle.

These types of engineering controls, which
either prevent the start of or stop hazardous
motion, may be used in place of guards or as
supplemental control measures when guards alone
do not adequately enclose the hazard. In order for
these safeguarding devices to accomplish this
requirement, they must be properly designed and
installed at a predetermined safe distance from the
machine’s danger area. Other safeguarding devices
(probe detection and safety edge devices) that
merely detect, instead of prevent, inadvertent

_**Table 2.**_ **Types of Safeguarding Devices**

access to a hazard are not considered primary safeguards. (See _Table 2_ and _Figures 13 through 17_ for
the types of safeguarding devices.)

_**Figure 13**_ **Pullback Device on a Power Press**

|Pullback<br>Devices|Cords connected to<br>operator’s wrists and<br>linked mechanically to<br>the machine automatically<br>withdraw the hands from<br>the point of operation<br>during the machine cycle.|•  Allows the hands to enter<br>the point of operation for<br>feeding and removal.<br>•  Provides protection even<br>in the event of mechani-<br>cal repeat.|•  Close supervision ensures<br>proper use and adjust-<br>ment.  Must be inspected<br>prior to each operator<br>change or machine set-up.<br>•  Limits operator’s move-<br>ment and  may obstruct<br>their work space.<br>•  Operator may easily make<br>device ineffective by not<br>adjusting the device<br>properly.|

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_**Table 2.**_ **Types of Safeguarding Devices (continued)**

|Restraint<br>Devices|Wrists are connected by<br>cords and secured to a<br>fixed anchor point which<br>limit operator’s hands from<br>reaching the point of oper-<br>ation at any time.|• Simple, few moving<br>parts; requires little<br>maintenance.<br>• Operator cannot reach<br>into the danger area.<br>• Little risk of mechanical<br>failure; provides protec-<br>tion even in the event of<br>mechanical repeat.|• Close supervision re-<br>quired to ensure proper<br>use and adjustment.<br>Must be inspected prior<br>to each operator change<br>or machine set-up.<br>• Operator must use hand<br>tools to enter the point of<br>operation.<br>• Limits the movement of<br>the operator; may<br>obstruct work space<br>around operator.<br>• Operator may easily make<br>device ineffective by dis-<br>connecting the device.|
|Presence-<br>Sensing<br>Devices|Interlock into the machine’s<br>control system to stop<br>operation when the sens-<br>ing field (photoelectric,<br>radio frequency, or electro-<br>magnetic) is disturbed.|• Adjusts to fit different<br>stock sizes.<br>• Allows access to load<br>and unload the machine.<br>• Allows access to the<br>guarded area for main-<br>tenance and set-up<br>activities.|• Restricted to machines<br>that stop operating cycle<br>before operator can reach<br>into danger area (e.g.,<br>machines with partial<br>revolution clutches or<br>hydraulic machines).<br>• Must be carefully main-<br>tained and adjusted.<br>• Does not protect<br>operator in the event<br>of a mechanical failure.<br>• Operator may make<br>device ineffective.|
|Presence-<br>Sensing<br>Mats|Interlock into machine’s<br>control system to stop<br>operation when a predeter-<br>mined weight is applied to<br>the mat. A manual reset<br>switch must be located out-<br>side the protected zone.|• Full visibility and access<br>to the work area.<br>• Install as a perimeter<br>guard or over an entire<br>area.<br>• Configure for many<br>applications.|• Restricted to machines<br>that stop operating cycle<br>before operator can reach<br>into danger area (e.g.,<br>

e.g.,<br>machines with partial<br>revolution clutches or<br>hydraulic machines).<br>• Must be carefully main-<br>tained and adjusted.<br>• Does not protect<br>operator in the event<br>of a mechanical failure.<br>• Operator may make<br>device ineffective.|
|Presence-<br>Sensing<br>Mats|Interlock into machine’s<br>control system to stop<br>operation when a predeter-<br>mined weight is applied to<br>the mat. A manual reset<br>switch must be located out-<br>side the protected zone.|• Full visibility and access<br>to the work area.<br>• Install as a perimeter<br>guard or over an entire<br>area.<br>• Configure for many<br>applications.|• Restricted to machines<br>that stop operating cycle<br>before operator can reach<br>into danger area (e.g.,<br>machines with part-<br>revolution clutches or<br>hydraulic machines).<br>• Some chemicals can<br>degrade the mats.<br>• Does not protect<br>operator during<br>mechanical failures.|

**1 4**

|Two-<br>Hand<br>Control|Requires concurrent and<br>continued use of both<br>hands, preventing them<br>from entering the danger<br>area.|•  Operator’s hands are at<br>a  predetermined safety<br>distance.<br>•  Operator’s hands are free<br>to pick up new parts after<br>completion of first part of<br>cycle.|•  Requires a partial cycle<br>machine with a brake<br>and anti-repeat feature.<br>•  Operator may make<br>devices without anti-<br>tiedown ineffective.<br>•  Protects the operator<br>only.|
|Two-<br>Hand Trip|Requires concurrent use of<br>both hands, prevents them<br>from being in danger area<br>when machine cycle starts.|•  Operator’s hands are at<br>a predetermined safety<br>distance.<br>•  Can be adapted to<br>multiple operations.<br>•  No obstruction to hand<br>feeding.|•  Operator may make<br>devices without anti-<br>tiedown ineffective.<br>•  Protects the operator<br>only.<br>•  Sometimes impractical<br>because distance require-<br>ments may reduce pro-<br>duction below acceptable<br>level.<br>•  May require adjustment<br>with tooling changes.<br>•  Requires anti-repeat<br>feature.|
|Type “A”<br>Gate<br>(move-<br>able<br>barrier)|Applicable to mechanical<br>power presses. Provides<br>barrier between danger<br>area and operator (or other<br>employees) until comple-<br>tion of  machine cycle.|•  Prevents operator from<br>reaching into danger area<br>during machine cycle.<br>•  Provides protection from<br>machine repeat.|•  May require frequent<br>inspection and regular<br>maintenance.<br>•  May interfere with opera-<br>tor’s ability to see work.|
|Type “B”<br>Gate<br>(move-<br>able<br>barrier)|Applicable to mechanical<br>power presses and press<br>brakes.  Provides a barrier<br>between danger area and<br>operator (or other employ-<br>ees) during the down-<br>stroke.|•  May increase production<br>by allowing the operator<br>to remove and feed the<br>press on the upstroke.|•  Can only be used on<br>machines with a part-<br>revolution clutch or<br>hydraulic machines.<br>•  May require frequent<br>inspection and regular<br>maintenance.<br>•  May interfere with the<br>operator’s ability to see<br>work.|

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_**Figure 14**_ **Restraint Device on a Power Press**

_**Figure 15**_ **Presence-Sensing Device on a Power Press**

_**Figure 17**_ **Power Press with a Gate**

**Secondary Safeguarding Methods**
Other safeguarding methods, such as those described
in the _Performance Criteria for Safeguarding_ (ANSI
B11.19-2003), may also provide employees with
some protection from machine hazards. Detection
safeguarding devices, awareness devices, safeguarding methods and safe work procedures are
described in this section. These methods provide a
lesser degree of employee protection than the primary safeguarding methods and they are considered secondary control measures as they do not
prevent employees from placing or having any part
of their bodies in the hazardous machine areas.

Secondary safeguarding methods are acceptable only when guards or safeguarding devices
(that prevent you from being exposed to machine
hazards) cannot be installed due to reasons of
infeasibility. Where it is feasible to use primary
safeguarding methods, secondary safeguarding
methods may supplement these primary control
measures; however, these secondary safeguarding
methods must not be used in place of primary safeguarding methods.

**Probe Detection and Safety Edge Devices**
A probe detection device (sometimes referred to as
a _ring guard_ ) detects the presence or absence of a
person’s hand or finger by encircling all or part of
the machine hazard area. The _ring guard_ makes
you aware of your hand’s entry into a hazardous
area and usually stops or prevents a hazardous
machine cycle or stroke, thereby reducing the likelihood of injuring yourself in the point of operation.
These types of detection devices are commonly
used on spot welders, riveters, staplers and stack

_**Figure 16**_ **Two-Hand Control**

**1 6**

ers because primary safeguarding methods are not
possible. However, probe detection devices do not
prevent inadvertent access to the point-of-operation
danger area; rather, they serve as a warning mechanism and may prevent the initiation of or stop the
machine cycle if an employee’s hand or finger(s) is
too close to the hazard area.

A safety edge device (sometimes called a _bump_
_switch_ ) is another type of safeguard that detects the
presence of an employee when they are in contact
with the device’s sensing edge. A safety edge
device protects employees by initiating a stop command when the sensing surface detects the presence of a person; however, they do not usually,
when used by themselves, prevent inadvertent
access to machine danger areas. Therefore, additional guarding or safeguarding devices must be
provided to prevent employee exposure to a
machine hazard.

**Awareness Devices**

Awareness devices warn employees of an impending, approaching or present hazard. The first type
is an awareness barrier which allows access to

machine danger areas, but it is designed to contact
the employee, creating an awareness that he or she
is close to the danger point. Awareness signals,
through the use of recognizable audible or visual
signals, are other devices that alert employees to
an approaching or present hazard. Lastly, awareness signs are used to notify employees of the
nature of the hazard and to provide instructions
and training information. OSHA standard 1910.145
provides design, application, and use specifications
for accident prevention (danger, caution, safety
instruction) signs and (danger, caution, warning)
tags.

**Safeguarding Methods**
Safeguarding methods protect employees from
hazards by the physical arrangement of distance,
holding, openings or the positioning of the
machine components to ensure that the operator
cannot reach the hazard. Some safeguarding work
methods include safe distance safeguarding, safe
holding safeguarding and safe opening safeguarding. Requirements for these secondary control
measures may be found in ANSI B11.19-2003.
Proper training and supervision are essential to
ensure that these secondary safeguarding methods
are being used properly. Safeguarding work methods may require the use of awareness devices,
including the use of accident prevention signs where
there is a need for warning or safety instruction.

**Safe Distance Safeguarding**
Safeguarding by safe distance (by location) may
involve an operator holding and supporting a workpiece with both hands at a predetermined minimum safe distance or, if both hands cannot be used
to hold the work-piece at a distance so that the
operator cannot reach the hazard with the free
hand. For example, the feeding process itself can
create a distance safeguard if the operators maintain a safe distance between their hands and the

point of operation. Additionally, where material
position gauges are used, they need to be

position gauges are used, they need to be of sufficient height and size to prevent slipping of the
material past the gauges.
Another example of a safe distance safeguarding method is the use of gravity feed methods that
reduce or eliminate employee exposure to machine
hazards as the part slides down a chute into the
point of operation. Automatic and semiautomatic
feeding and ejection methods can also protect the
employee by minimizing or eliminating employee
exposure with potentially hazardous machinery
components. An employee places the part in a
magazine which is then fed into the point of operation. Automatic and semiautomatic ejection methods
include pneumatic (jet of air), magnetic, mechanical
(such as an arm), or vacuum. _Figures 18 and 19_
illustrate different types of automatic feeding and
ejecting methods.

_**Figure 18**_ **Power Press with a Plunger Feed**

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_**Figure 19**_ **Shuttle Ejection Mechanism**

**Slide in**

**Safe Holding Safeguarding (** _**Safe Work-Piece**_
**Safeguarding)**
Operator’s hands are maintained away from the
hazardous portion of the machine cycle by requiring that both hands are used to hold or support the
work-piece, or by requiring that one hand holds the
work-piece while the other hand operates the
machine. For instance, if the stock is several feet long
and only one end of the stock is being worked on,
the operator may be able to hold the opposite end
while performing the work. The operator’s body
parts are out of the machine hazard area during the
hazardous portion of the machine cycle. However,
this work method only protects the operator.

**Safe Opening Safeguarding**
This method limits access to the machine haz
ardous areas by the size of the opening or by closing off the danger zone access when the work-piece
is in place in the machine. Operators are prevented
from reaching the hazard area during the machine
operation; however, employee access to the danger
area is not adequately guarded when the workpiece is not in place.

**Safe Work Procedures**

Safe work procedures are formal, written instructions which describe how a task is to be performed.
These procedures should incorporate appropriate
safe work practices, such as prohibiting employees
from wearing loose clothing or jewelry and requiring the securing of long hair with nets or caps.
Clothing, jewelry, long hair, and even gloves can get
entangled in moving machine parts.

**Complementary Equipment**
Complementary equipment is used in conjunction
with selected safeguarding techniques and it is, by
itself, not a safeguarding method. Some common
complementary equipment used to augment
machine safeguarding include:

**Emergency Stop Devices**
Emergency stop devices are designed to be used
in reaction to an incident or hazardous situation

and, as such, are not considered machine safeguarding. These devices, such as buttons, ropepulls, cable-pulls, or pressure-sensitive body bars,
neither detect nor prevent employee exposure to
machine hazards; rather they initiate an action to
stop hazardous motion when an employee recognizes a hazard and activates them. (See _Figure 20_ .)

_**Figure 20**_ **Safety Tripod on a Rubber Mill**

**Work-Holding Equipment**
Work-holding equipment is not used to feed or remove the work-piece, but rather to hold it in place
during the hazardous portion of the machine cycle.
Clamps, jigs, fixtures and back gauges are examples of work-holding equipment. This equipment
may be used to reduce or eliminate the need for an
employee to place their hands in the hazard area.

**Feeding and Ejection Systems**
A feeding and ejection system (e.g., a gravity fed
chute; semi-automatic and automatic feeding and
ejection equipment), by itself, does not constitute
secondary safeguarding. However, the use of properly designed feed and ejection mechanisms can
protect employees by minimizing or eliminating the
need for them to be in a hazard area during the
hazardous motion of the machine.

**Hand-Feeding Tools**
Operators can use tools to feed and remove material into and from machines so as to keep their
hands away from the point of operation. However,
this must be done only in conjunction with the
guards and safeguarding devices described previously. Hand tools are not point-of-operation guard

**1 8**

ing or safeguarding devices and they need to be
designed to allow employees’ hands to remain outside of the machine danger area. Using hand tools
requires close supervision to ensure that the operator does not bypass their use to increase production. It is recommended that these tools be stored

near the operation to promote their use.
To prevent injury and repetitive trauma disorders, hand-feeding tools should be shatterproof
and ergonomically designed for the specific task
being performed. ( _Figure 21_ shows typical handfeeding tools.)

