CONVEYOR & CRUSHER CONVEYOR & CRUSHER SAFETY SAFETY

NCMAQDNCMAQD

Steve FranklinSteve Franklin

56.14107(a56.14107(a

• Guarding of Moving Machine Guarding of Moving Machine PartsParts

• 2,960 2,960

• 13.7% 13.7%

GuardsGuards

NONMETAL MINE NONMETAL MINE FATALITYFATALITY• On March 18, 1999, a 56-On March 18, 1999, a 56-

year-old superintendent year-old superintendent with 4 weeks mining with 4 weeks mining experience was fatally experience was fatally injured at a sand and injured at a sand and gravel operation. The gravel operation. The victim was using a metal victim was using a metal bar to clean mud off of a bar to clean mud off of a return roller underneath return roller underneath a conveyor belt when he a conveyor belt when he was caught and drawn was caught and drawn into the pinch point. into the pinch point.

Best PracticesBest Practices

• Maintenance should not be performed unless the Maintenance should not be performed unless the power is off and machinery components are blocked power is off and machinery components are blocked against hazardous motion. against hazardous motion.

• Moving machine parts should be guarded to protect Moving machine parts should be guarded to protect persons from contact that could cause injury. persons from contact that could cause injury.

• Mine operators should take measures to ensure all Mine operators should take measures to ensure all personnel are trained in safe work procedurepersonnel are trained in safe work procedure

NONMETAL MINE NONMETAL MINE FATALITYFATALITY• On August 9, 1999, a 25-On August 9, 1999, a 25-

year-old laborer with 4 year-old laborer with 4 weeks mining experience weeks mining experience was fatally injured at a sand was fatally injured at a sand and gravel operation. The and gravel operation. The victim was using a hoe to victim was using a hoe to clean material underneath clean material underneath an operating conveyor belt an operating conveyor belt when he was caught and when he was caught and drawn into the pinch point drawn into the pinch point at a return roller. at a return roller.

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Best PracticesBest Practices

• Maintenance should not be performed unless the Maintenance should not be performed unless the power is off and machinery components are power is off and machinery components are blocked against hazardous motion. blocked against hazardous motion.

• Moving machine parts should be guarded to Moving machine parts should be guarded to protect persons from contact that could cause protect persons from contact that could cause injury. injury.

• Mine operators should take measures to assure Mine operators should take measures to assure all personnel are trained in safe work procedures. all personnel are trained in safe work procedures.

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56.14112(b56.14112(b

• Guard ConstructionGuard Construction

• 622622

• 2.9%2.9%

NONMETAL MINE NONMETAL MINE FATALITYFATALITY• On April 28, 1998, a 36-On April 28, 1998, a 36-

year old plant operator year old plant operator was fatally injured at an was fatally injured at an open pit limestone mine. open pit limestone mine. The victim climbed a The victim climbed a conveyor structure and conveyor structure and became caught in a became caught in a pinch point while pinch point while attempting to clean a attempting to clean a moving conveyor belt moving conveyor belt with a shovel. The with a shovel. The victim's arm was severed victim's arm was severed and he fell 9 feet to the and he fell 9 feet to the ground. ground.

Best PracticesBest Practices

• Conveyors should be de-energized and Conveyors should be de-energized and blocked against motion before work is blocked against motion before work is performed on them. performed on them.

• Guards around moving machine parts Guards around moving machine parts should cover all areas which miners can should cover all areas which miners can contact inadvertently. contact inadvertently.

• Substantially constructed work platforms Substantially constructed work platforms should be provided at all worksites. should be provided at all worksites.

• Where there is a danger of falling, Where there is a danger of falling, persons should wear safety belts and persons should wear safety belts and lines.lines.

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Paperwork & TrainingPaperwork & Training

Walkway Walkway

AccidentsAccidentsIn a recent six year period, 21 In a recent six year period, 21 miners died in conveyor-belt miners died in conveyor-belt

accidents. The leading cause of accidents. The leading cause of these accidents was trying to these accidents was trying to

remove material sticking to a roller remove material sticking to a roller or pulley while the belt was running or pulley while the belt was running

Consider the following: Consider the following: • In these fatal accidents, In these fatal accidents,

belt speeds were belt speeds were typically in the range of typically in the range of 300 to 500 feet per 300 to 500 feet per minute (fpm). This minute (fpm). This means the belt was means the belt was moving from 5 to over moving from 5 to over 8 feet per second. 8 feet per second.

• For the average person, For the average person, the time needed to the time needed to react to an unexpected react to an unexpected sensation is about one sensation is about one second.second.

FACTSFACTS• Putting these facts together Putting these facts together

shows why working near a shows why working near a running conveyor belt is so running conveyor belt is so dangerous. Even at 300 fpm, dangerous. Even at 300 fpm, in that one second that the in that one second that the average person needs to average person needs to react, the belt moves over react, the belt moves over the pulleys and rollers a the pulleys and rollers a distance of 5 feet. That's far distance of 5 feet. That's far enough to draw your tool, enough to draw your tool, your loose clothing, gloved your loose clothing, gloved or bare hand and arm, into a or bare hand and arm, into a pinch point before you can pinch point before you can react. react.

