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AA RP 0154 CONVEYOR GUARDING VERSION 1


02 FEBRUARY 2012
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CONVEYOR GUARDING
1 Scope 2
2 Definitions 2
3 Risk Management 2
4 Guarding of Conveyor Belts 4
4.1 Five Human Motions 4
4.2 Physical Hazards (Danger Points) 5
4.3 Safety Barriers 6
4.4 Typical Installation Requirements 10
5 Material Specifications 25
5.1 Primary Safety Barrier 25
5.2 Secondary Safety Barrier 26
5.3 Power Drive Unit 26
6 Maintenance 26
7 Removal of Guards 27
Appendix A: Reference Documents 28
Appendix B: Record of Amendments 28




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AA RP 0154 CONVEYOR GUARDING VERSION 1
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1 SCOPE
This document serves to provide the necessary guidelines on the safeguarding of belt
conveyor equipment. It outlines the interface between general human motion and known
danger points on a belt conveyor installation.
2 DEFINITIONS
HIRA : Hazard Identification and Risk Assessment
Danger Points : This is identified as nip points and any rotating machines
or parts thereof that are a threat to the health and safety
of persons in the vicinity of belt conveyors.
Primary Safety Barrier : A guard installed to prevent human contact with a source
of danger created by a rotating pulley or idler and
eliminate the possibility of any person being drawn into
the nip point. Such guards include nip guards.
Secondary Safety Barrier : A guard, fence or barrier structure designed,
manufactured and installed of such material and strength
as to afford the necessary protection against inadvertent
human contact with a moving or rotating component of a
conveyor belt system.
Tertiary Safety Measures : Such measures cover personal protective equipment
(PPE).
Indirect Safety Measures : Such measures will include operator and personnel
training which is likely to move in the vicinity of a conveyor
belt.
3 RISK MANAGEMENT
All exposed machinery which, when in motion, may be dangerous to any person shall be
securely fenced off or effectively guarded. Efficient guards shall be provided to such parts
of any machinery as may be a source of danger to any person.
The wording may be dangerous to any person and may be a source of danger to any
person clearly implies that at places where persons may reasonably be expected to work
or move about, machinery must be guarded of fenced off. It does not matter whether a
person has or has not any right to approach such items of machinery, for should an
accident result, the plea of safety by position will not normally be accepted in a court of
law unless at least certain minimum requirements were complied with. Also implicit in the
statutory requirements, is the fact that it is not sufficient to act with hindsight but, as far as
is humanly possible hazards must be identified before danger arises. Guards or fences
must therefore be constructed to protect against unforeseen contingencies, not merely
against normally expected operational hazards.
The employer must take reasonably practicable measures to prevent persons from being
injured as a result of them, the clothes being worn by them or any equipment being held


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by them coming into contact with or being drawn into any moving part of any machine.
The measures to be taken by the employer to prevent any person from coming into
contact with any moving part of machinery or any equipment attached thereto, must
include:
a) Effective physical barriers at the machinery such as screening, guarding or fencing;
or
b) failsafe electric or electronic barriers interlocked with the machinery in such a way
that the machinery would be stopped before persons come into contact with moving
machinery or parts thereof; or
c) Effective barriers at a safe distance away from any machinery
Key Words: All Exposed; In motion; All sources of danger; Efficiently guarded, Source of
danger
Hazard is the Source of or exposure to danger
Risk is The likelihood that occupational injury or harm to a person will occur
Ergonomics is the Study of the relationship between man, the equipment with which he
works, and the physical environment in which this man-machine system operates.
Safety Objectives are:
a) Prevent any person from being injured at any belt conveyor installation
b) Guards must be adequately designed and installed
c) Do adequate maintenance on and around guards to prevent guard from being
ineffective due to its design or any external influence such as spillage, impact
damage, etc.
d) Only persons authorised by the employer may start, operate and maintain belt
conveyors.
e) Only persons permitted by the employer may be in the vicinity of any belt conveyor
installation.
f) Belt conveyors may only operate if ALL safety guards, as determined by legislation
and Risk Assessment for the particular conveyor, is installed correctly and
effectively maintained for safety.
g) Persons may not wear loose clothing, or anything else that can be caught in the
event that the moving parts of a conveyor are exposed.
h) All stored mechanical, electrical, hydraulic, chemical or other forms of energy will be
removed from the conveyor installation before any safe guard is removed.
i) Barriers must be installed and so positioned at a safe distance away from moving
machinery or their parts.
The following serves to establish the requirements of effective guarding:
a) IDENTIFY all the danger points with regards to the belt conveyor installation.


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b) DESIGN - Determine the extent to which the danger point is to be safe guarded.
c) CONSTRUCT the guard to the required dimension using the correct material to
ensure and maintain safe guarding.
d) ISOLATE the belt conveyor installation following the correct lockout procedure and
INSTALL the constructed guards.
e) MAINTAIN the safe guards according to correct installation, deterioration of guards.
f) REPLACE guards when they become ineffective in its function as a safety barrier.
ISOLATION & LOCKOUT When any repairs, maintenance, routine cleaning and
cleaning of spillage is done on or in the vicinity of conveyor belt installation the power
supply of a conveyor belt installation shall be removed and when the belt conveyor has
become stationary this stationary conveyor belt installation shall be locked out.
4 GUARDING OF CONVEYOR BELTS
4.1 Five Human Motions
Mechanical danger points around the conveyor are identified by a risk assessment
process. Each of these danger points must be addresses in terms of the extent to which
the danger point is to be guarded and followed by the specified materials used to safe
guard such danger point. The extent to which such danger points are safe guarded is
dependent on the five physical motions of a human being when in the vicinity of operating
machines.
For a guard or a fence to be effective it must be so constructed that a person is prevented
from reaching the danger point. A person may normally be regarded as capable of
reaching upward, over, into, around or through a guard or fence and all five these aspects
must be taken into account when considering the effectiveness of a guard or fence:
a) Reaching Upwards - Any rotating or moving equipment or machinery, including
pulleys and idlers which are installed and operated at a height above 3,5 m from the
ground or a working platform where persons might be positioned will be regarded as
positionally safe and need not to be guarded. The possible reduction of this
minimum safe clearance, due to a build-up of spillage or discharge of material, must
be taken into account in the design of the guards. Risk Assessments must be
routinely conducted within the workplace to identify such areas of change.
b) Reaching Over Head and tail pulleys must be guarded on at least the two sides
and the top unless the guards or fences on the sides are carried to such a height
that it is impossible to reach over it into the nip point. If the side guards only are
provided with a very small clearance between the edge of the carry belt and the side
guard, this may perhaps be regarded as adequate to prevent reaching over the
guard and touching the nip point but this will not necessarily prevent tools or clothing
from being caught in the nip point. If the head end is provided with a top guard it
must be high enough above the belt to ensure that the moving load will not impact
and damaged the guard. Tail pulleys in addition to the sides must be guarded
across the rear end from the end of the one side-guard to the end of the other side-
guard. Such guard must not be installed closer than 150 mm from the tail pulley
circumference.
c) Reaching Into The distance that the guard or fence is away from the side of the
belt will really determine the distance the guard or fence must be extended away