_**Figure 21**_ **Typical Hand-Feeding Tools**

**Foot Controls**

Foot controls that are not securely fixed at a safe
distance do not constitute machine safeguarding
because they do not keep the operator’s hands out
of the danger area. If you use foot-actuated controls that are not single-control safeguarding
devices, they will need to be used with some type
of guard or other safeguarding device.
Improperly used foot-actuated controls may
increase productivity, but the freedom of hand
movement increases the risk of a point-of-operation
injury or amputation. Foot controls must be guarded to prevent accidental activation by another
employee or by falling material. Do not ride the
foot pedal. Ensure that the machine control circuit
is properly designed to prevent continuous cycling.
(See _Figure 22_ for an example of a properly guarded foot control.)

_**Figure 22**_
**Properly Guarded**

**Foot Control**

**Administrative Issues**

As an employer, you need to consider housekeeping practices, employee apparel, and employee
training. Implement good housekeeping practices
to promote safe working conditions around machinery by doing the following:

- Remove slip, trip, and fall hazards from the
areas surrounding machines;

- Use drip pans when oiling equipment;

- Remove waste stock as it is generated;

- Make the work area large enough for machine
operation and maintenance; and

- Place machines away from high traffic areas to
reduce employee distraction.

Employees should not wear loose-fitting clothing, jewelry, or other items that could become
entangled in machinery, and long hair should be
worn under a cap or otherwise contained to prevent entanglement in moving machinery.
Adequate instruction in the safe use and care of
machines and supervised on-the-job training are
essential in preventing amputation injuries. Only
trained employees should operate machinery.

**Train Employees in the Following:**

 - All hazards in the work area, including
machine-specific hazards;

 - Machine operating procedures, lockout/tagout
procedures and safe work practices;

 - The purpose and proper use of machine safeguards; and

 - All procedures for responding to safeguarding
problems such as immediately reporting unsafe conditions such as missing or damaged
guards and violations of safe operating practices to supervisors.

In addition to employee instruction and training,
employers need to provide adequate supervision
to reinforce safe practices. Take disciplinary action to enforce safe work practices and working
conditions.

**Inspection and Maintenance**
Good inspection, maintenance and repair procedures contribute significantly to the safety of the
maintenance crew as well as to the operators. To
ensure the integrity of the machinery and machine
safeguards, a proactive, versus a _break-down_ main

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tenance program needs to be established based
upon the:

- Manufacturer’s recommendations;

- Good engineering practice; and

- Any applicable OSHA provisions (such as the
mechanical

 and training,

upon the:

mechanical power press inspection and maintenance requirements, contained in 1910.217(e)).

**Lockout/Tagout**
OSHA’s lockout/tagout (LOTO) standard, 29 CFR
1910.147, establishes minimum performance requirements for controlling hazardous energy and it
is intended to complement and augment machine
safeguarding practices. The lockout/tagout standard
applies only if employees are exposed to hazardous energy during servicing/maintenance activities.
An employer may avoid the requirements of the
LOTO standard if the safeguarding method eliminates your employees’ exposure to the machine
danger area during the servicing or maintenance
work by using Machinery and Machine Guarding
methods in accordance with the requirements contained in 29 CFR 1910, Subpart O.
Additionally, because some minor servicing may
have to be performed during normal production
operations, an employer may be exempt from
LOTO in some instances. Minor tool changes and
adjustments and other minor servicing operations,
which take place during normal production operations, are not covered by lockout/tagout if they are
routine, repetitive and integral to the use of the
machine for production and if work is performed
using alternative effective protective measures that
provide effective employee protection.
In short, a hazardous energy control program is
a critical part of an overall strategy to prevent
workplace amputations during machine servicing
and maintenance activities, such as during the setting up of machines for production purposes, bypassing guards to clear jams or lubricate parts, and
inspecting, adjusting, replacing, or otherwise servicing machine parts. Machine amputations occur
when an employer does not have or fails to implement practices and procedures to disable and control a machine’s energy sources during machine
servicing and maintenance work.

#### **Specific Machine Hazards** **and Safeguarding Methods**

As discussed earlier, 8,450 known non-fatal amputation cases (involving days away from work)
occurred in 2005 for all of private industry. The
most prevalent injury source was, by far, machinery, which accounted for approximately 60% (5,080
instances) of the amputation cases. [1] The machinery
listed here cause amputation injuries, and appropriate safeguarding and hazardous energy control
(lockout/tagout) methods are addressed in this section. Employers need to consult the OSHA standard
for specific machinery to ensure compliance with
all requirements. For other types of hazardous
sources of injury, see Appendix B.

**Machinery Associated with Amputations**

1. Mechanical Power Presses

2. Power Press Brakes

3. Powered and Non-Powered Conveyors
4. Printing Presses
5. Roll-Forming and Roll-Bending Machines
6. Shearing Machines
7. Food Slicers

8. Meat Grinders

9. Meat-Cutting Band Saws
10. Drill Presses

11. Milling Machines
12. Grinding Machines
13. Slitters

**Hazards of Mechanical Power Presses**

Although there are three major types of power
presses—mechanical, hydraulic, and pneumatic—
the machinery that accounts for a large number of
workplace amputations are mechanical power

presses.
In mechanical power presses, tools or dies are
mounted on a slide, or ram, which operates in a
controlled, reciprocating motion toward and away
from the stationary bed or anvil containing the
lower die. When the upper and lower dies press
together – to punch, shear or form – the workpiece, the desired piece is produced. Once the
downstroke is completed, the re-formed work-piece

1 U.S. Department of Labor, Bureau of Labor Statistics
(BLS); Annual Survey data, Table R25. Number of nonfatal occupational injuries or illnesses involving days
away from work by source of injury or illness and selected natures of injury or illness, 2005.

**2 0**

is removed either automatically or manually, a new
work-piece is fed into the die, and the process is
repeated. (See _Figure 23_ .)

_**Figure 23**_ **Part Revolution Mechanical Power Press with**

**a Two-Hand Control**

**Controls for Machines with Clutches**

Certain machines can be categorized based on
the type of clutch they use—full-revolution or
part-revolution. Differing modes of operation for
these two clutches determine the type of guarding that can be used.
Full-revolution clutches, once activated, complete a full cycle of the slide (lowering and raising of the slide) before stopping at dead center
and cannot be disengaged until the cycle is complete. So, presence-sensing devices will not
work and operators must be protected during
the entire press operating cycle. For example,
properly applied barrier guards or two-hand
trip devices that are installed at a safe distance
from the hazard area may be used.
Machines incorporating full-revolution
clutches, such as mechanical power presses,
must also incorporate a single-stroke device and
anti-repeat feature.
The majority of part-revolution presses are
air clutch and brake. They are designed to trap
air in a chamber or tube. When the compressed
air is put into these chambers, the clutch is
engaged, the brake disengaged and the press

makes a single stroke. To stop the press, the
reverse takes place. Thus, the part-revolution
clutch can be disengaged at any time during the
cycle to stop the cycle before it completes the
downstroke.

For safeguarding purposes, part-revolution
mechanical power presses can be equipped with
presence-sensing devices, but full-revolution
mechanical power presses cannot.
NOTE: Likewise, most hydraulic power presses
and their associated control systems are similar to
part-revolution mechanical power presses in that
the slide can be stopped at any point in the cycle.
In order to ensure the integrity of the safety-related
functions, safeguarding devices (such as presencesensing devices) may only be used on hydraulic
power presses that are properly designed and constructed (in accordance with good engineering
practice) to accommodate the safeguarding system.
Refer to OSHA’s Machine Guarding eTool for additional information on hydraulic presses.
Amputations occurring from the point of operation hazards are the most common types of injuries
associated with mechanical power presses.
Improperly applied safeguarding methods (such as
using a guard with more than maximum allowable
openings or 2-hand palm buttons that are mounted
within the safety distance of the press) may allow
operators unsafe access to the press’s hazardous
area. These unsafe conditions may result in an
amputation when an operator, for example, instinctively reaches into the point of operation to adjust a
misaligned part or release a jam. Also, amputations
occur when an operator’s normal feeding rhythm is
interrupted, resulting in inadvertent placement of the
operator’s hands in the point of operation. Such
injuries usually happen while the operator is riding
the foot pedal. Additionally, some amputations are
linked to mechanical (such as the failure of a singlestroke linkage), electrical (such as a control relay failure), or pneumatic (such as the loss of air pressure
to the clutch/brake) machine component failure.
Examples of inadequate or ineffective safeguarding and hazardous energy control practices
include the following:

- Guards and devices disabled to increase production, to allow the insertion of small-piece work, or
to allow better viewing of the operation.

- Two-hand trips/controls bridged or tied-down to
allow initiation of the press cycle using only one
hand.

- Devices such as pullbacks or restraints improperly adjusted.

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- Controls of a single-operator press bypassed by
having a coworker activate the controls while
the operator positions or aligns parts in the die,
or repairs or troubleshoots the press.

- Failure to properly disable, isolate press energy
sources, and lockout/tagout presses before an
employee performs servicing or maintenance
work.

**Case History #1**
While using an unguarded, foot-pedal-operated,
full-revolution mechanical power press that
made trip collars

hand.

work.

made trip collars for wood stoves, an employee
used his hands to feed and remove finished parts
and scrap metal. He placed the completed part to
the left side of the press, and then turned to
place the scrap in the bin behind him. As he
turned back to face the press, he inadvertently
stepped on the foot pedal and activated the press
while his hand was in the die area. His left hand

was amputated at the wrist.

**Case History #2**
An employee was operating an unguarded 10ton, full-revolution mechanical power press to
stamp mailbox parts, and using a hand tool to
load the press, she placed her left hand in the
lower die to reposition a misaligned part. At the
same time, she inadvertently depressed the foot
pedal, activating the press and crushing her left
index finger.

**Case History #3**
A power press operator and helper were instructed to temporarily halt production and each
employee decided to perform servicing tasks.
The operator had a problem with a hydraulic
fluid leak and decided to deflect the liquid spray
by installing a temporary barrier while, at the
same time, the helper decided to clean up the
metal chips from the press area. The operator
then activated the press and repositioned the
press slide in order to install the cardboard barrier. This mechanical power press action fatally
crushed the helper’s head because his head was
between the dies while he was in the process of
cleaning up the metal chips.

Source: OSHA IMIS Accident Investigation Database.

**Safeguarding Mechanical Power Presses**
Mechanical power presses are extremely versatile
and selecting appropriate safeguarding methods
depends on the specific press design and use. You
should consider the press, the type of clutch used,

the stock size, the length of production runs, and
the method of feeding.
You can use primary safeguarding methods,
such as guards or safeguarding devices, to prevent
injuries. For example, 29 CFR 1910.217 requires
employers to provide and ensure the use of point
of operation guards or properly installed devices on
every operation performed on a press when the die
opening is greater than [1] / [4] inch.
In addition, guards must conform to the maximum permissible openings of Table O-10 of 29 CFR
1910.217. Guards must prevent entry of hands or
fingers into the point of operation through, over,
under, or around the guard.

**Mechanical Power Press Safeguarding**
**Methods by Clutch Type**

_Full-Revolution Clutch_ _Part-Revolution Clutch_

Point of Operation Guard Point of Operation Guard

Pullback Pullback

Restraint Restraint

Type A Gate Type A Gate
Two-Hand Trip Type B Gate*

Two-Hand Control*

Presence-Sensing Device*

*”Hands-in-Die” operations require additional safeguarding measures: See 1910.217(c)(5).

**Mechanical power press point of operation safe-**
**guards must accomplish the following goals:**

 - Prevent or stop the normal press stroke if the
operator’s hands are in the point of operation;

or

 - Prevent the operator from reaching into the
point of operation as the die closes; or

 - Withdraw the operator’s hands if inadvertently
placed in the point of operation as the die clos
es; or

 - Prevent the operator from reaching the point of
operation at any time; or

 - Require the operator to use both hands for the
machine controls that are located at such a dis
tance that the slide completes the downward
travel or stops before the operator can reach
into the point of operation; or

 - Enclose the point of operation before a press
stroke can be started to prevent the operator
from reaching into the danger area before die
closure or enclose the point of operation prior
to stoppage of the slide motion during the
downward stroke.

Source: 29 CFR 1910.217(c)(3)(i).

**2 2**

**“No Hands-in-Die” Policy**

In general, a “no-hands-in-die” policy needs to
be implemented and followed whenever possible
– that is, in the event the press is not designed
for “hands-in-die” production work. Under this
policy, operators must never place their hands in
the die area (point-of-operation) while performing normal production operations. Adherence to
this safety practice will reduce the risk of point of
operation amputations.
In terms of part-revolution mechanical power
presses that use a two-hand control, presencesensing device or type B gate, OSHA does allow
“hands-in-die” operation if the press control reliability and brake monitoring system requirements are met. If these press design safety features are not complied with, then employers
must incorporate a “no-hands-in-die” policy.

Source: 29 CFR 1910.217(c)(5).

**Other Controls for Mechanical Power**
**Press Servicing and Maintenance**
Secondary safeguarding methods may be used
alone or in combination (to achieve near equivalent
protection) only when the employer can show that
it is impossible to use any of the primary safeguarding methods. The following are some work
practices, complementary equipment and energy
control measures that may be used to supplement
primary safeguarding:

- If employees operate presses under a “nohands-in-die” policy using complementary feeding methods such as hand-tool feeding, employers still must protect operators through the use
of primary safeguarding methods, such as a
properly applied two-hand control or trip safeguarding device. Hand-tool feeding alone does
not ensure that the operator’s hands cannot
reach the danger area. ( _Figure 24_ illustrates the
use of hand-feeding tools in conjunction with
pullbacks on a power press.)

_**Figure 24**_ **Hand-Feeding Tools Used in Conjunction with**

**Pullbacks on a Power Press**

- Removing scrap or stuck work with tools is
required even when hand feeding is allowed
according to 29 CFR 1910.217(d)(1)(ii). Employers must furnish and enforce the use of
hand tools for freeing or removing work or
scrap pieces from the die to reduce the amount
of time an operator’s hand is near the point of

- Control point of operation hazards created when
guards are removed for set-up and repair by
operating the machine in the inch mode. This
involves using two-hand controls (or a single
control mounted at a safe distance from the

machine hazards) to gradually inch the press
through a stroke when the dies are being tested
on part-revolution clutch presses.