Take these tips to work with Take these tips to work with you: you: • Don't take chances around a conveyor belt. Don't take chances around a conveyor belt.

• Don't perform work that will expose you to Don't perform work that will expose you to a pinch point, like clearing caked material a pinch point, like clearing caked material from a roller, while a belt is in operation. from a roller, while a belt is in operation.

• Only work on a conveyor that is locked and Only work on a conveyor that is locked and tagged out. tagged out.

• If you are working near a stopped belt, and If you are working near a stopped belt, and a start-up warning is given, stop what a start-up warning is given, stop what you're doing and get clear!you're doing and get clear!

TipsTips

• Never cross a moving belt. Never cross a moving belt.

• Always cross at a bridge or Always cross at a bridge or designated crossing point.designated crossing point.

FACTSFACTS

An average of forty miners are injured An average of forty miners are injured each year by material falling from each year by material falling from

belt conveyors. Although these belt conveyors. Although these injuries are generally not serious, injuries are generally not serious,

almost half result in lost work time. almost half result in lost work time. Over a five-year period, the average Over a five-year period, the average number of lost-work days per injury number of lost-work days per injury

was 12 at metal and nonmetal mines was 12 at metal and nonmetal mines and 23 at coal mines. and 23 at coal mines.

Skirt BoardsSkirt Boards• The use of skirt The use of skirt

boards can limit the boards can limit the amount of material amount of material that falls from that falls from conveyors and conveyors and exposes miners to exposes miners to injuries. The cost can injuries. The cost can be optimized by be optimized by placing the skirt placing the skirt boards at "high-risk" boards at "high-risk" areas along the belt areas along the belt line, where these line, where these type of accidents are type of accidents are more likely to occur. more likely to occur.

To reduce such accidents, mine To reduce such accidents, mine operators should do the following:operators should do the following:

• 1) Install skirt boards on 1) Install skirt boards on conveyors at locations that conveyors at locations that have a higher likelihood of have a higher likelihood of material falling off the belt, or material falling off the belt, or a higher chance for miners to a higher chance for miners to be exposed to this hazard, be exposed to this hazard, such as: such as:

• At loading and transfer areas At loading and transfer areas it is recommended that the it is recommended that the skirt boards be at least 2-1/2 skirt boards be at least 2-1/2 times longer than the belt is times longer than the belt is wide, to allow the material to wide, to allow the material to ‘settle down'; ‘settle down';

To reduce accidentsTo reduce accidents

• At areas that have unusual features, such as At areas that have unusual features, such as magnets, crushers, and grizzlies; magnets, crushers, and grizzlies;

• At places where persons regularly travel At places where persons regularly travel along or cross under the belt; and along or cross under the belt; and

• At areas where maintenance, clean-up, or At areas where maintenance, clean-up, or inspection activities are frequently inspection activities are frequently performed. performed.

2) 2) At your periodic safety meetings, At your periodic safety meetings,

emphasize the followingemphasize the following::

• In the ‘high-risk' areas mentioned above, In the ‘high-risk' areas mentioned above, miners need to be aware of the potential for miners need to be aware of the potential for falling material while doing clean-up, falling material while doing clean-up, maintenance, or inspection work. maintenance, or inspection work.

• Under certain operating conditions, such as Under certain operating conditions, such as when a belt is not fully loaded, material when a belt is not fully loaded, material may be more likely to bounce or fall off a may be more likely to bounce or fall off a belt. belt.

safety meetingssafety meetings

• When traveling along conveyors (even in When traveling along conveyors (even in a vehicle), miners should keep as far a vehicle), miners should keep as far away from the conveyor as possible, away from the conveyor as possible, without exposing themselves to other without exposing themselves to other hazards. hazards.

• Even small material can cause injury if it Even small material can cause injury if it falls from a height or from a fast moving falls from a height or from a fast moving belt.belt.

NONMETAL MINE NONMETAL MINE FATALITYFATALITY

On April 4, 2006, a 23-On April 4, 2006, a 23-year-old laborer, with one year-old laborer, with one month mining experience, month mining experience,

was fatally injured at a was fatally injured at a sand and gravel operation. sand and gravel operation. The victim had entered the The victim had entered the

area under the crusher area under the crusher and traveled near the back and traveled near the back

side of the discharge side of the discharge conveyor tail pulley. His conveyor tail pulley. His

clothing became clothing became entangled in the rotating entangled in the rotating

tail pulley. tail pulley.

Best PracticesBest Practices

• Establish policies that ensure employees are Establish policies that ensure employees are trained on required procedures to safely trained on required procedures to safely remove spillage near moving conveyor belts. remove spillage near moving conveyor belts.