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from the nip point along the length of the belt. The distance from the guard to the
edge of the belt must be a minimum of 150 mm while the side guard extends at least
850 mm away from the position of the nip guard along the belt line.
d) Reaching Around This really has the same meaning as into as far as the
conveyor pulley guard is concerned but may also be applied to determine the length
of the top section of the guard. The same minimum distance of 850mm must apply.
If there is a V-belt or chain drive associated with the conveyor installation a very
common defect is often found where the V-belts or chains are perfectly guarded
around the perimeter and on one side, but the guard is so installed that the nip
points can easily be contacted by reaching around the section forming the perimeter
guard.
e) Reaching Through - The protection afforded against injury by reaching through
the guard will be determined by the shape and size of openings in the material used
for construction of the guard or fence and is governed by this document.
4.2 Physical Hazards (Danger Points)
The following exposed hazards require ONLY a Secondary Safety Barrier
a) Electric motor shaft
b) Gearbox in- and output shaft
c) Gearbox external fan
d) High speed coupling and associated in-and output shafts (such as Fluid Couplings
or Semi-flexible Coupling)
e) Pulley shafts extending past the outside of both plummer blocks to which persons
could be exposed to (could be idle or driving shafts)
f) Take-up carriage area
g) Take-up counterweight tower
h) Take-up rope, sheaves and winches
i) Belt turnover(s)
The following exposed hazards require ONLY a Primary Safety Barrier
a) Return Idler nip points When the belt is moving onto the face of the return idler
rolls and when access underneath the conveyor is possible, exposing such nip
points.
b) Where idlers are specifically designed and installed to restrict the upward movement
of a conveyor belt during a start-up or run-down procedure
c) When the belt tension is such that the additional normal force and belt weight
pressing down on idlers in a convex curve posses a significant risk to safety of
persons.
d) In areas where idler sets or impact cradles are installed below a bunker, feeder-bin,
silo hopper or transfer chute to support a belt, eliminate spillage and improve the
loading profile onto the belt and also applies, even more so, to belt on which hand


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sorting is performed.
The following exposed hazards require a Primary AND Secondary Safety Barrier
a) Pulley nip points Where belt moves onto the pulley face
The following point DO NOT require a Primary or Secondary Safety Barrier
a) Carry Idler nip point Where the belt is moving onto the carry wing idler roll surface.
4.3 Safety Barriers
4.3.1 Primary Safety Barriers
Definition
A nip point is created when a belt moves onto a rotating pulley or return idler and require a
primary safety barrier and is positioned with respect to the rotation of a pulley or return
idler. This guard extends over the whole width of the pulley or idler and may be regarded
as a reasonable solution to prevent access to danger points. A person is not completely
prevented from reaching around it and therefore cannot, by itself, be regarded as
sufficient protection and it is therefore essential that guarded pulley nip points be further
guarded or fenced off with a secondary safety barrier.
The nip point created by a carry idler cannot in all circumstances be regarded as a threat
to life or limb. The mass of the belt, load and convex curve normal force will affect the
decision on whether or not carry idlers required guarding. This will be installation specific
and each engineer must determine the necessity of such guards.
Positioning
At the point where a moving belt moves onto the pulley face of a rotating pulley or where
access underneath a conveyor is possible and the nip point, created by the belt moving
onto a return idler(s), is exposed/reachable:
a) Belt onto Pulley - The entry point of the belt onto the pulley is known as a dangerous
nip point. Any object making contact with any nip point while the belt is in motion will
result in the object being drawn into the nip point. An effective means to safe guard
this nip point is to install a primary AND secondary safety barrier.

Head
Pulley
Tail
Pulley


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Figure 1
b) Belt onto Idlers - The entry point of the belt onto the return idler is known as a
dangerous nip point. A dangerous condition exists when access underneath (h) the
run of conveyor is possible and such nip point is less than 3, 5m and more than 1m
above the walking platform or ground where persons may be positioned or moving.
Any object making contact with this nip point while the belt is in motion will result in
the object being drawn into the nip point. An effective means to safe guard this nip
point is to install a primary OR secondary safety barrier. This will include a nip point
guard, fully or semi-enclosed guard or barricading the dangerous portion on both
sides of the conveyor to prevent access underneath the conveyor. Barricading
include cross bracing two or three 8 gauge galvanized steel wire rope with No-
Entry signs on such bracing.