- Observe energy control procedures and practices for press servicing and maintenance work.
For example, the changing of dies on a mechanical power press requires the employer to establish a die-setting procedure that employs pointof-operation safeguarding method(s) such as the
safe usage of an _inch_ or _jog_ safety device for die
set-up purposes together with LOTO. These
devices safely position the mechanical power
press slide utilizing a point-of-operation safeguarding technique. Thus, an energy control
procedure for these types of presses would

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **2 3**

need to integrate both point-of-operation safeguarding method(s) for slide positioning as well
as LOTO procedures for the die setting operation.

Additional power press energy control precautions (e.g., use of safety blocks; LOTO the press disconnect switch if re-energization presents a hazard)
will be necessary if employees need to place their
hands/arms in a press working area (the space
between the bolster plate and the ram/slide) to
perform the servicing and/or maintenance activity
(such as adjusting, cleaning or repairing dies) because the _inch_ or _jog_ safety device will not protect
employees from ram movement due to potential
mechanical energy (resulting from the ram/slide
position and associated gravitational force), press
component or control system malfunction, or press
activation by others.

**Minor Servicing**

At times, OSHA recognizes that some minor
servicing may have to be performed during

** **2 3**

servicing may have to be performed during normal production operations, so a lockout/tagout
exception is allowed. See the 29 CFR 1910.147(a)
(2)(ii) Note for details. For example, a press operator may need to perform a minor die cleaning
task on a regular basis for product quality purposes and the use of safety blocks – inserted
between the press dies – that are interlocked with
the press electrical controls would constitute
effective protection. Properly designed and
applied safety block interlocks may be used in
lieu of locking or tagging out the press’s electrical
energy source for purposes of the minor servicing exception.

Source: 29 CFR 1910.147(a)(2)(ii) Note.

**Training**
Training is essential for employee protection. As an
employer, you should:

- Train operators in safe mechanical press operation and hazardous energy control (lockout/
tagout) procedures and techniques before they
begin work on the press.

- Supervise operators to ensure that correct procedures and techniques are being followed.

**Additional Requirements**
In addition, work practices such as regular mechanical power press inspection, maintenance, and
reporting are essential.

- 29 CFR 1910.217(e)(1)(i) requires a program of
periodic and regular inspections of mechanical
power presses to ensure that all of the press
parts, auxiliary equipment and safeguards are
in safe operating condition and adjustment.
Inspection certification records must be maintained.

- 29 CFR 1910.217(e)(1)(ii) requires you to inspect
and test the condition of the clutch/brake mech
anism, anti-repeat feature, and single-stroke
mechanism on at least a weekly basis for presses without control reliability and brake system
monitoring. Certification records must be maintained of these inspections and the maintenance
performed.

- 29 CFR 1910.217(g)(1) requires the reporting of
all point of operation injuries to operators or
other employees within 30 days to either the
Director of the Directorate of Standards and

Guidance, OSHA, U.S. Department of Labor,
Washington, DC 20210, or the state agency
administering a plan approved by OSHA. You
can also use the Internet to report injuries (www.
osha.gov/pls/powerpress/mechanical.html).

**Applicable Standards**

 - 29 CFR 1910.147, _Control of hazardous energy_
_(lockout/tagout)._

 - 29 CFR 1910.217, _Mechanical power presses._

 - 29 CFR 1910.219, _Mechanical power-transmis-_
_sion apparatus._

**Sources of Additional Information**

 - OSHA Instruction CPL 3-00-002 [CPL 2-1.35],
_National Emphasis Program on Amputations_

 - OSHA Publication 3067, _Concepts and_
_Techniques of Machine Safeguarding_
(http://www.osha.gov/Publications/Mach_
Safeguard/toc.html)

 - OSHA _Machine Guarding eTool_ (http://www.
osha.gov/SLTC/etools/machineguarding/index.
html)

  - _OSHA Lockout/Tagout Interactive Training_
_Program_ (http://www.osha.gov/dts/osta/

 - NIOSH CIB 49, _Injuries and Amputations_
_Resulting From Work with Mechanical Power_
_Presses_ (May 22, 1987)

 - OSHA Instruction STD 01-12-021 [STD 112.21]—29 CFR 1910.217, _Mechanical Power_
_Presses, Clarifications_ (10/30/78)

 - ANSI B11.1-2001, _Safety Requirements for_
_Mechanical Power Presses_

**2 4**

**Power Press Brakes**

Power press brakes are similar to mechanical
power presses in that they use vertical reciprocating motion and are used for repetitive tasks. Press
brake operation is either mechanical or hydraulic.
Press brakes are either general-purpose or special-purpose brakes, according to ANSI B11.3-2002,
_Safety Requirements for Power Press Brakes_ .
General purpose press brakes have a single operator control station. A servo-system activates the
special purpose brake, which may be equipped
with multiple operator/helper control stations. (See
_Figure 25_ for a power press brake operation.)

_**Figure 25**_ **Power Press Brake Bending Metal**

**Hazards of Power Press Brakes**

As with mechanical power presses, point of operation injuries are the most common type of injury
associated with power press brakes. Here are some
frequent causes of amputations from power press
brakes:

- Foot controls being inadvertently activated while
the operator’s hand is in the point of operation.
The likelihood of this type of injury increases as
the size of stock decreases and brings the operator’s hands closer to the point of operation.

- Parts of the body caught in pinch points created
between the stock and the press brake frame
while the bend is being made.

the operator positions or aligns stock or repairs
or troubleshoots the press.

- Failure to properly lockout/tagout presses during
the necessary tasks of making adjustments,
clearing jams, performing maintenance,
installing or aligning dies, or cleaning the
machine.

**Case History #4**
An operator was bending small parts using an
80-ton unguarded press brake. This required the
employee’s fingers to be very close to the point
of operation; and, consequently, the operator lost
three fingers when his hand entered the point
of operation. The operator on the previous shift
had reported to the supervisor that the operator placed his fingers close to the point of operation, but was told that nothing could be done and
that the operator should be careful.

**Case History #5**
An operator was bending metal parts using a 36ton part-revolution power press brake that was
foot-activated and equipped with a light curtain.
About 3-4 inches of the light curtain had been
“blanked out” during a previous part run. While
adjusting a part at the point of operation, the
employee accidentally activated the foot pedal
and amputated three fingertips.

**Safeguarding Power Press Brakes**
Primary safeguarding methods, such as physical
guards and point of operation safeguarding devices
(movable barrier devices, presence-sensing devices, pull-back devices, restraint devices, singleand two-hand devices) can be used to effectively
guard power press brakes. ( _Figure 26_ shows a general-purpose power press brake used in conjunction with pullbacks.) Some safeguarding methods,
such as presence-sensing devices, may require
muting or blanking to allow the bending of material. Always ensure that these safety devices are
properly installed, maintained, and used in accordance with the manufacturer’s guidelines for the
specific stock and task to be performed. Failure to
do so could leave sensing field channels "blanked
out" and expose operators to point-of-operation
hazards as the safeguarding device’s safety distance increases when blanking is used.

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **2 5**

_**Figure 26**_ **Two-Person Power Press Brake Operation**

**with Pullbacks**

In other instances, such as with special-purpose
power press brakes, machines are equipped with
advanced control systems that are adaptable to all
forms of safeguarding concepts and devices, such
as two-hand controls and multiple operator/helper
actuating controls. For example, _two-hand down,_
_foot through (actuation)_ methods are used to safeguard employees while they operate press brakes.
With this safeguarding system, an operator uses a
two-hand control to lower the press brake ram, for
example, to within [1] / [4] inch or less of the lower die
(which is considered a safe opening). The operator
then has the ability to maneuver and align the
work-piece within this [1] / [4] inch safe opening area
and he or she is protected from the amputation
hazard. Then

** **2 5**

hazard. Then the foot control is used by the operator to safely actuate the machine to produce the
desired product.
Because of constraints imposed by certain manufacturing or fabricating processes, safeguarding
by maintaining a _safe distance_ from the point of
operation may be acceptable. However, this is permitted only when safeguarding by barrier guard
or safeguarding devices is not feasible (impossible) – that is, where the use of primary safeguarding method (such as a restraint device) is not feasible. Additional information about a _safe distance_

safeguarding program can be found in OSHA
Instruction 02-01-025 [CPL 2-1.25] – _Guidelines for_
_Point of Operation Guarding of Power Press_
_Brakes._

**Other Controls for Power Press Brakes**

The following are some secondary safeguarding
methods and complementary equipment that may
be used to supplement primary safeguarding or
alone or in combination when primary safeguarding methods are not feasible:

- Safe distance safeguarding,

- Safe holding safeguarding,

- Safe work procedures,

- Work-holding equipment (such as back gauges),

- Properly designed and protected foot pedals,
and

- Hand-feeding tools.

Ensure that proper safeguarding and lockout/
tagout procedures are developed and implemented
for power press brakes. Train and supervise employees in these procedures and conduct periodic
inspections to ensure compliance.

 - 29 CFR 1910.212, _General requirements for all_
_machines._

html)

 - OSHA Directive – CPL 02-01-025 [CPL 2-1.25],
_Guidelines for Point of Operation Guarding of_
_Power Press Brakes_

 - ANSI B11.3-2002, _Safety Requirements for_

**Hazards of Conveyors**
Conveyors are used in many industries to transport
materials horizontally, vertically, at an angle, or
around curves. Many conveyors have different and
unique features and uses, so that hazards vary due

**2 6**

to the material conveyed, the location of the conveyor, and the proximity of the conveyer to the
employees. Types include unpowered and powered, live roller, slat, chain, screw, and pneumatic.
Conveyors eliminate or reduce manual material
handling tasks, but they present amputation hazards associated with mechanical motion. (See
_Figures 27 through 30_ for examples of common
conveyors.)
Conveyor-related injuries typically involve a
employee’s hands or fingers becoming caught in
nip points or shear points on conveyors and may
occur in these situations:

- Cleaning and maintaining a conveyor, especially
when it is still operating.

- Reaching into an in-going nip point to remove
debris or to free jammed material.

- Allowing a cleaning cloth or an employee’s
clothing to get caught in the conveyor and pull
the employee’s fingers or hands into the con
veyor.

Other conveyor-related hazards include improperly guarded gears, sprocket and chain drives, horizontal and vertical shafting, belts and pulleys, and
power transmission couplings. Overhead conveyors warrant special attention because most of the
conveyor’s drive train is exposed. Employees have
also been injured or killed while working in areas
underneath conveyors and in areas around lubrication fittings, tension adjusters, and other equipment
with hazardous energy sources.

**Case History #6**
While removing a cleaning rag from the ingoing
nip point between the conveyor belt and its tail
pulley (the unpowered end of the conveyor), an
employee’s arm became caught in the pulley,
which amputated his arm below the elbow.

**Case History #7**
While servicing a chain-and-sprocket drive
assembly on a roof tile conveyor system, an
employee turned off the conveyor, removed the
guard, and began work on the drive assembly
without locking out the system. When someone
started the conveyor, the employee’s fingers
became caught in the chain-and-sprocket drive
and were amputated.

_**Figure 27**_ **Belt Conveyor**

_**Figure 28**_ **Screw Conveyor**

_**Figure 29**_ **Chain Driven Live Roller Conveyor**

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **2 7**

_**Figure 30**_ **Slat Conveyor**

**Safeguarding Conveyors**
As conveyor hazards vary depending on the application, employers need to look at each conveyor to
evaluate and determine what primary safeguarding
methods and energy control (lockout/tagout)
practices are required. Where necessary for the
protection of employees, conveyors need to have
mechanical guards that protect the employee from
nip points, shear points, and other moving parts,
including power-transmission apparatus. Guards
may include barriers, enclosures, grating, fences, or
other obstructions that prevent inadvertent physical
contact with operating machine components, such
as point of operation areas, belts, gears, sprockets,
chains, and other moving parts. A brief description
of the hazards and recognized safeguarding methods is presented for common types of conveyors.

**Typical Conveyor Hazards and**

**Belt Conveyors**

_**Hazards:**_ Belt-conveyor drive mechanisms and
conveying mediums are hazardous as are the following belt-conveyor areas: 1) conveyor take-up
and discharge ends; 2) where the belt or chain
enters or exits the in-going nip point; 3) where
the belt wraps around pulleys; 4) snub rollers
where the belt changes direction, such as takeups; 5) where multiple conveyors are adjoined;
or 6) on transfers or deflectors used with belt

conveyors.

_**Controls:**_ The hazards associated with nip and
shear points must be safeguarded. Side guards
(spill guards), if properly designed can prevent
employee contact with power-transmission component, in-going nip points and the conveying

medium. Secondary safeguarding methods for
hazard control include the use of standard railings
or fencing, or safeguarding by distance (location),
and installing hazard awareness devices, such as
pre-start-up signals and warning signs.

**Screw Conveyors**

_**Hazards:**_ Screw conveyors are troughs with a
revolving longitudinal shaft on which a spiral or
twisted plate is designed. In-going nip points, of
turning helical flights for the entire length of the
screw conveyor, exist between the revolving
shaft and trough. Since the trough is not usually
required to be covered for proper operation of
the conveyor and because many screw conveyors are located at or near the floor level, the hazard of stepping into the danger area is ever present. Once caught, the victim is pulled further into
the path of the conveying medium.

_**Controls:**_ A screw conveyor housing must completely enclose the moving elements (screw
mechanism, power transmission apparatus) of
the conveyor, except for the loading and discharge points. Permanently affixed grids or polycarbonate can be installed for visibility purposes
to allow the operator to inspect the operation.
Alternatively, the trough side walls should be
high enough to prevent employees from reaching over and falling into the trough. Open
troughs can be used if covers are not feasible

 is designed. In-going nip points, of

troughs can be used if covers are not feasible;
but employees need to be protected by secondary safeguarding methods, such as a railing or
fence.

Feed loading and discharge points can usually
be guarded by providing enclosures, screening,
grating, or some other interruption across the
openings which will allow the passage of the
material without allowing the entry of a part of
the employee’s body into the moving part(s).

**Chain Conveyors**

_**Hazards:**_ Nip points occur when a chain contacts
a sprocket, such as when a chain runs around a
sprocket or when the chain is supported by a
sprocket or when a shoe above the chain precludes the chain from lifting off the sprocket. Nip
points also occur at drives, terminals, take-ups
(automatic take-ups may also have shear points),
and idlers. Employee clothing, jewelry, and long
hair may also get entangled and caught in the
moving chain conveyor.

