Industrial guarding systems are a critical component of workplace safety in manufacturing facilities, warehouses, and other industrial settings. Their purpose is to physically separate people from hazardous machinery and prevent access to dangerous areas. Effective guarding helps minimize the risk of injuries and fatalities from mechanical hazards like getting caught in moving parts or being struck by objects. The following guide provides an overview of common types of industrial guards, their design considerations, regulatory requirements, and best practices for implementation.
Example of Industrial Guarding Systems
Industrial guarding systems are physical barriers and restraints designed to shield people and equipment from various hazards. Some common locations where an industrial guarding system would be implemented include manufacturing facilities, warehouses, construction sites, and other workplaces with heavy machinery. Guards would likely be placed around conveyor belts, presses, saws, robotic arms, and other dangerous moving parts and pinch points. They prevent workers from accidentally making contact with hazardous areas. Forklifts, pallet jacks, and other motorized equipment would also have guards to protect pedestrians in busy warehouse environments, and construction sites utilize guardrails and safety netting to prevent falls from heights.
Machine safety guards are often customized for specific equipment and configured to allow safe access for operation and maintenance while restricting access to dangerous zones during normal operation. Implemented properly, industrial guarding systems greatly reduce risks of injury from a variety of mechanical, projectile, and other hazards inherent to industrial work. They are a fundamental safeguard to protect personnel, equipment, and processes.
System Categories
There are several main categories of industrial guards based on their location and function. Point of operation guards protect workers from hazards at the point where work is performed on a machine. They are located on the machine itself and enclose the dangerous moving parts, like blades or rollers. Common types include fixed barriers, interlocked guards, and presence-sensing devices.
Fixed guards provide a permanent physical barrier around the hazard using materials like expanded metal, sheet metal, or mesh. Interlocked guards physically block access to the danger zone and are connected to a power source so that the machine cannot operate without the guard in place. Presence-sensing safeguarding devices use sensors like light curtains, pressure mats, or two-hand controls to detect a worker’s presence and prevent or stop hazardous motion when triggered.
Specific Systems
Perimeter guards are placed around the perimeter of a restricted or hazardous area. They cordon off access and prevent unauthorized entry. Examples include railings, fences, chains, and other barriers. Barriers controlling access to elevated platforms and walkways would fall into this category. Perimeter guarding helps protect against hazards like falls, electric shock from live equipment, and burns from hot surfaces. Access gates with interlocks allow authorized entry but prevent operation while opened.
Guards that enclose the entire machine or danger zone are known as enclosure guards. They use complete physical barriers like sheet metal, expanded metal, wire mesh, or plastic screens to completely isolate the hazard. Common examples include fixed guards around robotic work cells, CNC machines, mills, lathes, and grinders. Enclosures help protect workers from all mechanical motion hazards, flying debris, and noise. Maintenance access panels allow entry while the power is disconnected.
Safety Features
The design of industrial guards focuses on providing maximum protection while allowing necessary access and visibility for operation and maintenance. Important factors include material strength, opening size, distance from moving parts, and ergonomic access points. Guards must be affixed securely to the machine frame or flooring and withstand expected impacts.
Smooth, rounded edges promote safety. Mesh and other materials with small openings prevent fingers from reaching moving parts, while larger openings require increased distance from the hazard. Interlocked or linked access doors ensure power disconnect when opened. Guard design should facilitate equipment cleaning, inspection, and maintenance tasks through conveniently located access panels.
Industrial Guarding Regulations and Standards
In the United States, the Occupational Safety and Health Administration (OSHA) oversees regulations and standards for industrial machine guarding. OSHA requires that guards protect operators and other workers from hazards like ingoing nip points, rotating parts, flying chips, and sparks. The guards must not introduce any new caught-in or struck-by hazards.
Employers are responsible for performing risk assessments, providing appropriate guarding, and training workers on safe procedures related to removing guards. OSHA references relevant consensus standards from organizations like the American National Standards Institute (ANSI) when evaluating guarding methods. Violations of OSHA guarding requirements often result in citations and penalties if injuries occur.
Effective Systems
Implementing effective industrial guarding requires proper installation, maintenance, and safety management. Guards should be securely mounted using fasteners that require tools for removal. Areas guarded by presence-sensing devices require precise positioning with frequently scheduled checkups. If electrical interlocks are used, the wiring must have redundancy in case of failure.
Guarding systems should undergo routine inspections and testing to check for damaged components or malfunctions, as preventive maintenance helps ensure continuing effectiveness. Safety managers should track guarding performance, conduct audits, and assess new risks. Adequate worker training is vital on guarding principles and procedures for safe removal and replacement during servicing. Proper guarding plays a critical role in protecting the most important element of any workplace, which is the people performing vital jobs.
Choosing a Guarding System Provider
When selecting an industrial guarding system provider, it is important to consider several factors. Look for a company with extensive experience installing guarding solutions in your industry, as familiarity with regulations and equipment is critical. Ask about the range of guarding products they offer to ensure they can provide suitable options for all your hazardous machinery. Request examples of past guarding projects to evaluate the quality of their work.
The provider should conduct on-site risk assessments before proposing a customized guarding system. Make sure they cannot only install the guarding but also provide maintenance and repairs down the road. Evaluate their training services to ensure your staff is properly educated on the use and care of the guards. Choose a provider that offers strong project management and customer service throughout the process. With the right partner, you can implement a comprehensive industrial guarding system to protect your employees from equipment-related hazards.
Industrial guarding systems enhance workplace safety through physical barriers and access controls around hazardous areas and equipment. Various guarding methods are tailored to different types of mechanical and operational hazards. Guarding must meet strict regulatory requirements for design, installation, and maintenance. When effectively implemented with proper safety management, industrial machine guards provide an invaluable line of defense against preventable injuries and save lives. The responsibility for providing adequate safeguarding rests with employers who must make worker protection a top priority.