Figure 2
The positioning of pulley nip guards is illustrated in Figure 3. The belt running away
from the pulley surface is not shown in the figure. The figure therefore shows
different variations of angles at which the belt runs onto the pulley surface for all
angles around the pulley and how the nip guard should be positioned. The tail pulley
nip guard shown in green is the exception to the general orientation as indicated in
blue.
Figure 3 is as illustration of pulleys rotating in the counter clockwise rotation, but
equivalent requirements will apply for clockwise rotation.
1m < h < 3,5m
Ground / Working platform


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Figure 3 Position of Nip guard when belt run onto pulley surface
General
On its own a nip guard is not regarded as sufficient or effective protection and it is a
requirement that all pulleys must be further guarded, barricaded or fenced off with a
secondary safety barrier.
4.3.2 Secondary Safety barriers
Definition
Such barriers consist of a guard or fence and is designed, manufactured and installed of
such material and strength as to provide the necessary protection against inadvertent
human contact with moving or rotating components of a conveyor system.
Positioning
Figure 4 illustrates the specific areas along a conveyor system which is most likely to be
90
270
0 180
Third Quadrant (180 - 270) Forth Quadrant (270 - 360)
45
225
180
270
90
0
Second Quadrant (90 - 180) First Quadrant (0 - 90)
PULLEY
Tail pulley nip
guard


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equipped with secondary safety barriers. The following locations typically require
secondary safety barriers depending on the conveyor design layout:
a) A Head/Discharge End comprising of a driving or idling pulley(s)
b) Drive area which is located either at the Head End, Intermediately or Tail End
c) Return belt Take-up system situated behind the intermediate or head drive
d) The Loading Point where material is loaded onto the belt
e) Run of Conveyor consists of a conveyor stringer (structure) with the carry and
return idler brackets and normal run of belt and are typically situated between:
1. The Head and Intermediate Drive, And / Or
2. The Head Drive and following Take-up, And / Or
3. The following Take-up and the last Loading Point
4. Between Loading Points
5. First Loading Point and Tail End
f) A Tail End comprising of a driving or idling pulley
For clear understanding and purpose, this specification will address each of these
locations in the following paragraphs in an attempt to understand the requirements of
primary and secondary safety barriers.

Figure 4 Secondary Barriers
4.3.3 Tertiary Safety measures
Such safety measures are defined as personal protective equipment(PPE) and each
person will at all times wear the appropriate PPE applicable to the conveyor installations
and other machines which the person will be exposed to. Persons in close proximity of
moving parts of machinery must not wear clothing or anything else that may be caught in
such moving parts.
Head End
And/Or
Head- Drive
location
Intermediate
Drive
location
Following
Take-up
location
Loading
point (s)
Tail End
And/Or
Tail-Take-up
location
And/Or
Tail-Drive
Run of
Conveyor
4.2.1 / 4.2.2
4.2.2 4.2.3
4.2.4
4.2.5
4.2.6 / 4.2.3


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4.3.4 Indirect Safety measures
Such safety measures include the necessary personnel training and management
required to safely manage, operate and maintain belt conveyor installations. The following
measures must be adhered to:
a) Only authorised persons may start, operate and maintain belt conveyors
b) When moving parts of a conveyor belt installation or other such conveyor
equipments poses a significant risk to any person, such movement will only be done
under the direct supervision of a competent person.
c) Only persons authorised to do so may enter the area where belt conveyor operate.
d) Persons in close proximity of moving parts of machinery must not wear clothing or
anything else that may be caught in such moving parts.
A properly guarded belt conveyor installation is not, in itself, inherently safe but with
adequate training and proper awareness of dangers, an operator may use it with perfect
safety.
Operator training is usually the personal responsibility of the person in charge of the
proper operation and running of the machinery. He must guard against the fact that over
familiarity with the machines on his part and an over estimation of operator skills and
knowledge does not result in and under estimation of the amount of instruction and
degree of supervision necessary for the safe execution of tasks. Comprehensive training
schemes to ensure that operators are made familiar with the equipment with which they
will be associated, (which includes re-training) are essential.
4.4 Typical Installation Requirements
4.4.1 Head End
The head end of a conveyor installation typically consists of a head pulley and in some
cases a snub pulley. The head pulley can either be driven or idling depending on
operational and design requirements.
In cases where the design of the head end is such that persons can move underneath the
head end, it is required that all pulleys, belting, material trajectory and material flow be
effectively guarded to prevent inadvertent contact with such moving equipment or material
flow and the construction of such guards will be such as to minimise or prevent the build-
up of fugitive material on such guards. Due to the general elevation of the head end, it is,
in most installations, not possible to access the pulleys and belting from beneath the head
end as the chute and supporting structure generally covers this area. No gaps and
opening may exist that would allow a finger or any part of limb of any person to reach any
danger points associated with the head end.
For the purpose of inspection and maintenance, a walkway platform is typically
constructed to move around the head end. Guarding around the head end must therefore
adhere to the following general requirements as referred to figure 5.
a) Dimension A1 The guard covering the sides of head and snub pulley shall extend
upward above the head pulley circumference enough so that no person standing on
the working platform next to the head end is able to reach over the guard and touch
the nip point of the head pulley. If the top of the head end is guarded, the height of


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the side guards can be reduced such that this top guard will not be closer than 900
mm from the head pulley circumference.
b) Dimension B1 The guard in front of the head pulley must be situated such that the
material trajectory will not impact directly onto the guard cover, unless the guard
structure has been designed with impact plates in order to ensure that safety guards
are not damaged by the impact from the trajectory.
c) Dimension C1 The guard covering the sides of head and snub pulley shall extend
downward up to the walking platform level in such a manner that it would be
impossible to reach the nip point of any pulley in the vicinity of the head end.
d) Dimension D1 - The guard covering the sides of head end shall extend a minimum
of 850 mm along the belt line (Figure 5):
1. As measured from the circumference of the head pulley if the head end only
consist of on head pulley.
2. As measured from the circumference of the snub pulley if the head end is
equipped with such a snub pulley out-bye of the head pulley.
e) Dimension E1 - The guards covering the sides of the head and snub pulleys shall
not be closer than 50 mm from the edge of the pulley shell.
f) Dimension F1 - The shaft of the head pulley and any other shaft extending through
the main guard side panels shall be guarded such that the gap between the rotating
shaft and the side guard panels are inaccessible to any persons standing or moving
on the working platform. Where the primary and secondary belt cleaning scraper
frame-shaft extends through these side guard panels, the gap between the scraper
frame-shaft and the guard panels is inaccessible to any persons standing or moving
on the working platform.