**2 8**

_**Controls:**_ Sometimes, moving chains cannot be
enclosed without impairing the functioning of the
conveyor. However, in some cases, barrier
guards may be installed around the moving parts
for hazard enclosure purposes or, in other instances, nip and shear points may be eliminated
by placing a guard at the nip point or shear
point. Other secondary safeguarding options
include safeguarding by distance (location) and
the use of awareness devices.

**Roller Conveyors**

_**Hazards:**_ Roller conveyors are used to move
material on a series of parallel rollers that are
either powered or gravity-fed. Powered roller
conveyors have the hazard of snagging and
pulling objects, including hands, hair, and clothing into the area between the rollers and the stationary components of the conveyor. In-going
nip points generally exist between the drive
chain and sprockets; between belt and carrier
rollers; and at terminals, drives, take-ups, idlers,
and snub rollers.

_**Controls:**_ Roller conveyors need to, where feasible, have permanent barrier guards that can be
adjusted as necessary to protect the employee
from nip and shear points. For example, the
unused section of rollers closest to the employees needs to be guarded when transporting
small items on a roller conveyor that do not
require the use of the entire roller width. Also,
conveyor hazards may be reduced by eliminating
or minimizing projections from the roller and
through the use of pop-up rollers. Other secondary safeguarding options include safeguarding
by distance (location) and the use of awareness
devices.

**Other Controls for Conveyors**
methods, work practices, and complementary
equipment that may be used to supplement primary safeguarding or alone or in combination
when primary safeguarding methods are not feasible:

- Safeguarding by safe distance (by location) —
locating moving parts away from employees to
prevent accidental contact with the hazard
point—is one option for safeguarding conveyors. It is particularly difficult, however, to use

this method when employees need to be at or
near unguarded moving parts.

- Use prominent awareness devices, such as
warning signs or lights, to alert employees to
the conveyor operation.

- Allow only trained individuals to operate conveyors and only trained, authorized staff to perform servicing and maintenance work.

- Visually inspect the entire conveyor and immediate work area prior to start-up to determine
that the actuation will not cause an employee
hazard.

- Inspect and test conveyor safety mechanisms,
such as its alarms, emergency stops, and safeguarding methods.

- Do not use any conveyor which is unsafe until it
is made safe.

- Forbid employees from riding on conveyors.

- Prohibit employees working with or near conveyors from wearing loose clothing or jewelry,
and require them to secure long hair with a net

or cap.

- Install emergency stop devices on conveyors
where employees work when they cannot otherwise control the movement of the conveyor.
This recognized safety feature provides employees with the means to shut off the equipment in
the event of a hazardous situation or emergency
incident.

For emergency stop devices, you will need these
engineering controls:

- Equip conveyors with interlocking devices that
shut them down during an electrical or mechanical overload such as product jam or other stoppage. Emergency devices need to be installed so
that they cannot be overridden from other locations.

- When conveyors are arranged in a series, all
should automatically stop whenever one stops.

- Equip conveyors with emergency stop controls
that require manual resetting before resuming
conveyor operation.

- Install clearly marked, unobstructed emergency
stop buttons or pull cords within easy reach of

- Provide continuously accessible conveyor belts
with emergency stop cables that extend the
entire length of the conveyor belt to allow access to
the cable from any point along the belt.

- Ensure that conveyor controls or power sources
can accept a lockout/tagout device to allow safe
maintenance practices.

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **2 9**

- Perform servicing and maintenance under an
energy control program in accordance with the
_Control of hazardous energy (lockout/tagout)_, 29
CFR 1910.147, standard. For example, instruct
employees to lubricate, align, service, and maintain conveyors when the conveyor is locked or
tagged out if the task would expose them to an
area of the conveyor (or adjacent machinery)
where hazardous energy exists.

(2)(ii) Note for details. An example of a common
conveyor minor servicing activity involves package jams where an employee must frequently
dislodge the jam. To prevent unexpected start-up
of the conveyor, employers may adopt alternative control measures, such as opening (placing
in the off position) local disconnects or control
switches to prevent conveyor start-up. These
properly applied devices, if used, must be
under the exclusive control of the employee performing the jam release, so that no other person
can restart the conveyor without the knowledge
and consent of the person performing the servicing work.

 - 29 CFR 1910.269, _Electric power generation,_
_transmission and distribution_ [as detailed in
section (v)(11)].

 - 29 CFR 1926.555, _Conveyors._

 - ANSI B20.1-57, _Safety Code for Conveyors,_
_Cableways, and Related Equipment_ – as incorporated by reference in 1910.218(j)(3),
1910.261(a)(3)(x), 1910.261(b)(1),
1910.261(c)(15)(iv), 1910.261(f)(4),
1910.261(j)(2), 1910.265(c)(18)(i)].

html)

 - ASME B20.1-2003, _Safety Standard for_
_Conveyors and Related Equipment._

 - ANSI/CEMA 350-2003, _Screw Conveyors._

 - ANSI/CEMA 401-2003

(c)(15)(iv), 1910.261(f)(4),

html)

 - ANSI/CEMA 401-2003, _Unit Handling_
_Conveyors—Roller Conveyors—Non-powered._

 - ANSI/CEMA 402-2003, _Unit Handling_
_Conveyors—Belt Conveyors._

  - _ANSI/CEMA 403-2003, Unit Handling_
_Conveyors—Belt Driven Live Roller Conveyors._

 - ANSI/CEMA 404-2003, _Unit Handling_
_Conveyors—Chain Driven Live Roller_
_Conveyors._

 - ANSI/CEMA 405-2003, _Package Handling_
_Conveyors—Slat Conveyors_

**Hazards of Printing Presses**
Printing presses vary by type and size, ranging
from relatively simple manual presses to the complex large presses used for printing newspapers,
magazines, and books. Printing presses are often
part of a larger system that also includes cutting,
binding, folding, and finishing equipment. Many
modern printing presses rely on computer controls,
and the high speeds of such equipment often require rapid machine adjustments to avoid waste.
This section discusses amputation hazards associated with two common types of printing presses:
web-fed and sheet-fed printing press systems.
Web-fed printing presses are fed by large continuous rolls of substrate such as paper, fabric or
plastic; sheet-fed printing presses, as their name
implies, are fed by large sheets of substrate. In both
types, the substrate typically feeds through a series
of cylinders containing printing plates and supporting cylinders moving in the opposite direction.
( _Figures 31 and 32_ illustrate a roll-to-roll offset
printing press and a sheet-fed offset printing press.)

**3 0**

_**Figure 31**_ **Roll-to-Roll Offset Printing Press**

_**Figure 32**_ **Sheet-Fed Offset Printing Press**

As with other machines, printing press-related
amputations occur during servicing and maintenance activities. For example, amputations occur
when employees get their fingers or hands caught
in the in-going nip points created between two
rollers while:

- Hand-feeding the leading edge of paper into the
in-running rollers during press set-up while the
machine is operating;

- Adjusting ink flow on a press;

- Cleaning ink off the press while it is operating;

- Attempting to free material from the rollers;

- Straightening misaligned sheets of paper in the

press;

- Jogging the printer and making adjustments to
the equipment (such as adjusting the nip wheel
on a sheeter);

- Using rags to clean machinery adjacent to unguarded rollers.

**Case History #8**
An employee was adding ink at the top of a
printing press when he spotted a small piece of
wood in the area of the moving rollers. He
caught his hand in the moving rollers as he
attempted to remove the wood and had to have
his forearm surgically amputated.

**Case History #9**
An offset printing press operator lost his right
hand while attempting to remove dried ink on a
moving roller using a rag. The guard covering
the lower ink train rollers had been flipped up,
exposing the rollers. The rag got caught in a
nearby roller, pulling the employee’s hand into
the in-going nip point. The employee immediately hit the press stop button, but the roller rotated
one-half turn before stopping. His hand was
crushed and had to be amputated at the hospital.

**Safeguarding Printing Presses**
As with most machinery, you can rely on primary
safeguarding methods to protect employees
against injuries when using printing presses. For
example, some primary safeguarding methods

- Install guards on all mechanical hazard points
that are accessible during normal operation -such as accessible in-going nip points between
rollers and power-transmission apparatus
(chains and sprockets).

- Safeguard nip point hazards with barrier guards
or nip guards. Nip guards need to be designed
and installed without creating additional hazards.

- Install fixed barrier guards, with tamper-proof
fasteners, at rollers that do not require operator

access.

- Properly designed, applied, and maintained
safeguarding devices (such as presence-sensing
devices and mats) may also be used to keep
your body out of machine danger areas. However, these control circuit devices are no substitute for lockout/tagout.

- Use hold-to-run controls (such as inch or reverse) that protect employees from machine
mechanical hazards by either: 1) requiring the
use of both hands for control initiation purposes; or 2) are mounted at a safe distance so that
an employee cannot inch or reverse the press

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **3 1**

and simultaneously access any unguarded danger area or otherwise reach into the danger zone
while the press is operating.

**Other Controls for Printing Presses**
equipment that may be used to supplement primary
safeguarding or alone or in combination when primary safeguarding methods are not feasible:

- Make sure that printing presses attended by
more than one operator or ones outside of the
operator’s viewing area are equipped with visual
and audible warning devices to alert employees
regarding the press’s operational status—in
operation, safe mode, or impending operation.

- Install visual warning devices of sufficient number and brightness and locate them so that they
are readily visible to press personnel.

- Ensure that audible alarms are loud enough to
be heard above background noise.

- Provide a warning system that activates for at
least 2 seconds prior to machine motion.

- Use additional secondary safeguarding methods
such as safeguarding by location and safe work
(operating) procedures for printing presses.

- Ensure that all press operators receive appropriate training and supervision until they can work
safely on their own.

- Prohibit employees working with or near printing presses from wearing loose clothing or jewelry and require them to secure long hair with a
net or cap.

- Conduct periodic inspections to ensure compli
ance.

CFR 1910.147, standard.

(2)(ii) Note for details. Minor servicing can
include, among other things, tasks such as clearing of certain types of minor paper jams; minor
cleaning; minor lubricating and minor adjusting
operations; certain plate and blanket changing

tasks; and, in some cases, paper webbing and
paper roll changing. Generally speaking, minor
servicing is considered to include those tasks
involving operations that can be safely accomplished by employees and where extensive disassembly of equipment is not required.
One such control method that does offer effec
tive alternative protection is the inch-safe-service
technique when it is used in conjunction with the
main drive control. This technique is specified in
the American National Standards (ANSI B65.1
and ANSI B65.2) for web- and sheet-fed printing
presses and binding and finishing equipment,
respectively.
Also, interlock guards and presence-sensing
safeguarding devices, if properly designed,
applied and maintained, would also be considered effective protection. For example, you could
simply open the barrier guard and rely on the
protection afforded by the properly designed
interlock control circuit while clearing minor
paper jams and other minor servicing functions
that occur using normal production operations
and which meet the criteria in the lockout/tagout
exception.

- 29 CFR 1910.147, Control of hazardous energy
(lockout/tagout).

- 29 CFR 1910.212, General requirements for all
machines.

- 29 CFR 1910.219, Mechanical power-transmission

65.1

machines.

- 29 CFR 1910.219, Mechanical power-transmission apparatus.

- OSHA Publication 3067, _Concepts and_

- OSHA _Machine Guarding eTool_ (http://www.
html)

- _OSHA Lockout/Tagout Interactive Training_

- ANSI B65.1-2005, _Safety Standard - Printing_
_Press Systems_

**3 2**

**Roll-Bending Machines**
Roll-forming and roll-bending machines primarily
perform metal bending, rolling, or shaping functions. Roll-forming is the process of bending a
continuous strip of metal to gradually form a predetermined shape using a self-contained machine.
Roll-forming machines contain a series of rolls that
may or may not have braking systems. Roll-forming machines may also perform other processes
on the metal, including piercing holes, slots, or
notches; stamping; flanging; and stretch-bending.
Roll-bending machines usually have three rolls
arranged like a pyramid and they perform essentially the same process as roll-forming, except that the
machine produces a bend across the width of flat
or pre-formed metal to achieve a curved or angular
configuration.
Roll-forming and roll-bending machines frequently are set up and operated by one person.
( _Figure 33_ illustrates a roll-forming machine producing a finished product. _Figure 34_ illustrates the
in-feed section of a roll-forming machine.)

_**Figure 33**_ **Roll-Forming Machine**

The most common type of amputation hazard
associated with roll-forming and roll-bending
machines are point of operation hazards created by
in-running nip points. Amputations occur when the
hands of the operator feeding material through the
rolls get caught and are then pulled into the point
of operation. Causes of amputations related to rollforming and roll-bending machines can occur from

- Having an unguarded or inadequately guarded
point of operation;

- Locating the operator control station too close to
the process;

- Activating the machine inadvertently; and

- Performing cleaning, clearing, changing, or
inspecting tasks while the machine is operating
or is not properly locked or tagged out.

**Case History #10**
While feeding a metal sheet into a roller, an
employee caught his right hand in the roller and
amputated one finger.

**Case History #11**
An employee wearing gloves caught his left
hand in a roll-forming machine, resulting in partial amputation of two fingers. The employee
was standing close to the moving rollers, feeding
flat steel sheet from behind and catching it on
the front side. There was no point of operation
guard on the front roller and the foot operating
pedal was very close to the machine.

**Safeguarding Roll-Forming and Roll-**
**Bending Machines**
Roll-forming and roll-bending machines are available in a wide variety of sizes and designs, and
safeguarding methods must be tailored for each
machine. Several factors affect the ways to safeguard the equipment, including whether a machine
has a brake system, its size, operating speed, thickness of product, length of production runs, required
production accuracy, sheet feeding methods, and
part removal methods. Depending on the size and
type of machine, a number of different primary
safeguarding methods may be required to adequately protect the operator as well as other employees nearby. For example, you can do the

- Install fixed or adjustable point of operation barrier guards at the in-feed and out-feed sections
of machines. If the stock or end-product does

_**Figure 34**_ **In-Feed Area of a Roll-Forming Machine**

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **3 3**

not differ greatly from run to run, a fixed guard
may be preferable. If the stock or end-product is
variable, however, an adjustable guard may be
more suitable.

- Install fixed point of operation guards to cover
the sides of the rollers to prevent entry of clothing and parts of your body into the in-going nip
points of the rollers.

- Install fixed or interlocked guards to cover any
other rotating parts, such as power-transmission
apparatus.