• Establish policies that ensure employees are Establish policies that ensure employees are trained on required procedures to safely trained on required procedures to safely remove spillage near moving conveyor belts. remove spillage near moving conveyor belts.

• Before assigning miners to clean up spillage, Before assigning miners to clean up spillage, have them identify hazards and demonstrate have them identify hazards and demonstrate how they would safely complete the tasks. how they would safely complete the tasks.

Best PracticesBest Practices

• Stop, Look, Analyze, Manage ( SLAM ) Stop, Look, Analyze, Manage ( SLAM )

• Ensure that conveyor belts are Ensure that conveyor belts are deenergized and blocked against deenergized and blocked against motion before positioning yourself motion before positioning yourself near the drive, head, tail, and take-near the drive, head, tail, and take-up pulleys. up pulleys.

NONMETAL MINE NONMETAL MINE FATALITYFATALITY On May 3, 2006, a 19-On May 3, 2006, a 19-

year-old laborer, with 4 year-old laborer, with 4 weeks mining experience, weeks mining experience, was fatally injured at a was fatally injured at a sand and gravel sand and gravel operation. The victim was operation. The victim was underneath a feeder underneath a feeder conveyor belt and was conveyor belt and was adjusting it when he adjusting it when he became entangled became entangled between the belt and the between the belt and the return idler. return idler.

Best PracticesBest Practices

• Ensure that miners are properly task trained Ensure that miners are properly task trained in procedures to safely adjust conveyor belts in procedures to safely adjust conveyor belts that are in operation. A competent person that are in operation. A competent person should closely observe the miner while he should closely observe the miner while he performs the task to ensure they are performs the task to ensure they are protected from hazardous motion of the protected from hazardous motion of the conveyor. conveyor.

• Before assigning miners to adjust belts, have Before assigning miners to adjust belts, have them identify hazards and demonstrate how them identify hazards and demonstrate how they would safely complete the task. Stop, they would safely complete the task. Stop, Look, Analyze, Manage ( SLAM ). Look, Analyze, Manage ( SLAM ).

Best PracticesBest Practices

• Keep all guards securely in place except Keep all guards securely in place except when testing or making adjustments. when testing or making adjustments.

• Install local stop switches at all conveyor Install local stop switches at all conveyor locations and ensure start up warning locations and ensure start up warning alarms are operational where visual alarms are operational where visual observation of the entire conveyor is not observation of the entire conveyor is not possible from the start up control. possible from the start up control.

NONMETAL MINE NONMETAL MINE FATALITYFATALITY• On September 28, 2004, a On September 28, 2004, a

64-year-old plant operator, 64-year-old plant operator, with 17 years mining with 17 years mining experience, was fatally experience, was fatally injured at a sand and gravel injured at a sand and gravel operation. He was using a operation. He was using a water hose to clean spillage water hose to clean spillage under a conveyor. under a conveyor. Apparently, a large rock fell Apparently, a large rock fell from a conveyor located from a conveyor located overhead and struck him, overhead and struck him, resulting in fatal injuriesresulting in fatal injuries. .

Best PracticesBest Practices

• Conduct a Risk Assessment evaluating all Conduct a Risk Assessment evaluating all tasks and identifying potential hazards tasks and identifying potential hazards before performing work. before performing work.

• Never walk under or perform work near Never walk under or perform work near moving conveyor belts where there is a moving conveyor belts where there is a danger of being stuck from falling danger of being stuck from falling material. material.

• Ensure that guards, shields, or other Ensure that guards, shields, or other devices are installed to protect persons devices are installed to protect persons from hazards of falling material near from hazards of falling material near conveyors, screens, or crushers. conveyors, screens, or crushers.

NONMETAL MINE FATALITYNONMETAL MINE FATALITY• On January 25, 2005, a 49-On January 25, 2005, a 49-

year-old quarry operator, with year-old quarry operator, with 14 years mining experience, 14 years mining experience, was fatally injured at a was fatally injured at a cement operation. The victim cement operation. The victim was cleaning loose material was cleaning loose material and pumping water from the and pumping water from the primary crusher conveyor belt primary crusher conveyor belt basement. He contacted an basement. He contacted an unguarded return idler that unguarded return idler that was about four feet above the was about four feet above the ground and was trapped ground and was trapped between the conveyor belt between the conveyor belt and the return idler. and the return idler.

Best PracticesBest Practices

• Examine work areas to identify all Examine work areas to identify all possible hazards and take all possible hazards and take all precautions to safely perform the task precautions to safely perform the task before the work begins. before the work begins.

• Ensure that moving machine parts are Ensure that moving machine parts are guarded to protect persons. guarded to protect persons.

• Ensure that miners are prohibited from Ensure that miners are prohibited from traveling through areas or performing traveling through areas or performing work where they are exposed to moving work where they are exposed to moving machine parts that can cause injury. machine parts that can cause injury.

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Man vs. MachineMan vs. Machine

Man lost.