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Figure 5 Guarding at the Head End
4.4.2 Drive
The drive can be located either at the head end, intermediately at a point along the length
of the conveyor, at the tail or a combination of these locations. The location(s) of the drive
largely depends on the conveyor design and geometry.
The drive typically consists of the drive pulley(s) and associated snub pulleys to achieve
the necessary drive pulley wrap angle(s).
The electric motor output shaft is mechanically connected to the gear reduction unit with a
high speed coupling and in a lot of cases this high speed coupling unit serves as a start-
up control device, better known as hydraulic (fluid) couplings. The output shaft of the gear
reduction unit is then connected to the drive pulley shaft with a low speed coupling.
Primary safety barriers are required for the drive and snub pulleys whereas secondary
safety barriers are required to cover all pulleys, the low and high speed couplings, all
WORKING PLATFORM
C1
B1 D1
A1
D1
B1
E1
F1
SIDE VIEW
PLAN VIEW
Primary Safety Barriers
(Nip guards)
Pulleys
Conveyor Belt
Chute
Structure


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exposed shafts and cooling fans of both the electric motor and gear reducer.
The guarding of drive bend pulleys in the vicinity of walkways will be covered in the
section dealing with similar take-up bend pulleys.
Driving belts, chains and couplings between driving motors and gearboxes or drive pulleys
must be effectively guarded. Experience has shown that even when transmissions are
apparently inaccessible they can still be a hazard. If the driving mechanism or any other
part is fenced off completely in such a way that access thereto can only be obtained
through a gate or door forming part of the fencing, then this gate or door should be
interlocked so that the conveyor is stopped when this gate or door is opened.
Head Drives
The head chute structure is generally considered as the secondary safety barrier guarding
the pulleys and primary safety barriers (nip guards) will be installed accordingly. The drive
unit(s) (motor, couplings & gear unit) will be either base plate mounted or shaft-hung
mounted with a torque arm connected to the supporting structure and such units are
located on the outside of the head chute structure in the walkway area and safe guarding
of these drive units are therefore imperative. Figure 6 is a plan view of drive units in the
head area and where guarding is required.
For installations where access is required around the power drive unit(s) of a head pulley,
it is necessary to ensure:
a) The electric motor cooling fan is effective guarded to prevent contact with the blades
or shaft of the fan.
b) The high speed coupling located between the electric motor and reducer is
effectively guarded. This guard shall not consist of any holes or openings and shall
be constructed of plate metal. No inspection doors or openings shall be allowed as
part of the design of the guard.
c) The cooling fan on the gear reduction unit is effectively guarded to prevent contact
with the blades or shaft of the fan.
d) The low speed coupling located between the reducer and head pulley shall be
effectively guarded to prevent contact with any part of the coupling.
e) All shafts forming part of the drive unit and pulley system shall be effectively
guarded as to prevent any contact with any part of such shafts. A guard shall be
installed to cover the gap between the pulley shaft and the chute when the minimum
gap between the plummerblock and the bearing exceeds 100 mm.
f) If the head or any other pulley is equipped with an external low speed holdback
(back stop) this unit will be guarded in such a manner that is would be impossible to
contact any part of the unit including its torque arm.
g) In the event of a V-belt or chain drive associated with the conveyor installation, such
drives must be guarded on its perimeter and both sides that will prevent persons
from reaching around the perimeter guard and contacting the danger nip points on
such a drive.
h) All of these above mentioned guards will be secure to the component or supporting
base plate. The guard of any fluid coupling will be bolted on all four corners to
maintain safety in the event that a fusible plug is blown.


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Figure 6 Guarding of pulleys and power drive unit
Intermediate Drives
In some installations where the entire OR secondary drives and pulleys are situated at a
point along the run of conveyor, specific guarding requirements apply. There are two
methods of effective guarding of such drive areas:
a) Independent Guarding
This guarding method comprises of one guard frame to safeguard all drive pulleys
and associated snub pulleys independent from the power drive unit. In this case the
drive pulley shaft will extend through the guarding toward the power drive units
situated outside the guarded drive pulley system.
In this case, power drive units will be guarded in the same manner as explained
above.
It will be required to install primary safety barriers (nip guards) on each pulley
whether they are accessible or inaccessible to human contact and such nip guards
will be positioned in accordance with figure 3.
When any person, standing or moving on ground level or on any elevated working
platform, are required to move next to such pulleys, the following requirements apply
with regards to secondary safety barriers in order to safe guard persons from such
pulleys (refer to figure 7):
Motor Gear Unit
Couplings
Walkway
Platform
Legend: Guarding Required
Conveyor Belt
Bearing
Bearing
Chute
Structure
Pulleys
Cooling Fans
>100 mm


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1. Dimension A2 - The height of the side guard panels shall be such that no
portion of any pulley or belting can be touch when standing on the ground
level or working platforms. These side guard panels will be constructed from
ground or working platform level in order to prevent any person reaching
underneath the guard and touching any part any pulley or belting. The height
of these guards will be restricted to a minimum height of 2, 5 m, unless these
guards have reached the bottom of the conveyor stringer. In such cases the
side of the return stand will also be guarded up to the carry deck and a deck
plate will be constructed between the carry and return strand long enough to
extend at least 850 mm past the nip point of any reachable pulley in both
directions of belt line.
2. Dimension B2 In most cases, this rear guard panel is not installed due to the
integration of the drive guarding with the take-up system guards. In the event
that this drive pulley system is guarded independently from the take-up
system, it is recommended to install this guard not closer than 150 mm as
measured from the closest pulleys circumference to this guard. The height of
this rear guard will be restricted to a minimum height of 2, 5 m unless the
guard has reached the bottom of a stringer.
3. Dimension C2 This front guard shall not be closer than 150mm to any of the
pulleys circumference. The height of this guard will be restricted to a minimum
height of 2, 5m unless the guard has reached the bottom of a stringer but will
be have sufficient as to prevent any person contacting any part of the pulley or
belt while standing on the ground level or working platform.
4. Dimension D2 Guards in this area are generally constructed on the outside
of support structural members, but these side guard panels must not be closer
than 150 mm as measured from the edge of the pulley shell.