- Install and use properly applied presence-sensing safeguarding devices (light curtains, safety
mats) on roll-forming and roll-bending machines
(those equipped with brakes) to protect you
from hazardous machine areas during normal
production operations.

- Install and use properly applied two-hand control safeguarding devices to protect you from
the machine hazards during roll-bending production operations.

- Ensure that operators use the jog mode during
feeding operations, if appropriate, and that the
control station requires the use of both hands
or is mounted at a safe distance from the ma
chine’s danger areas.

- Allow only one control station to operate at any
one time when a single machine has more than
one set of operator controls. This does not apply
to the emergency stop controls, which must be
operable from all locations at all times, such as
accessible in-going nip points between rollers
and power-transmission apparatus (chains and
sprockets).

- Use proper lighting and awareness barrier
devices (such as interlocking gates around the
perimeter of the machine to prevent unauthorized entry), awareness signals and signs.

- Position (safeguard by location) operating stations in a way that ensures that operators are
not exposed to the machine’s point of operation.

- Locate foot pedal controls away from the point
of operation and guard them in such a way as to
prevent inadvertent activation. Some foot controls use dead-man (hold-to-run) features so that

the rolls stop turning (via a brake and clutch
assembly) when you release the foot switch.

- Develop and implement safe work (operating)
procedures for roll-forming and roll-bending
machines.

- Safeguard operator control stations to prevent
inadvertent activation by unauthorized employees.

- Ensure that all operators receive appropriate onthe-job training under the direct supervision of
experienced operators until they can work safely
on their own.

net or cap.

- Install safety trip controls, such as a pressuresensitive body bar or safety tripwire cable, on
the in-feed section of the machine to shut down

the machine if an employee gets too close to the
point of operation.

- Install emergency stop controls that are readily
accessible to the operator.

ance.

html)

_Program_ (http://www

 in accordance with the

html)

 - ANSI B11.12-2005, _Safety Requirements for_
_Roll-Forming and Roll-Bending Machines_

**3 4**

**Hazards of Shearing Machines**
Mechanical power shears contain a ram for their
shearing action. The ram moves a non-rotary
blade at a constant rate past the edge of a fixed
blade. Shears may be mechanically, hydraulically,
hydra-mechanically, pneumatically, or manually
powered and are used to perform numerous functions such as squaring, cropping, and cutting to
length.
In the basic shear operation, stock is fed into the
point of operation between two blades. A holddown may then be activated that applies pressure
to the stock to prevent movement. One complete
cycle consists of a downward stroke of the top
blade until it passes the lower fixed blade followed
by an upward stroke to the starting position. (See
_Figures 35 and 36_ for examples of alligator and
power squaring shears.)

_**Figure 35**_ **Hydraulic Alligator Shear**

**Shears can be categorized as stand-alone manu-**
**al shears, stand-alone automatic shears, and**
**process-line shears.**

**Stand-alone manual shears.** An operator controls
them from a control station. The operator feeds
the shear either by hand or by activating the
automatic loading mechanism and activates the
equipment using hand or foot controls or a tripping device on the back side of the shear. An
example is an alligator shear.

**Stand-alone automatic shears.** These feed and

stroke automatically and continuously. The operator uses hand-activated or foot-activated con
trols to initiate the operation, which requires limited additional operator interaction. An example
is a guillotine shear.

**Process-line shears.** These are integrated into an
automated production process and are controlled
automatically as part of the process. Examples
include crop shears and cut-to-length shears.

The two primary point-of-operation hazards on
shears are the shear blade and the material hold
downs. Amputations may occur in the following
situations:

- The foot control inadvertently activates while
the operator’s hands are in the point of operation. Such amputations usually relate to footactivated, stand-alone manual shears that
require the use of both hands to feed the stock.

- A tripping device located on the back side of the
shear’s mouth operates the shear but does not
prevent the operator from reaching into the
hazard area. Such tripping devices, commonly
found on stand-alone manual shears, may increase productivity but must be used in conjunction with primary safeguards.

- When there is no hold-down and stock being fed
into a stand-alone manual shear kicks out and

strikes the operator’s hands or fingers.

**Case History #12**
After breaking metal with a mechanical alligator shear, an employee turned the shear off and
was picking up debris on the ground when he
placed his left hand on the shear and amputated his fingers. The shear’s flywheel was not
equipped with a clutch or similar device. So,
when the shear was shut off, the jaw continued
to operate on stored energy.

_**Figure 36**_ **Power Squaring Shear**

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **3 5**

**Case History #13**
An employee was cutting material with a 50-inch
guillotine shear equipped with two-hand trip buttons to prevent employees from reaching into
the blade area. He had taped up one of the buttons and used his knee to trip the other button.
With both hands under the blade, he inadvertently hit the free button with his knee. This activated
a stroke of the blade which amputated both of
his hands just below the wrists.

**Safeguarding Shearing Machines**
Because shears have a wide variety of applications,
safeguarding methods must be determined individually for each machine based on its use. A number
of different safeguarding methods may be necessary to adequately protect the operator as well as
other employees nearby. For example, you will
need to consider the machine size, operating
speed, size and type of material, length of production runs, required accuracy of the work, methods
for material feeding and removal, operator controls,
and clutch type.
Here are some primary safeguarding options for
protecting employees from the shear’s point of
operation during feeding activities at the front of
the machine:

- Install a properly applied fixed or adjustable
point of operation guard at the in-feed of the
shearing machine to prevent operator contact
with the shear’s point of operation as well as
the pinch point of the hold-down. The guard’s
design must prevent the employee from reaching under or around it.

- Install and arrange two-hand trips and controls
so that the operator must use both hands to initiate the shear cycle. Two-hand trips and controls need to be designed so that they cannot be
defeated easily. The Safety Requirements for
Shears (ANSI B11.4-2003) standard recommends
the installation of additional safeguarding when
two-hand controls are used on part-revolution
shears, based on the nature of the shearing
operation. This national consensus standard
specifies the use of guards on full-revolution
shears.

- Use a properly applied presence-sensing
device, such as a light curtain, on shears that
are hydraulically powered or equipped with a
part-revolution clutch.

- Mount guarded foot-pedal controls at a safe distance (single control safeguarding devices) away
from the point of operation to protect the operator during the operating cycle.

- Use pull-backs or restraints for stand-alone
manual shears when other guarding methods
are not feasible or do not adequately protect
employees. (These devices may not be appropriate if the job requires employees’ mobility.)

- Use automatic-feeding devices such as conveyors with stand-alone manual shears when the

material is uniform in size and shape.

- Equip mechanical shears with either a part-revolution or full-revolution clutch. Methods of safe
guarding depend on the type of clutch in use.
Shears equipped with full-revolution clutches
used in single-stroke operations must be equipped with an anti-repeat feature.

**Other Controls for Shearing Machines**
equipment that may be used to supplement
primary safeguarding or alone or in combination
when primary safeguarding methods are not
feasible:

- Install guarded operating stations at a safe distance (safeguarding by location) from the
shear’s point of operation to prevent inadvertent
activation.

procedures for shearing machines and conduct
periodic inspections to ensure compliance.

- Use proper lighting and awareness devices,
such as awareness barriers and warning signs,
to warn employees of the hazard.

- Install hold-down (work-holding) devices that
prevent the work piece from kicking up and
striking the operator. Hold-down devices may
eliminate the need for employees to hold the
material near the point of operation.

- Instruct operators to use distancing tools when
their hands might otherwise reach into the point
of operation because of the size of the material
being cut.

- Where it is possible to stop the shear during
its operating cycle, install an emergency stop
device—such as a pressure-sensitive body bar,
safety tripod, or safety tripwire cable—at the
in-feed section of the shear.

- Install an awareness barrier or a safety trip control (safety tripwire or safety tripod) on the back
side of the shear.

- Ensure that all operators receive on-the-job

**3 6**

training under the direct supervision of experienced operators until they can work safely on
their own.

- Instruct employees to perform routine maintenance on the clutch and braking systems.

- Instruct employees to inspect all guarding to
ensure that it is

being cut.

**3 6**

their own.

ensure that it is in place properly before the
machine is operated.

- Instruct supervisors to ensure that operators
keep their hands out of the shear’s point of operation at all times while the machine is energized
and not properly locked out.

- Instruct employees not to perform activities on
the back side of a shear while it is operating or
still energized.

- Prohibit employees from riding the foot activation pedal.

_sion apparatus_

_(lockout/tagout)_

 - OSHA Instruction CPL 03-00-002, _National_
_Emphasis Program on Amputations._

html)

 - ANSI B11.4-2003, _Safety Requirements for_
_Shears._

**Hazards of Food Slicers**

Food slicers are electrically powered machines typically equipped with a rotary blade, an on/off switch,
thickness adjustment, and a food holder or chute. A

pushing/guarding device or plunger may be used
to apply pressure to the food against the slicer
blade, or pressure may be applied by gravity and/or
by an attachment connected to the food holder.
(See _Figure 37_ .)

_**Figure 37**_ **Meat Slicer**

Amputations resulting from work with food
slicers can occur as follows:

- When the operator adjusts or services the slicer
while it is still operating or while it is switched
off but still plugged in, or energized. In the latter
case, amputations occur when the operator accidentally switches the slicer on.

- When the operator fails to use the sliding attachment on the food-holding device, especially
when slicing small pieces of meat.

- When the operator hand-feeds food into a
chute-fed slicer without using the proper pushing/guarding device or plunger.

**Case History #14**
Two employees, an operator and an assistant,
were using a meat slicer to slice turkey. The
assistant was holding a box of turkey in a tilted
position while the operator fed the turkey into
the slicer. The operator removed the guard
from the meat slicer because the turkey kept
jamming. The slicer’s knives caught the operator’s glove and pulled his hand into the knives,
amputating his finger just above the nail.

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **3 7**

**Case History #15**
An employee was cleaning a meat slicer that was
turned off but was still plugged in. He inadvertently turned the machine on by bumping the
on/off switch, resulting in an amputation of his
right ring finger.

**Safeguarding and Other Controls**
**for Food Slicers**

Food slicers must be used with guards that cover
the unused portions of the slicer blade on both the
top and bottom of the slicer. You should buy slicers
already equipped with a feeding attachment on the
sliding mechanism of the food holder or purchase
the attachment separately and install it before use.
Instruct employees to use a pushing/guarding device with chute-fed slicers.

methods, work practices and complementary

procedures for slicers and conduct periodic

their own.

- Use warning signs to alert employees of the
hazard and safety instructions.

- Instruct operators to use plungers to feed food
into chute-fed slicers. For other slicers, they
should use the feeding attachment located on
the food-holder.

- Never place food into the slicer by hand-feeding
or hand pressure.

- Instruct operators to retract the slicer blade during cleaning operations.

- Instruct operators to turn off and unplug slicers
when not in use or when left unattended for any
period of time.

_Control of hazardous energy (lockout/tagout),_ 29
CFR 1910.147, standard. You can avoid slicer
lockout/tagout if the equipment is cord-and-plug
connected equipment simply by having exclusive control over the attachment plug after you
shut the slicer off and unplug it from the energy

source.

**Hazards of Meat Grinders**

Electric meat grinders typically have a feeding tray
attached to a tubular throat, a screw auger that
pushes meat to the cutting blade and through the
cutting plate, an on/off switch, a reverse switch,
and a plunger. (See _Figure 38_ .)

_**Figure 38**_ **Stainless Steel Meat Grinder**

Amputations can occur when:

- The operator reaches into the throat of the
grinder while it is still operating or while it is
switched off but still plugged in (energized). In
the latter case, amputations can occur when the
operator accidentally switches the grinder back

on.

- The operator fails to use the attached feeding
tray and throat.

Defective meat grinders, such as ones with
holes in the throat or screw auger area, are also a
source of workplace amputations and must be
taken out of service.

**Case History #16**
An operator amputated his arm below the elbow
while hand-feeding potatoes into a 5-horsepower
meat grinder through a feed throat with a 4-inchby-6-inch opening and no point of operation
guard. This untrained employee had been working on the machine for only 15 minutes.

**Case History #17**
An employee amputated her hand about 4 inches
above the wrist while using an inadequately
guarded meat grinder. She had disassembled the
grinder to clean it, but did not replace the fixed
guard along with the stainless steel tray when

**3 8**

she reassembled it. Also, she did not use the
plunger provided for feeding the meat into the
grinder. The machine pulled her hand into the
3-inch diameter auger and amputated it above
the wrist.

**Meat Grinders**

Meat grinders must be retrofitted with a primary
safeguard, such as a properly designed tapered
throat or fixed guard, in cases where the machine
design is such that an employee’s hand may come
in contact with the point-of-operation (that is the
auger cutter area). You should buy meat grinders
already equipped with this primary safeguard.
The following are some other secondary safeguarding methods, work practices, and complementary equipment that may be used to supplement primary safeguarding or alone or in combination when primary safeguarding methods are not
feasible:

procedures for meat grinders to ensure that the
guards are adequate and in place, and that the
grinder feeding methods are performed safely.
Conduct periodic inspections of grinder operations to ensure compliance

 it above
the wrist.

feasible:

Conduct periodic inspections of grinder operations to ensure compliance.

- Ensure that all operators receive appropriate
on-the-job training under direct supervision of

- Provide operators with properly sized plungers
to eliminate the need for their hands to enter the

feed throat during operation.

- Instruct operators to use the proper plunger
device to feed meat into grinders. No other
device should be used to feed the grinder.

- Instruct employees to operate grinders only with
feeding trays and throats installed.

- Instruct operators to use the meat grinder only
for its intended purpose.

- Instruct operators to turn off and unplug grinders

source.

html)

**Hazards of Meat-Cutting Band Saws**
Band saws can cut wood, plastic, metal, or meat.
These saws use a thin, flexible, continuous steel
strip with cutting teeth on one edge that runs
around two large motorized pulleys or wheels. The
blade runs on two pulleys (driver and idler) and
passes through a hole in the work table where the
operator feeds the stock. Blades are available with
various teeth sizes, and the saws usually have
adjustable blade speeds.
Unlike band saws used in other industries,
meat-cutting band saws are usually constructed of
stainless steel for sanitary purposes and for easy
cleaning. The table, which may slide or roll, has a
pushing guard installed to protect the operator
while feeding the saw. Meat-cutting band saws
may also be equipped with a fence and pushing
guard to feed the meat through the band saw. (See
_Figure 39_ .)