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Figure 7
5. If any pulley shaft extends through the guards, such portion of the shaft will be
effectively guarded so that it would be impossible for any person to contact
any part of that shaft.
6. In the event of a V-belt or chain drive associated with the conveyor installation,
such drives must be guarded on its perimeter and both sides that will prevent
persons from reaching around the perimeter guard and contacting the danger
nip points on such a drive.
b) Fully Enclosed Guarding
Fully enclosed guarding involves fencing off the entire drive area. All associated
drive pulleys, power drive units and in some cases take-up systems are fenced off
and access to the area can only be made through a door(s) or gate(s) and such
doors and gates must each be interlocked such that power is removed from the
power drive units once the door or gate of the fencing is opened. The opening of
such gates or doors will be such that they hinge on the sides and swing outwardly.
Secondary
Drive
Primary Drive
Ground level or working platform
A2
B2
C2
SIDE VIEW
D2
B2 C2
Conveyor Belt
Pulleys
Front
Guard
panel
Rear
Guard
panel
Example of drive pulley layout


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It will be required to install primary safety barriers (nip guards) on each pulley
whether they are accessible or inaccessible to human contact and such nip guards
will be positioned in accordance with figure 3.
When any person, standing or moving on ground level, the following requirements
will apply to fenced-off guarding which forms part of secondary safety barriers:
1. The height of the fence shall be such that no portion of any pulley, belt, drive
unit or take-up moving parts can be touch when standing on such ground level
outside the fenced-off area. These side guard panels will be constructed from
ground level in order to prevent any person reaching underneath or over the
guard. The height of these guards will be restricted to a minimum height of 2,
5m.
2. This guard shall not be closer than 150mm to any of the pulleys circumference
and any part of the power drive unit(s) or take-up system.
3. The gate(s) or door(s) constructed to access such areas shall hinge on the
sides of the panel and shall swing away from the fenced off area.
4. The guards covering the fan of both the motor and gear box will be present
and secure. In the event that a fluid coupling is used as the start-up control
device, the entire fluid coupling will be guarded as explained previously.
Tail Drives
In the event that the tail end consists of a power drive unit, the same independent
guarding requirements will apply with regards to the power drive unit and pulleys. Primary
and secondary safety barriers will comply as stipulated in the section covering guarding of
the Tail End of conveyor installations. The nip point of associated snub pulley will also be
equipped with a nip guard.
4.4.3 Take-up Area
The take-up system design of a belt conveyor largely depends on what the belt conveyor
require for successful operation under starting, running and stopping conditions. For this
reason, the following list of typical take-up design layout exists:
a) Vertical Gravity Consist of a pulley-counterweight system moving vertically in a
tower.
b) Horizontal Gravity Consists of a pulley- carriage system moving horizontally on
rails and a counterweight moving vertically in a tower.
c) Horizontal Automatic/Manual Winch Consist of a pulley-carriage system moving
horizontally on rails and an automatic or manual winch system also acting in the
horizontal plane.
d) Horizontal Screws Consists of a pulley plummer block arrangement which is
manually locked in position with screws acting on the plummer blocks in the
horizontal plane.
Due to the variety of take-up designs as mentioned, the specification will deal with
guarding of counterweight towers, take-up carriages, screws, associated bend pulleys as
well ancillary take-up equipments such as rope, sheaves and winches.


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a) Counterweight towers
The counterweight tower can facilitate the operation of a counterweight box or a
combination of a counterweight box with a pulley.
It will be required to install primary safety barriers (nip guards) on all pulleys whether
they are accessible or inaccessible to human contact and such nip guards will be
positioned in accordance with figure 3.
For counterweight boxes operating less than 5m from ground level, it will be
required to install guarding around the tower starting from ground level to a
minimum height of 3m or until it is impossible to reach over the guard and touch the
counterweight. For counterweight boxes operating higher than 5m from ground
level, it will be required to install guarding around the tower starting from ground
level to a minimum height of 2,5m or until it is impossible to reach over the guard
and touch the counterweight.
The guard shall not be closer than 250mm as measured from the counterweight
box, pulley, guide rolls or belt. If such guards consist of gates, such gates will be
kept locked and interlock switch will be installed that will remove power from the
conveyor installation once the gate is opened. The area inside and outside the
counterweight tower shall be kept clean to avoid damage to guards as a result of
build-up material.
For installations where elevated walkways provided movement next to such
counterweight towers it will be required to install guarding on that portion of the
counterweight tower to a minimum height of 3m as measured from the elevated
walkway level or until it is impossible to reach over the guard and touch the
counterweight and shall proceed around the tower to such extend as to prevent
contact with any part of the counterweight box, pulley, guide rolls or belt inside the
tower. If elevated platform levels exist around such a counterweight tower it will be
required to install such guards all around the tower to a minimum height of 3m or
until it is impossible to reach over the guard and touch the counterweight.
b) Take-up Carriages
Take-up carriages consist of a moving trolley unit which supports the take-up pulley
and this unit will move on rails in a horizontal or inclined angle depending on the
conveyor layout design.
In the case where the top of the carriage remain unguarded, it is recommended that
the guards surrounding the carriage extend from ground or working platform level to
a minimum height of 2, 5m or until it is impossible to reach over the guard and touch
any moving part of the carriage system. If the top of the carriage is guarded it is
recommended that the guard be at least 500mm above the circumference of the
pulley and these guards shall be kept clean from material build-up. The side guards
of the carriage will not be closer than 150mm as measured from the carriage
wheels. The guard at tail portion of the carriage system (upper limit of carriage
movement) shall not be closer than 3 times sheave outer diameter or 1m to this
upper limit, whichever is greatest and the height of this guard will be similar to the
height of the side guards.
The gap where steel ropes move through the guard will be covered such that no


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contact with this gap is possible while the conveyors power drive unit(s) is
energised.
c) Manual Screws
If the take-up tension is maintained through the application of a manual screw, it will
be required that the screw and take-up pulley be fully enclosed. If the top of the
take-up pulley remains unguarded the guards will extend around the pulley to a
maximum height of 2, 5m. If the top of the pulley is guarded, this top guard shall not
be closer than 500mm above the pulley circumference and these guards shall be
kept clean from material build-up. The side guards will not be closer than 150mm
from the screw. The guard at the back of the pulley shall not be closer than 150mm
to the pulley circumference.
d) Take-up and Drive Bend pulleys
It will be required to install primary safety barriers (nip guards) on all pulleys whether
they are accessible or inaccessible to human contact and such nip guards will be
positioned in accordance with figure 3.
On installations where walkways or platforms are constructed next to incline
elevated conveyors, it is often found that drive or take-up snub pulley are in a
reachable distance from such walkways or platforms. Guards must be constructed
such as to extend at least 850mm before and after such snub pulleys in the direction
of belt line. Guards must not be closer than 150mm from the pulley shaft edge and if
for some reason it is required that a pulley shaft extend through the guard it must be
guarded such that contact with such shaft is impossible. The extension of such
pulley shaft through guarding will not cause any tripping hazard for persons walking
on such elevated walkways.
For the portion where walkways are situated next to these snub pulleys it is required
to install deck plates beneath the carry and return belt strand to prevent persons
standing on the walkway to reach over guards an contact pulley danger points.
e) Ancillary Take-up Equipment
Such equipment includes winches, ropes and sheaves. Danger points associated
with such installed equipment is:
1. Nip point between rope and sheaves
2. Nip point between rope and winch
3. Nip point between rope and surrounding structure, guards or brackets.
For the purpose of simplicity it can be stated that such equipment and associated
danger points shall be guarded such that it will be impossible to contact any such
equipment or danger points unless energy has been removed from the power drive
unit of that conveyor installation. The guards will be so constructed such that it will
not contact the rope or sheave during operation.
If mesh guarding is to be used, such guarding will be at least 150mm away from
such equipment to prevent finger contact with danger points. Caution should be


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taken as material build-up inside such guards will render the take-up system
ineffective and compromise safety of the installation.
4.4.4 Run of Conveyor
The run of conveyor can be defined as the normal conveyor comprising of the carry- and
return belt, idlers and structure and does not include the head, drive, take-up, loading or
tail section.
The danger points associated with regards to the run of conveyor becomes evident when
persons are required to cross over or underneath the belt conveyor structure, when the
belt is pressing down on rolls in a convex curve or when pressing rolls are used to prevent
belt liftout in specific areas.
Trip Wire & Switches
When faults, accidents or blockages occur, it is normally necessary to bring the conveyor
to an immediate halt. A continuous trip-wire stretching over the whole length of the
conveyor, to actuate the stop switch of the conveyor, is an effective and essential safety
device. With such a facility available the operator will be less tempted to try and rectify
faults with the conveyor turning. It must however stretch the full length of the conveyor. If
the belt conveyor is so installed that persons can walk along the conveyor on either side
of it then a trip-wire must be installed on both sides of the conveyor. It is also
recommended that a lockout facility be provided on this trip wire arrangement.
Carry Belt Convex Curves
When the profile of the belt shapes in a convex curve, the tension in the belt will further
increase the force exerted on a carry idler roll in the convex curve and when excessive,
can cause severe harm to a human hand when caught in the nip point between the belt
and carry idler. When it is known the curve could/will experience high belt tensions and
material loads resulting in the nip points causing harm, it will be required to guard such
idlers for the length necessary to safeguard persons in that vicinity of the conveyor
installation.
Carry Belt Pressing Rolls
Although it was stated that it is essential that head tail and snub pulleys of belt conveyor
installations, which are within reach, should be guarded, accidents have happened on
carrying idlers with serious consequences, particularly where the distance the belt can lift
off the idlers is restricted. The danger at idlers is even more evident when fixed hoppers
or skirt plates under which the hand can be trapped, are fitted directly above the idlers. If
this is the case the danger points must be very carefully guarded or completely enclosed.
This also applies, even more so, to belts on which hand-sorting is performed.
Some conveyor installations incline upward and the conveyor structure will form a
concave curve. Under some operating tensions the conveyor belt could lift-out of the
curve. When such lift-out occurs in the vicinity of the loading points or fixed hoppers or
where some other structural member or equipment is situated above the belt, it becomes
necessary to press the belt down in order to prevent such lift-out. This is done by installing
pressing rolls on the sides of the conveyor belt. These rolls then present dangerous nip-
points and will cause severe harm to limbs. In such cases it is recommended to install


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guards along the portion of the conveyor equipped with such pressing rolls and such
guards must extend at least 850 mm outside the first and last pressing rolls. The guards
must be such that it will be impossible to reach over such guards and make contact with
such nip points under any belt running condition, whether starting, running or stopping.
Elevated walkways
In cases where walkways are fitted on elevated conveyors, adequate hand and knee rails
must be installed on the outside of such walkways. Kick/toe boards shall be provided on
the hand rail and conveyor stringer side to keep movement of feet restricted to the
walkway platform. Walkways must have and even, non-slip surface, be properly drained
and free from obstructions.
Inclined shafts
Another condition exists on the walkways next to inclined shaft conveyors. Spillage on
walkways can cause persons to slip or loose footing and to prevent such person grabbing
hold of the conveyor structure or other dangerous equipment, it is imperative that some
form of handrail be constructed to aid persons walking on such walkways.
Cross-Over Bridges
It is often necessary for an attendant to cross a conveyor at various points. It is
dangerous to climb over any belt. Where it is impossible to establish safe passageways
underneath the belt, cross over bridges with handrails, must be provided. The position of
these bridges will depend on conditions at the belt conveyor installations but, unless a
sufficient number are installed they will not always be used. Access to the cross over
bridge must be provided by means of stairs equipped with handrails. Vertical ladders
should be avoided. The cross over bridge should also be equipped with a toe-board and
an intermediate or knee rail.
Such structures must be adequately designed and constructed of steel members and
include suitably inclined access stairs of non-slip platforms made from steel grid plate and
fitted with handrails on both sides to a minimum height of 1,2m.
The handrails and stanchions must be bolted to the support steel members. Kick/toe
boards and and intermediate or knee rail must be fitted on both sides of the walking
platform. The number and position of such bridges must be determined by a Risk
Assessment and based on the maintenance and inspection requirements for such belt.
Vertical ladders must be avoided. The cross over bridge must elevate to a minimum
height of 1, 4m above the ground or working platform level on which the conveyor is
supported, before extending across the conveyor.
Crossing Underneath Belts
On belt conveyors, the return belt and idlers may also present a hazard especially at
specific places where persons regularly pass through or works underneath the belt. At
such places it is recommended that the underside should be guarded.
In areas where persons or mobile machinery are permitted to cross underneath conveyor
belt installations, the following must be complied with:


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a) All passageways and roadways shall be conspicuously sign-posted to indicate their
purpose i.e. men and/or machinery.
b) Height restrictions through such passageways and roadways must be prominently
displayed on both sides.
c) If the return idler or any pulley is less than 3,5 m from the ground or working
platform level, such return idlers or pulleys must be guarded such to provide safe
passage to any person or machine operator whilst crossing below such conveyor
belt. The passageway must extend to a minimum of 1 m beyond both sides of the
conveyor structure. Crossing at other places which are not properly guarded must
prevented with No-Entry signs on a barricade, even if only two or three strands of 8
gauge galvanized wire is used along the outside of the supporting framework to
achieve this purpose. For the purpose of complete safeguarding, it is recommended
to construct a canopy over the road/walkway below the return belt to protect persons
and vehicles whenever belt sags, snaps or for cases of spillage which falls from the
belt onto the road.
Under no circumstances will the crossing under or over conveyor belts be
permitted at any point along its length unless via the approved passageway
referred to above.
Belt Turnovers
On some conveyor installations it is required to turn-over the return belt in order to run
the non-carry side of the belt in contact with return idler sets in order to reduce spillage
and material build-up known as carry-back.
Mangle rolls are typically double flat idler rolls which gradually changes the twisting angle
of the belt in order to turn the belt over 180. These turnover sections must be fully
enclosed and effectively guarded to prevent any contact with any of these mangle roll
sets. Side guard panels must extend to a minimum height of at least 2, 5m and must not
be closer than 150mm from the rolls end disk.
4.4.5 Loading Point
At the loading point material is fed onto the conveyor by means of a transfer chute.
Danger point associated with the loading point is:
a) Point(s) of impact in the transfer chute
b) Point of impact on the moving conveyor belt
c) Material settling zone
d) Nip point between conveyor belt and chute structure
e) Maintenance and inspection doors on the transfer chute
To safeguard persons in the vicinity of the loading point it is required that the flow of
material be guarded with a transfer chute in a manner that no person can contact the
flowing stream of material in the chute while standing next to the conveyor installation,
whether on ground level or other designated walkways or platforms. The construction of
the chute will also prevent the escape of material from the chute and any rapid
deterioration of the chute due to material flow will be re-engineered to prevent such rapid
deterioration.


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The loading portion of the chute shall act as the safe guarded to prevent persons from
reaching the material impact zone on the belt and the chute shall extend in the direction of
belt travel for the distance required for material to settle in order to prevent unsettled
lumps from falling off the belt due to loading conditions.
The chute nip point is the gap that exists between the rear end of the chute and the carry
belt surface. This gap shall be minimized to not more than 50mm.
The design of the conveyor shall prevent belt lift-out in the loading area.
Maintenance and inspection doors shall be positioned outside the normal trajectory of
material flow and such doors shall be kept closed and secured under belt starting, running
and stopping conditions.
4.4.6 Tail End
Non-Driven
The tail end will always be situated behind the loading point and will redirect the belt run
from the return run direction to the carry run direction.
For any tail end constituting only of an idling pulley, the following danger points exist:
a) Nip point between the return belt and the tail pulley.
b) Rotating shafts
It will be required to install primary safety barriers (nip guards) on each pulley whether
they are accessible or inaccessible to human contact and such nip guards will be
positioned in accordance with figure 3.


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Figure 8
A secondary guard will be constructed around the rear end of the pulley starting at least
850mm (B3) in front of the tail pulley or snub pulley nip guard, whichever is closes to the
loading point, and will cover all around the rear end of the pulley to the other side of the
pulley to a distance of 850mm (B3) in front of the tail pulley or snub pulley nip guard.
These guards shall extend vertically ground or working platform level to a minimum height
where the guard covering the pulley will be at least 400mm (A3) above the circumference
of the pulley, whichever is closes to the loading point. The vertical guard on the rear end
of the pulley shall not be closer than 150mm (D3) from the circumference of the pulley.
The side guards will be constructed not closer than 150mm (E3) from the edge of the
pulley shell. This is illustrated in Figure 8.
If shaft extend through any of the above mentioned guards, such shaft shall be guarded in
such a manner that will prevent any contact with any part of such rotating shaft.
In the event that the tail end is integrated with the take-up system, the associated pulleys
and take-up equipment shall be guarded in accordance with the take-up guarding
requirements as stipulated in section 4.4.3.
Driven
Tail ends which are equipped with power drive units will be guarded in accordance to the
requirements as stipulated in section 4.4.2 in the paragraph covering tail drives.
C3
B3
D3
A3
B3
E3
SIDE VIEW
PLAN VIEW
Primary Safety Barriers
(Nip guards)
Conveyor Belt
Secondary Safety
Barrier
D3