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **3 9**

_**Figure 39**_ **Stainless Steel Meat-Cutting Band Saw**

moved too close to the saw blade. The employee
was not using the pusher guard provided for the

saw.

**Meat-Cutting Band Saws**
Primary safeguarding methods that you can use

- Install a self-adjusting guard over the entire
blade, except at the working portion, or point
of operation of the blade. The guard must be
adjustable to cover the unused portion of the
blade above the meat during cutting operations.

- Enclose the pulley mechanism and motor completely.

The following are some secondary safeguarding methods, work practices, and complementary

procedures for meat-cutting band saws to
ensure that the guards are adequate and in
place and that operators safely perform feeding
methods.

- Ensure that all operators receive adequate onthe-job training under the direct supervision of

- Install a brake on one or both wheels to prevent
the saw blade from coasting after the machine is
shut off.

- Provide a pushing guard or fence to feed meat
into the saw blade.

- Instruct operators to use the pushing guard or
fence to feed the saw, especially when cutting
small pieces of meat.

- Instruct operators to adjust the point of operation guard properly to fit the thickness of the

meat.

- Instruct operators to use only sharp meat-cutting blades and to tighten blades to the appropriate tension with the machine’s tension control
device.

Amputations occur most frequently when operators’ hands contact the running saw blade while
feeding meat into the saw. The risk of amputation
is greatest when operators place their hands too
close to the saw blade, in a direct line with the saw
blade, or beneath the adjustable guard during feeding operations. Here are some common causes of
amputations involving meat-cutting band saws:

- The operator’s hand slips off the meat or otherwise accidentally runs through the blade.

- The operator attempts to remove meat from the
band saw table while the blade is still moving.

- The operator’s gloves, jewelry, or loose-fitting
clothing became entangled in the saw blade.

**Case History #18**
While operating a band saw to cut pork loin, an
employee amputated his right index finger when
his hand slipped and contacted the moving blade.

**Case History #19**
An operator amputated the tip of his right ring
finger while using a band saw to cut [1] / [4] -inch
slabs of meat from a 4-inch thick piece of beef.
As the piece of meat got smaller, his hands

**4 0**

- Instruct operators not to wear gloves, jewelry, or
loose-fitting clothing while operating a band
saw and to secure long hair in a net or cap.

- Prohibit operators from removing meat from the
band saw while the saw blade is still moving.

- Instruct operators to turn off and unplug band
saws when not in use or when left unattended

for any period of time.

- Conduct periodic inspections of the saw operation to ensure compliance.

shut the band saw off and unplug it from the

energy source.

html)

 - OSHA Publication 3157, _A Guide for Protecting_
_Workers from Woodworking Hazards_ (http://
www.osha.gov

 _Control of hazardous energy_

html)

www.osha.gov/Publication/osha3157.pdf)

**Hazards of Drill Presses**

Electric drill presses use a rotating bit to drill or cut
holes in wood or metal. The holes may be cut to a
desired preset depth or completely through the
stock. A basic drill press operation consists of
selecting an appropriate drill bit, tightening the bit
in the chuck, setting the drill depth, placing the

material on the drill press bed, securing the work
to the bed so that it will not rotate during drilling,
turning the drill press on, and pulling the drill press
lever down so that the drill bit will be lowered into

the stock. (See _Figure 40_ .)

_**Figure 40**_ **Drill Press with a Transparent Drill Shield**

Amputations typically occur when the operator’s
gloves, loose-fitting clothing, or jewelry become
entangled in the rotating drill bit. Here are some
other causes of drill press-related amputations:

- Inadequately guarding points of operation or
power-transmission (such as belt and pulleys)
devices;

- Removing a part from a drill press while wearing gloves;

- Making adjustments to the drill press, such as
setting the depth, securing the material to the
drill press bed, and repositioning the wood or
metal, while the drill bit is still rotating;

- Changing the drill bit with the operating control
unprotected so that a falling object or otherwise
bumping the switch can accidentally start up the
press spindle and tool assembly;

- Performing servicing and maintenance activities,
such as changing pulleys and belts, without deenergizing and locking/taging out the drill press.

**Case History #20**
A mechanic amputated the first joints of his left
index and middle fingers while changing the belt
position on a multi-pulley drill press. While the
mechanic was pulling the belt on, it suddenly
went around the outside pulley, pulling the
mechanic’s fingers through the nip point.

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **4 1**

**Case History #21**
A machinist amputated his left index finger at the
first joint while drilling holes in a machined part.
As he moved the part to begin drilling another
hole, his gloved hand got caught in the drill bit.

**Drill Presses**

For drill presses, you must be protected from the
rotating chuck and swarf that is produced by the
drill bit. Guarding at the point-of-operation is difficult because of the nature of the drilling press. The
following primary safeguarding methods can be
installed to guard the operator and other employees from rotating parts, flying chips, and cuttings:

- Specifically designed shields can be attached to
the quill and used to guard this area. For example, telescopic shielding that retracts as the drill
bit contacts the piece or a more universal-type
shield can be applied.

- Automatic machines and high-production machines could have enclosures designed and
installed to guard the employee from the entire
drilling operation.

- Install guarding over the motor, belts, and pulleys.

- Install an adjustable guard to cover the unused
portion of the bit and chuck above the material
being worked.

- Automatic machines and high-production
machines could use barricades to separate the
employee from the entire drilling operation.

practices, such as removing the chuck immediately after each use, for drill press operations
and conduct periodic inspections to ensure compliance.

- Train and supervise all operators until they can
work safely on their own.

- Use the drill press only for its intended purposes.

- Instruct employees not to wear gloves, jewelry,
or loose-fitting clothing while operating a drill
press and to secure long hair in a net or cap.

- Make sure that operators secure material to the
drill press bed with clamps (work-holding equipment) before drilling, so that the material will
not spin and strike the operator. The operator
should not manually secure the work to the drill
press bed while drilling holes.

- Do not adjust the drill press while the drill bit is
still rotating.

- Replace projecting chucks and set screws with
non-projecting safety-bit chucks and set screws.

- Cover operator controls so that the drill press
cannot be turned on accidentally.

- Shut off the drill press when not in use or when
left unattended for any period of time.

exception is allowed. See the 29 CFR
1910.147(a)(2)(ii) Note, for details. For example,
minor drill press tool changes and adjustments
may be performed without lockout/tagout if the
machine’s electrical disconnect or control (on/off)
switches control all the hazardous energy and
are: 1) properly designed and applied in accordance with good engineering practice; 2) placed
in an off (open) position; and 3) under the exclusive control of the employee performing the
minor servicing task.

**Cord- and Plug-connected Electric Equipment**

The OSHA LOTO standard would not apply when
employees are performing servicing and maintenance work on a cord- and plug-connected drill
press if the press is unplugged and the plug is in
the exclusive control of the employee performing
the task. The employee would be able to control
the press from being energized by controlling the
attachment plug.

Source: 29 CFR 1910.147(a)(2)(ii)(A).

**4 2**

_**Figure 41**_ **Bed Mill**

 - 29 CFR 1910.213, _Woodworking machinery_
_requirements._

html)

 - ANSI B11.8-2001, _Safety Requirements for_
_Manual Milling, Drilling and Boring Machines_
_with or without Automatic Control_

 - ANSI O1.1-2004, _Safety Requirements for_
_Woodworking Machinery_

**Hazards of Milling Machines**
Electric milling machines cut metal using a rotating
cutting device called a milling cutter. These machines cut flat surfaces, angles, slots, grooves,
shoulders, inclined surfaces, dovetails, and
recessed cuts. Cutters of different sizes and shapes
are available for a wide variety of milling operations.

Milling machines include knee-and-column
machines, bed-type or manufacturing machines,
and special milling machines designed for special
applications. Typical milling operations consist of
selecting and installing the appropriate milling

3157, _A Guide for Protecting_

selecting and installing the appropriate milling cutter, loading a work-piece on the milling table, controlling the table movement to feed the part against
the rotating milling cutter, and callipering or measuring the part. (See _Figure 41_ .)

Some frequent causes of amputation from
milling machines include:

- Loading or unloading parts and callipering or
measuring the milled part while the cutter is still
rotating;

- Operating milling machines with the safety door
selector switch on bypass;

- Inspecting the milling machine gearbox with the
machine still operating;

- Manually checking the machine for loose gears
(by removing the gearbox cover) while computerized cutting software program was operating;

- Performing servicing and maintenance activities
such as setting up the machine, changing and
lubricating parts, clearing jams, and removing
excess oil, chips, fines, turnings, or particles
either while the milling machine is stopped but
still energized, or while the cutter is still rotating;
and

- Getting jewelry or loose-fitting clothing entangled in the rotating cutter.

**Case History #22**
While replacing parts on a horizontal milling
machine, an employee shut off the machine,
which put the revolving cutter in a neutral position. The employee, however, did not disengage
the clutch to stop the cutter and proceeded to
replace parts while the cutter was still moving.
He amputated three fingers.

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **4 3**

**Case History #23**
An employee was using a milling machine to cut
metal samples to length. After a part had been
cut, the employee needed to gauge the part size.
While he was checking the edge of the sample,
the blade caught the tip of his glove, pulled his
hand into the cutting area, and amputated his
right ring finger and part of his middle finger.

**Milling Machines**
The following primary safeguarding methods will
help protect you from point-of-operation and other
milling machine hazard areas:

- Install guards (fixed, movable, and interlocked)
that enclose the milling cutter’s point-of-operation;

- Install properly applied safeguarding devices,
such as presence-sensing devices and two-hand
control methods;

- Install guards around the machine’s power
transmission components (such as drive mechanisms).

- Use other safeguarding devices such as splash
shields, chip shields, or barriers if they provide
effective protection to the operator and when it
is impractical to guard cutters without interfering with normal production operations or creating a more hazardous situation.

- Install awareness devices, such as barriers and
warning signs, around the milling table.

- Instruct operators not to use a jig or vise (workholding equipment) that prevents the point of
operation guard from being adjusted appropriately.

- Develop and implement safe (operating) work
procedures for machine operators, such as safe
work procedures for installing and using fixtures
and tooling.

- Instruct operators to place the jig or vise locking
arrangement so that force must be exerted away
from the cutter.

safe work procedure training by experienced
operators until they can work safely on their

own.

- Instruct operators to move the work-holding
device back to a safe distance when loading or
unloading parts and callipering or measuring
the work and not to perform these activities
while the cutter is still rotating unless the cutter
is adequately guarded.

or loose-fitting clothing while operating a milling
machine and to secure long hair in a net or cap.

- Prohibit operators from reaching around the cutter or hob to remove chips while the machine is
in motion or not locked or tagged out.

ance.

minor milling machine tool changes and adjustments may be performed without lockout/tagout
if the machine’s electrical disconnect or control

(on/off) switches control all the hazardous energy
and are: 1) properly designed and applied in
accordance with good engineering practice; 2)
placed in an off (open) position; and 3) under the
exclusive control of the employee performing the

**4 4**

html)

 - National Safety Council, Accident Prevention
Manual for Industrial Operations: Engineering
and Technology. 10th Ed. Itasca, IL

**Hazards of Grinding Machines**
Grinding machines primarily alter the size, shape,
and surface finish of metal by placing a work-piece
against a rotating abrasive surface or wheel. Grinding machines may also be used for grinding glass,
ceramics, plastics, and rubber.
Examples of grinding machines include abrasive
belt machines, abrasive cutoff machines, cylindrical
grinders, centerless grinders, gear grinders, internal
grinders, lapping machines, off-hand grinders, surface grinders, swing frame grinders, and thread
grinders. (See _Figure 42_ .)

_**Figure 42**_ **Horizontal Surface Grinder**

Amputation injuries can occur when the operator’s hands enter the point of operation during the
following activities:

- Bypassing the grinding machine safety switch
feature in order to clean the machine while it is

running;

- Wearing gloves while grinding, where it is possible to have the glove get caught between the
revolving disc and the table;

- Fixing a jammed grinder machine by turning
the machine off, removing the blade guard and
reaching into the danger area before the blades
stop turning;

- Operating a grinding machine with non-functional interlocks and without the guard in place;

- Using an incorrectly adjusted or missing work
rest or a poorly maintained or unbalanced abrasive wheel;

- Adjusting the work rest, balancing the wheel,
cleaning the area around the abrasive wheel and
loading and unloading parts or measuring parts
while the abrasive wheel is still rotating;

- Attempting to stop a rotating abrasive wheel by
hand.

**Case History #24**
After grinding a piece of steel on an off-hand
grinder, an employee turned off the machine and
tried to stop the wheel with a piece of scrap
steel. His hand slipped and hit the rotating abrasive wheel, amputating the tip of his left middle
finger.

**Case History #25**
An employee was operating a large surface
grinder to grind a groove into a steel part in a
large pump repair

 the blade guard and

hand.

finger.

large pump repair shop. The part was secured
with a vise and placed on a magnetic table. The
employee was trying to measure the groove
while the table was moving back and forth
beneath the grinding wheel. The safe practice,
both written and customary, is to disengage the
hydraulics for the table and stop the wheel
before reaching in to measure or remove a part.
Though experienced at operating this machine
and aware of the strict rule, the employee
attempted to take measurements while the table
and wheel were moving and ground off part of
his left index finger.

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **4 5**

**Grinding Machines**
You can help prevent employee accidents and
injuries by using primary safeguarding methods.
Here are some examples:

- Install safety guards that cover the spindle end,
nut, and flange projections or otherwise ensure
adequate operator protection;

- Install adjustable and rigid work rests on offhand grinding machines; and

- Install guards over power belts and drives.

safeguarding or alone or in combination when
primary safeguarding methods are not feasible:

- Develop and implement safe work procedures
for grinding machine operations.

- Install warning and safety instruction signs.

- Ensure that all operators receive appropriate onthe-job training and supervision until they can

- Use abrasive discs and wheels that are correctly
rated for the grinder’s maximum operating spindle speed. The disc or wheel rating is marked on
the disc or wheel in surface feet per minute.

- Inspect and sound test the grinding wheel to
ensure that it is not defective, unbalanced,
loose, or too small.

- Adjust the work rest to within [1] / [8] inch of the
wheel.

- Do not wear gloves, jewelry, or loose-fitting
clothing while operating grinding machines and
secure long hair in a net or cap.

- Do not adjust the guard or clean the grinding
machine while the abrasive wheel is still rotating.

ance.

employees are performing servicing and maintenance work on a cord- and plug-connected grinding machine if the grinder is unplugged and the
plug is in the exclusive control of the employee

performing the task. The employee would be
able to control the grinder from being energized
by controlling the attachment plug.

 - ANSI B7.1-1970, _Safety Code for the Use, Care_
_and Protection of Abrasive Wheels_ [incorporated by reference in 1910.94(b)(5)(i)(a),
1910.215(b)(12) and 1910.218(j)(5)].

 - 29 CFR 1910.215, _Abrasive wheel machinery._

 - 29 CFR 1926.303, _Abrasive wheels and tools._

html)

 - ANSI B7.1—2000, _Use, Care, and Protection of_
_Abrasive Wheels._

 - ANSI B11.9—1975 (R2005), _Safety Require-_
_ments for the Construction, Care, and Use of_
_Grinding Machines._

**Hazards of Slitters**

Slitters use rotary knives to slit flat rolled metal,
plastic film, paper, plastic, foam, and rubber as well
as other coiled or sheet-fed materials. Slitters range
from small hand-fed paper slitters to large-scale
automated metal slitters, complete with metal processing and handling units such as unwinders and
rewinders. Both light and heavy gauge slitters are
available. (See _Figure 43_ .)

**4 6**

_**Figure 43**_ **Paper Slitter**

Amputations often occur when clothing or body
parts come in contact with slitter blades or get
caught in the movement of coils and rolls. Here are
some examples:

- Employees can inadvertently get their fingers
and hands caught in the in-going nip points of
the slitter or associated machinery such as rewinders.

- Gloves, jewelry, long hair and loose clothing
can get entangled in in-going nip points or in
the rotary knives of the slitter.

- Employees can suffer an amputation when
clearing, adjusting, cleaning, or servicing the
slitter while it is either still operating, or shut
off but still plugged in (energized).

**Case History #26**
An employee was operating a precision slitting
machine to slit a roll of aluminum. As the em
ployee reached into the machine to make an
adjustment because the aluminum was not being
slit properly, the employee’s right arm got caught
in the slitter. A set of rollers pulled his arm and
amputated his right thumb and forefinger.

**Case History #27**
An employee was feeding cardboard strips onto
slit steel as it was being coiled on a slitter
machine. While the machine was operating, the
employee was placing the cardboard strips on the
coils. After reaching over the steel strips, the
coiled steel on the mandrel pulled his right arm
into the machine and amputated it.

**Slitters**

The following primary safeguards may be used to
protect employees from the hazardous portions of
the slitter and auxiliary equipment:

- Install a fixed or adjustable point-of-operation
guard to prevent inadvertent entry of body parts
into a hazardous area of the slitter system.

- Install a fixed point of operation guard to cover
the sides of the unwinder or rewinder to prevent
an employee’s hands or clothing from entering
into the rollers.

- Properly applied presence-sensing devices (such
as light curtains, radio-frequency devices, safety
mats) may be used to control employee exposure
to certain types of hazards (such as the slitter
knives’ point-of-operation hazard) by stopping
or preventing machine system operation in the
event any part of an employee’s body is detected in a sensing field.

- Install fixed or interlocked guards to cover other
moving parts of the machine such as the powertransmission apparatus.

- Use awareness devices, such as an awareness
barrier or fence (with an interlocking gate) and
hazard warning/safety instruction signs around
the perimeter of the machine to alert people of
the hazard and prevent unauthorized entry.

- Awareness signals may also be used to alert
you of an existing or approaching hazard as
these devices issue a warning sound or provide
a visible warning light.

- Restrict employee access to hazardous areas
through the application of safeguarding by location techniques – such as utilizing the facility layout (walls) and equipment location (elevation)
for isolation purposes.

for machine operators and conduct periodic

-

- Develop an operator training program to ensure
that all operators are knowledgeable and proficient in the safeguarding methods and work
procedures. Employees need to be supervised
on a regular basis to ensure that they are following the safety program requirements.

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **4 7**

html)

- ANSI B11.14—1996, _Coil Slitting Machines_
_Safety Requirements for Construction, Care_
_and Use_

**4 8**

#### **OSHA Assistance**

programs, including technical assistance about effective safety and health programs, state plans, workplace consultations, voluntary protection programs,
strategic partnerships, training and education, and
more. An overall commitment to workplace safety and
health can add value to your business, to your workplace, and to your life.

**Safety and Health Program Management Guidelines**

Effective management of employee safety and health
protection is a decisive factor in reducing the extent
and severity of work-related injuries and illnesses and
their related costs. In fact, an effective safety and
health program forms the basis of good employee
protection and can save time and money (about $4
for every dollar spent) and increase productivity and
reduce employee injuries, illnesses, and related workers’ compensation costs.

To assist employers and employees in developing
effective safety and health programs, OSHA published recommended Safety and Health Program
Management Guidelines (54 Federal Register (16):
3904-3916, January 26, 1989). These voluntary guidelines can be applied to all places of employment covered by OSHA.

The guidelines identify four general elements critical to the development of a successful safety and
health management system:

- Management leadership and employee involvement,

- Worksite analysis,

- Hazard prevention and control, and

- Safety and health training.
The guidelines recommend specific actions, under
each of these general elements, to achieve an effective safety and health program. The _Federal Register_
notice is available online at www.osha.gov.

**State Programs**

The _Occupational Safety and Health Act of 1970_ (OSH
Act) encourages states to develop and operate their
own job safety and health plans. OSHA approves and
monitors these plans. Twenty-four states, Puerto Rico
and the Virgin Islands currently operate approved
state plans: 22 cover both private and public (state
and local government) employment; Connecticut,
New Jersey, New York and the Virgin Islands cover
the public sector only. States and territories with their
own OSHA-approved occupational safety and health
plans must adopt standards identical to, or at least as
effective as, the Federal OSHA standards.

**Consultation Services**

Consultation assistance is available on request to
employers who want help in establishing and maintaining a safe and healthful workplace. Largely funded
by OSHA, the service is provided at no cost to the
employer. Primarily developed for smaller employers
with more hazardous operations, the consultation
service is delivered by state governments employing
professional safety and health consultants. Comprehensive assistance includes an appraisal of all mechanical systems, work practices, and occupational safety and health hazards of the workplace and all aspects
of the employer’s present job safety and health program. In addition, the service offers assistance to
employers in developing and implementing an effective safety and health program. No penalties are proposed or citations issued for hazards identified by the
consultant. OSHA provides consultation assistance to
the employer with the assurance that his or her name
and firm and any information about the workplace will
not be routinely reported to OSHA enforcement staff.

Under the consultation program, certain exemplary
employers may request participation in OSHA’s Safety
and Health Achievement Recognition Program
(SHARP). Eligibility for participation in SHARP includes receiving a comprehensive consultation visit,
demonstrating exemplary achievements in workplace
safety and health by abating all identified hazards, and
developing an excellent safety and health program.

Employers accepted into SHARP may receive an
exemption from programmed inspections (not complaint or accident investigation inspections) for a period of 1 year. For more information concerning consultation assistance, see OSHA’s website at

**Voluntary Protection Programs (VPP)**

Voluntary Protection Programs and on-site consultation services, when coupled with an effective enforcement program, expand employee protection to
help meet the goals of the OSH Act. The VPPs motivate others to achieve excellent safety and health
results in the same outstanding way as they establish a cooperative relationship between employers,
employees, and OSHA.

For additional information on VPP and how to

apply, contact the OSHA regional offices listed at the
end of this publication.

**Strategic Partnership Program**

OSHA’s Strategic Partnership Program, the newest
member of OSHA’s cooperative programs, helps
encourage, assist, and recognize the efforts of partners to eliminate serious workplace hazards and
achieve a high level of employee safety and health.
Whereas OSHA’s Consultation Program and VPP entail

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **4 9**

one-on-one relationships between OSHA and individual worksites, most strategic partnerships seek to
have a broader impact by building cooperative relationships with groups of employers and employees.
These partnerships are voluntary, cooperative relationships between OSHA, employers, employee representatives, and others (e.g., trade unions, trade and professional associations, universities, and other government agencies).

For more information on this and other cooperative programs, contact your nearest OSHA office, or
visit OSHA’s website at www.osha.gov.

**Alliance Program**

The Alliance Program enables organizations committed to workplace safety and health to collaborate with
OSHA to prevent injuries and illnesses in the workplace. OSHA and the Alliance participants work
together to reach out to, educate, and lead the
nation’s employers and their employees in improving
and advancing workplace safety and health.

Groups that can form an Alliance with OSHA
include employers, labor unions, trade or professional
groups, educational institutions and government
agencies. In some cases, organizations may be building on existing relationships with OSHA that were
developed through other cooperative programs.

There are few formal program requirements for
Alliances and the agreements do not include an
enforcement component. However, OSHA and the
participating organizations must define, implement,
and meet a set of short- and long-term goals that fall
into three categories: training and education; outreach
and communication; and promotion of the national
dialogue on workplace safety and health.

**OSHA Training and Education**

OSHA area offices offer a variety of information services, such as compliance assistance, technical advice,
publications, audiovisual aids and speakers for special
engagements. OSHA’s Training Institute in Arlington
Heights, IL, provides basic and advanced courses in
safety and health for Federal and state compliance
officers, state consultants, Federal agency personnel,
and private sector employers, employees, and their

 institutions and government

representatives.

The OSHA Training Institute also has established
OSHA Training Institute Education Centers to address
the increased demand for its courses from the private
sector and from other federal agencies. These centers
are nonprofit colleges, universities, and other organizations that have been selected after a competition for
participation in the program.

OSHA also provides funds to nonprofit organizations, through grants, to conduct workplace training
and education in subjects where OSHA believes there

is a lack of workplace training. Grants are awarded
annually. Grant recipients are expected to contribute
20 percent of the total grant cost.

For more information on grants, training, and education, contact the OSHA Training Institute, Office of
Training and Education, 2020 South Arlington Road,
Arlington Heights, IL 60005, (847) 297-4810, or see
_Outreach_ on OSHA’s website at www.osha.gov. For
further information on any OSHA program, contact
your nearest OSHA regional office listed at the end of
this publication.

**Information Available Electronically**

OSHA has a variety of materials and tools available on
its website at www.osha.gov. These include electronic
compliance assistance tools, such as Safety and
Health Topics, eTools, Expert Advisors; regulations,
directives and publications; videos and other information for employers and employees. OSHA’s software
programs and compliance assistance tools walk you
through challenging safety and health issues and
common problems to find the best solutions for your
workplace.

A wide variety of OSHA materials, including standards, interpretations, directives and more can be
purchased on CD-ROM from the U.S. Government
Printing Office, Superintendent of Documents, toll-free
phone (866) 512-1800.

**OSHA Publications**

OSHA has an extensive publications program. For a
listing of free or sales items, visit OSHA’s website at
www.osha.gov or contact the OSHA Publications
Office, U.S. Department of Labor, 200 Constitution
Avenue, NW, N-3101, Washington, DC 20210:
Telephone (202) 693-1888 or fax to (202) 693-2498.

**Contacting OSHA**

To report an emergency, file a complaint, or seek
OSHA advice, assistance, or products, call (800) 321OSHA or contact your nearest OSHA Regional or Area
office listed at the end of this publication. The teletypewriter (TTY) number is (877) 889-5627.
Written correspondence can be mailed to the nearest OSHA Regional or Area Office listed at the end of
this publication or to OSHA’s national office at: U.S.
Department of Labor, Occupational Safety and Health
Administration, 200 Constitution Avenue, N.W.,
Washington, DC 20210.
By visiting OSHA’s website at www.osha.gov, you
can also:

- file a complaint online,

- submit general inquiries about workplace safety
and health electronically, and

- find more information about OSHA and occupational safety and health.

**5 0**

#### **References**

**American National Standards Institute**

- ANSI B5.52M-1980 (R1994), _Presses, General_
_Purpose, Single Point, Gap Type, Mechanical_
_Power (Metric)_

- ANSI B5.37—1970 (R1994), _External Cylindrical_
_Grinding Machines—Centerless_

- ANSI B5.42—198 (R1994), _External Cylindrical_
_Grinding Machines—Universal_

- ANSI B7.1—2000, _Use, Care, and Protection of_
_Abrasive Wheels_

- ANSI B11.1-2001, _Safety Requirements for_

- ANSI B11.3-2002, _Safety Requirements for the_
_Construction, Care, and Use of Power Press_
_Brakes_

- ANSI B11.4-2003, _Safety Requirements for_
_Construction, Care, and Use of Shears_

- ANSI B11.8-2001, _Safety Requirements for_

- ANSI B11.9—1975 (R2005), _Safety Requirements_
_for the Construction, Care, and Use of Grinding_
_Machines_

- ANSI B11.12-1996, _Safety Requirements for_
_Construction, Care, and Use of Roll-Forming and_
_Roll-Bending Machines_

_Safety Requirements for Construction, Care and_
_Use_

- ANSI B11.19-2003, _Performance Criteria for_
_Safeguarding_

- ANSI B20.1-57, S _afety Code for Conveyors,_
_Cableways, and Related Equipment_ [incorporated by reference in 1926.555(a)(8)]

- ANSI B65.1-2005, _Safety Standard—Printing_

- ANSI B65.2-2005, _Binding and Finishing_
_Systems_

- ANSI O1.1-2004, _Safety Requirements for_

**American National Standards Institute/**
**Conveyor Equipment Manufacturers**
**Association**

- ANSI/CEMA 350-2003, _Screw Conveyors for Bulk_
_Material_

- ANSI/CEMA 401-2003, _Unit Handling_

—
_Conveyors_ _Roller Conveyors—Non-powered_

- ANSI/CEMA 402-2003, _Unit Handling_
_Conveyors—Belt Conveyors_

- ANSI/CEMA 403-2003, _Unit Handling_
_Conveyors—Belt Driven Live Roller Conveyors_

- ANSI/CEMA 404-2003, _Unit Handling_
_Conveyors—Chain Driven Live Roller Conveyors_

- ANSI/CEMA 405-2003, _Unit Handling_

- ANSI/CEMA 406-2003, _Unit Handling_
_Conveyors—Line-shaft Driven Live Roller_
_Conveyors_

**American Society of Mechanical**
**Engineers**

- ANSI/ASME B20.1-2003, _Safety Standard for_
_Conveyors and Related Equipment_

**National Institute for Occupational**
**Safety and Health**

- NIOSH Current Intelligence Bulletin (CIB) 49,
_Injuries and Amputations Resulting from Work_
_with Mechanical Power Presses_ (May 22, 1987)