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4.4.7 Belt Cleaning Devices
Lateral movement of the belt is usually caused by a build-up of material at the head and
tail pulleys, the carrying idlers or snub pulleys. The manual removal of build-up is slow,
complicated and often dangerous. In order to keep the pulleys and rollers clean, suitable
mechanical devices must be installed. The manual removal of build-up should not be
permitted whilst the belt conveyor is in motion.
5 MATERIAL SPECIFICATIONS
Primary and secondary safety barriers will comply with the following material
specifications:
a) Manufactured from a non-corrosive material or galvanized steel to prevent a
corrosive environment from rendering the guard ineffective due to excessive
material loss during operation.
b) The completed guard must be manufactured from a material of adequate strength
and design to safely support the mass of an 85kg person distributed over an area of
2m.
c) A guard must not weigh in excess of 30kg to ensure that one person will capable of
removing or installing such a guard. If guard weigh in excess of 30kg, they must be
a permanent feature to the structure with hinges on the side that will allow the
opening of such guard by swinging it outwardly.
d) Colour-coded such guards with ORANGE paint to create an awareness that if such
guard is not in its correct position it will be conspicuous by its absence and alert
persons that it has been inadvertently removed.
e) Guards shall be securely fixed in position with fasteners or other suitable devices,
and which ensures that the guard cannot be altered or detached without the aid of a
tool or key.
f) Guards must be installed such that adjustments will not allow a loss of protection or
the modification of guards.
g) Guards must be such that they do not need to be removed for inspection.
h) The design, material and construction of guards must be such that they present no
burrs, sharp edges or pinch points that may be a hazard to safety.
5.1 Primary Safety Barrier
The minimum material dimensions for all nip guards must be 120mm x 120mm x 10mm
galvanized angle members.
With regards to the tail pulley, the guard must be secured to the base of the plummer
blocks in order to ensure that they follow the pulleys when repositioned.
These guards must be bolted to the conveyor structure so as to create a minimum
clearance of 8 mm from the pulley circumference and 20mm from the belt. No welding will
be allowed to remove or replace such nip guards.


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5.2 Secondary Safety Barrier
It may be assumed that there is no reach through an opening of 10mm x 10mm or less as
fingers cannot normally be admitted. If the opening is such that it will admit one, two or
three fingers the reach is restricted by the roots of the fingers, a distance normally not
exceeding 150mm.
When the opening is sufficient to admit the whole arm and the small portion of the
shoulder the reasonable safe distance is based on the distance from the fingertips to the
armpit, which may be assumed to be 850mm.
Screening material with openings in excess of 80mm x 80mm should not be used in the
construction of guards or fences. Preference should be given to materials with openings
not exceeding 25mm x 25mm.
ELONGATED OPENINGS (Openings with parallel sides):
a) Openings up to 6mm wide may be disregarded. The guard or fence so constructed
may virtually be regarded as a sheet and a working clearance of approximately 25
mm is all that is required.
b) Openings greater that 6mm but less that 13mm will admit part of a finger and
requires at least 50mm clearance from danger points.
c) Openings in excess of 13mm but not greater than 80mm are subject to the following
formula:
X = 10Y where X = reasonable safe distance from danger point in mm.
Y = width of opening in mm.

5.3 Power Drive Unit
Driving belts (V-belts), chains, high and slow speed couplings installed between electric
motors and gearboxes or transmission assemblies fall into the category of exposed
machinery and must be effectively guarded. All such exposed machinery must be totally
enclosed on all sides with guards manufactured from solid steel plate with a minimum
thickness of 3mm. They must be bolted securely in position.
Holdback or brakes can be guarded with mesh guarding but such guards will not be closer
than 150mm to any part of the hold back or brake and the extend of such guards will be
such that no part of the holdback or brake can be touched.
6 MAINTENANCE
Safety at belt conveyor installations may be further enhanced by creating the optimum
working environment including not only adequate ventilation, illumination, absence of
undue noise and adequate dust control, but also sufficient clearance around the
installation and along walkways. Walkways should have an even non-slip surface, be
properly drained and free from obstructions.
Any build-up of spillage material on guards must be removed to prevent deflection of such
guard that would compromise its position relative to the danger point and thereby present


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possible human contact with such danger points. Dimensions given in the best practice
must be maintained at all times.
Primary barrier guards which have been damaged, corroded or bent in any way that would
yield the barrier ineffective shall be replaced with a new guard.
If secondary barrier guards are in any way damaged, corroded or bent or mesh openings
or any other openings increased to sizes greater than stipulated in this document, such
guards shall be replaced immediately to cover the danger points and present a safe
conditions for persons positioned or walking in the vicinity.
Maintenance, travelling and access ways along, around, over or under conveyor belt drive
and tail-end installations must be adequately illuminated, kept dry and free of obstructions
or tripping hazards and allow sufficient clearance for routine maintenance and inspections
to be conducted in a safe manner.
Minimum clearances of 1m must be maintained for the above purpose. Areas where such
clearances cannot be maintained must be suitably barricaded to prevent the unsafe entry
of maintenance personnel.
The COP as required by the Inspectorate for the Operation and Maintenance all Conveyor
Systems at any Mine or Plant must be reviewed and updated annually to ensure the
safety of all persons who are required to work in close proximity to such equipment.
Every person who by the nature of his/her work requires training to be competent in the
operation or maintenance of conveyor systems must at all times be briefed and updated
on the requirements of this BPG and subsequent revisions.
Man-riding of conveyor belts are strictly prohibited.
7 REMOVAL OF GUARDS
Under no circumstances may any guard be removed, repositioned or modified unless the
belt conveyor has come to a COMPLETE stand still, power to the drive has been removed
and the correct lock-out procedure completed.


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APPENDIX A: REFERENCE DOCUMENTS
AA RP 000154, Conveyor Guarding
None
APPENDIX B: RECORD OF AMENDMENTS
Version 0 : New document (P. Nel, May 08)
Version 1 : Document Revised (C. Stensby, December 2011)
AA BPG 375001 document number changed to AA RP 0154 reflect
the new Anglo American document numbering system. (November
2013)

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