**National Safety Council**

- National Safety Council, Accident Prevention
and Technology. 9th ed. Itasca, IL

Manual for Business and Industry: Engineering
and Technology 11th ed. Itasca, IL

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **5 1**

**Occupational Safety and Health**
**Administration Standards**

- 29 CFR 1910.147— _Control of hazardous energy_

- 29 CFR 1910.211— _Definitions._

- 29 CFR 1910.212— _General requirements for all_

- 29 CFR 1910.213— _Woodworking machinery_

- 29 CFR 1910.215— _Abrasive wheel machinery._

- 29 CFR 1910.217— _Mechanical power presses._

- 29 CFR 1910.219— _Mechanical power-transmis-_

- 29 CFR 1926.300— _General requirements._

- 29 CFR 1926.301— _Hand tools._

- 29 CFR 1926.302— _Power-operated hand tools._

- 29 CFR 1926.303— _Abrasive wheels and tools._

- 29 CFR 1926.304—

147— _Control of hazardous energy_

- 29 CFR 1926.304— _Woodworking tools._

- 29 CFR 1926.307— _Mechanical power-transmis-_

- 29 CFR 1926.555— _Conveyors._

**Administration Instructions**

- OSHA Instruction CPL 03-00-003, _National_
_Emphasis Program on Amputations_

- OSHA Instruction STD 01-12-021—29 CFR

1910.217, _Mechanical Power Presses,_
_Clarifications_ (10/30/78)

- OSHA Instruction CPL 02-01-025, _Guidelines for_
_Brakes_

- OSHA Instruction STD 01-05-019, _Control of_
_Hazardous Energy (Lockout/Tagout)—Inspection_
_Procedures and Interpretive Guidance_

**Administration Training Programs**

- _OSHA’s Lockout Tagout Interactive Training_
_Program_ (http://www.osha-slc.gov/dts/osta/lototraining/index.htm)

**Administration Publications**

- OSHA Publication 3120 - _Control of Hazardous_

_Energy (Lockout/Tagout)_

- OSHA Publication 3157 - _A Guide for Protecting_
_Workers from Woodworking Hazards_
(http://www.osha.gov/Publication/osha3157.pdf)

**Administration Topic Pages**

- Safety and Health Topics – _Control of Hazardous_
_Energy – Lockout/Tagout_ (http://www.osha.gov/
SLTC/controlhazardousenergy/index.html)

- Safety and Health Topics – _Machine Guarding_
(http://www.osha.gov/SLTC/machineguarding/
index.html)

**5 2**

#### **Appendix A.** **Amputation Hazards Not** **Covered in this Guide**

The following amputation hazards and related
activities are not specifically covered in detail in this
document. They are either covered in other OSHA
publications or specific OSHA standards. While
you may find the general hazard recognition and
machine guarding concepts presented in the
_Recognizing Amputations Hazards and Controlling_
_Amputation Hazards_ sections of this document
helpful, please refer to the applicable topic-specific
resources and standards listed in the reference sec
tion of this publication for a complete discussion of
these hazards.

**with Saws**

Saws are the top source of amputations in wholesale and retail trade and in the construction indus
try. Stationary saws, such as band, radial arm and
table saws, account for a substantial number of
amputations in the workplace. Sawing machinery
used for woodworking applications is not specifically addressed in this guide.
You can find specific guidance on these saws in
OSHA Publication 3157, _A Guide for Protecting_
_Workers from Woodworking Hazards_ ; 29 CFR
1910.213, _Woodworking machinery requirements_ ;
29 CFR 1910.243, _Guarding of portable powered_
_tools_ ; and 29 CFR 1926.304, _Woodworking tools_ .
For additional information on how to safeguard
saws and implement hazardous energy control
practices, you can find guidance at OSHA’s
Machine Guarding eTool section for Saws (http://
www.osha.gov/SLTC/etools/machineguarding/saws.
html) Also, the national consensus standard, ANSI
O1.1-2004, _Safety Requirements for Woodworking_
_Machinery_, may provide you with valuable information on how to prevent amputations.

**Amputation Hazards Associated with**
**Plastics Machinery**
Plastics processing machines are complex pieces
of equipment that require safeguarding and a hazardous energy control program. Serious injuries,
including fatalities, amputations, avulsions, burns
and cuts can occur, especially during servicing and
maintenance work. You can find specific guidance
at OSHA’s “Machine Guarding” eTool section for
“Plastics Machinery” (http://www.osha.gov/SLTC/
etools/machineguarding/plastics/h_injectmold.html).

**Amputation Hazards in Agriculture and**
**Maritime Operations**
Requirements for machine guarding in agriculture
operations are contained in the Standards for
Agriculture, 29 CFR Part 1928 Subpart D— _Safety for_
_Agricultural Equipment_, and requirements for
machine guarding in maritime operations can be
found in the Shipyard Employment Standards, 29
CFR Part 1915 Subpart H— _Tools and Related_
_Equipment_, the Marine Terminals Standard, 29 CFR
Part 1917 Subpart G— _Machine Guarding_, and the
Longshoring Standard, 29 CFR Part 1918 Subpart
I— _General Working Conditions_ .

**Additional Health and Safety Hazards**
Other health and safety hazards associated with
using stationary machines, but not addressed in
this guide, include noise, vibration, ergonomic
stresses, exposure to hazardous chemicals (e.g.,
metalworking fluids) and dust, electric hazards, and
flying objects.
Please visit the OSHA website at www.osha.gov
for more information on how to recognize and control these hazards.

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **5 3**

#### **Appendix B.** **Amputation Hazards** **Associated with Other** **Equipment and Activities**

Although machinery is associated with amputations
more frequently than any other source, amputations can result from other sources. This appendix
briefly identifies other equipment and activities
associated with amputations:

- **Powered and Non-Powered Hand Tools.**

Portable hand tools, such as saws, grinders,
shears, and bolt cutters are associated with
amputations in the construction, retail trade,
and services industries.

- **Material Handling.** Amputations related to
manual material handling tasks often result
when heavy or sharp objects fall from an elevated surface or shift during transfer. Amputation
often occurs when the employee attempts to
limit the movement of, or damage to, material
as it shifts or falls.

- **Forklifts.** Amputation hazards related to forklift
operation and use include employees being
trapped or pinned between the forklift and
another object; struck or run over by the forklift;
struck by falling or shifting loads or overturning
forklifts.

- **Doors and Covers.** Amputation hazards are not
limited to mechanical equipment or heavy
loads. Doors also have the potential to amputate fingers. These injuries typically result when
a door closes while a person’s hands are in the
doorjamb. Manhole covers, commercial garbage
disposal covers, and tank or bin covers can also
amputate fingers and toes.

- **Trash Compactors.** Many businesses use small
trash compactors for reducing the volume of
wastes such as cardboard. Often these com
pactors are not properly guarded and employees are not properly trained in their use. The
majority of these amputations result from
employees being struck by the ram/piston either
during the initiating stroke or the return stroke.
The ram/piston should be guarded if any part of
an operator’s body is exposed to the danger
area during the operating cycle. Likewise, before
reaching into any trash compactor the operator
should de-energize and lock out the machine.

**5 4**

#### **Appendix C.** **OSHA Regional Offices**

(CT,* ME, MA, NH, RI, VT*)
JFK Federal Building, Room E340
(617) 565-9860

(NJ,* NY

**5 4**

201 Varick Street, Room 670
(212) 337-2378

(DE, DC, MD,* PA, VA,* WV)
The Curtis Center

Suite 740 West

(215) 861-4900

(AL, FL, GA, KY,* MS, NC,* SC,* TN*)
61 Forsyth Street, SW
(404) 562-2300

Room 3244

(312) 353-2220

(AR, LA, NM,* OK, TX)
525 Griffin Street, Room 602
(214) 767-4731 or 4736 x224

(816) 426-5861

1999 Broadway, Suite 1690
PO Box 46550

Denver, CO 80202-5716
(720) 264-6550

(American Samoa, AZ,* CA,* HI,* NV,*
71 Stevenson Street, Room 420
(415) 975-4310

1111 Third Avenue, Suite 715
Seattle, WA 98101-3212
(206) 553-5930

  - These states and territories operate their own
OSHA-approved job safety and health programs
and cover state and local government employees
as well as private sector employees. The
Connecticut, New Jersey, New York and Virgin
Islands plans cover public employees only. States
with approved programs must have standards that
are identical to, or at least as effective as, the

Federal standards.

**Note:** To get contact information for OSHA Area
Offices, OSHA-approved State Plans and OSHA
Consultation Projects, please visit us online at
www.osha.gov or call us at 1-800-321-OSHA.

**S A F E G U A R D I N G E Q U I P M E N T** **A N D** **P R O T E C T I N G** **E M P L O Y E E S** **F R O M** **A M P U T A T I O N S** **5 5**

**5 6**

Preventing the Injury of Workers by Robots (85-103) _ NIOSH _ CDC.pdf_dpr_chunk_0

7/24/25, 10:31 AM Preventing the Injury of Workers by Robots (85-103) | NIOSH | CDC

[The National Institute for Occupational Safety and Health (NIOSH)](https://www.cdc.gov/niosh/)

# Preventing the Injury of Workers by Robots

DHHS (NIOSH) PUBLICATION NUMBER 85-103 DECEMBER 1984

## Background

On July 21, 1984, a thirty-four-year-old male operator of an automated die-cast system went into cardiorespiratory arrest

and died after being pinned between the back end of an industrial robot and a steel safety pole. The hydraulic robot had

been installed in an existing production line to remove die-cast parts from a die-cast machine and to transfer these parts to
a trimmer. The victim had fifteen years’ experience in die-casting and had completed a one-week training course in robotics

three weeks before the fatal incident.

The victim entered the working range of the operating robot presumably to clean up scrap metal that had accumulated on
the floor. Despite training in the robotics course, instructions on the job, and warnings by fellow workers to avoid this
dangerous practice, the victim apparently climbed over, through, or around a safety rail which surrounded two sides of the

robot’s work envelope. The entry point in the safety rail was interlocked. No other presence-sensing devices were operative

in the system.

This preventable fatality demonstrates a growing problem of the failure of workers to recognize all the hazards associated

with robots. While workers may readily recognize hazards associated with the working zone of the robotic arm, they may

not recognize dangers associated with the movement of other parts of the robotic assembly. In this case, the victim was
trapped between a fixed object (a steel pole 4 inches in diameter) and the active back end of the robot which was outside
the working zone of the robotic arm; the worker apparently presumed this area to be “safe.”

## Recommendations By NIOSH

To minimize the risk of such incidents, NIOSH offers the following recommendations regarding the design of robotic

systems, the training of workers, and their supervision.

### A. The Design of Robotic System

Regarding both existing robotic equipment and new designs, NIOSH recommends that the robotic system:

1. Include physical barriers that incorporate gates equipped with electrical interlocks so that operation of the robot stops

when the gate is opened.

2. Include, as a backup to electrical interlocks, motion sensors, light curtains, or floor sensors that stop the robot

whenever a worker crosses the barrier.

3. Provide barriers, as may be appropriate, between robotic equipment and any freestanding objects such as posts

limiting robot arm movement so that workers cannot get between any part of the robot and the “pinch points.”

https://www.cdc.gov/niosh/docs/85-103/ 1/3

4. Provide adequate clearance distances around all moving components of the robotic system. It is of particular

importance that this be considered in plans for replacing a human worker with a robot; a robot often requires more

operational space than does a human worker doing the same task.

5. Include remote “diagnostic” instrumentation as much as possible so that the maximum amount of troubleshooting of

the system can be done from areas outside the operating range of the robot. Whenever it is necessary for a worker to

be within the operating range of a robot, additional special provisions for safety should be taken, including, at a

minimum, the presence of another worker who can turn off the robot should an emergency develop (buddy system).

6. Provide adequate illumination in the control and operational areas of the robotic system so that written instructions, as

well as buttons, levers, etc., are clearly visible.

7. Include on floors or working surfaces clearly visible marks that indicate the zones of movement of the robot.

### B. Training of Workers

Training specific to the particular robot in question should be provided to workers who will be programming, operating, or
maintaining robots. Moreover, refresher courses which re-emphasize safety and discuss new technological developments

should be provided for experienced programmers, operators, and maintenance workers. This training should emphasize safe

work practices and stress that:

1. Workers must be familiar with all working aspects of the robot, including full range of motion, known hazards, how the

robot is programmed, emergency stop buttons, and safety barriers, before operating or performing maintenance work

at robotic work stations.

2. Operators should never be in reach of the robot while it is operating.

3. Programmers, operators, and maintenance workers should operate robots at reduced speeds consistent with adequate

worker response to avoid hazards during programming and be aware of all conceivable pinch points, such as poles,

walls, and other equipment, in the robots’ operational area.

### C. Supervision of Workers

Supervisors should:

1. Assure that no one is allowed to enter the operational area of a robot without first putting the robot on “hold,” in a

“power down” condition, or at a reduced operating speed mode.

2. Recognize that with the passage of time, experienced workers doing automated tasks may become complacent,

overconfident, or unattentive to the hazards inherent in complex automated equipment. Close supervision of such
operations is imperative to assure safety.

We are requesting that company managers, editors of appropriate trade journals, robot equipment designers, and safety

and health inspectors institute these recommendations and bring them to the attention of the potential victims.

To report incidents regarding robotics and to obtain assistance or further information, call Mr. John Moran, Director, Division

of Safety Research, National Institute for Occupational Safety and Health, 944 Chestnut Ridge Road, Morgantown, West

Virginia 26505, Telephone (304) 291-4595.

[signature]

J. Donald Millar, M.D., D.T.P.H. (Lond.)

Assistant Surgeon General

Director, National Institute for Occupational Safety and Health

Centers for Disease Control

https://www.cdc.gov/niosh/docs/85-103/ 2/3

**[Preventing the Injury of Workers by Robots](https://stacks.cdc.gov/view/cdc/113263)**

Last Reviewed: June 6, 2014

https://www.cdc.gov/niosh/docs/85-103/ 3/3

Preventing the Injury of Workers by Robots (85-103) _ NIOSH _ CDC.pdf

C:\Users\megahefm\Dropbox\SIGHT Project\sight\app\data\Preventing the Injury of Workers by Robots (85-103) _ NIOSH _ CDC.pdf