Most serious accidents and fatalities involving conveyors result from inadequate guarding, between the conveyor belt and:
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If someone has been seriously injured, become seriously ill, or died as a result of work – phone us on 0800 030 040 straight away. We have staff available to respond to these 24/7.
If you’re not sure what a notifiable event is, including your obligation to hold a scene, visit What events need to be notified?
Notifications made through our online form won't be monitored between 12pm on Tuesday 24 December 2024 and 8.30am on Monday 6 January 2025.
If you’re not sure if you need to notify us, use our online notification system and we’ll respond to you after 6 January 2025.
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General enquiries
General enquiries made by phone or email after 12pm on Tuesday 24 December will be responded to from Monday 6 January 2025. This does not apply to notifications made by phone on 0800 030 040.
We wish you a safe and relaxing holiday.
Conveyor systems are a popular way of handling materials.
There are numerous varieties of conveyors such as flat belt, chain and screw or power roller. Most operate on the same basic principles and have similar significant hazards.
Figure 1: Conveyors
![[Image] Conveyor showing chain and a box sitting on the rollers](/assets/Topic/Machinery/Guarding-of-conveyors/manufacturing-guarding-of-conveyors-figure-1.png)
Figure 2: Conveyors
![[Image] Conveyor showing direction belt moves in, nip point and rotating shaft](/assets/Topic/Machinery/Guarding-of-conveyors/manufacturing-guarding-of-conveyors-figure-2.png)
Figure 3: Pop out roller
![[Image] Side view of conveyor with pop out roller, and close up side view of roller with arrow indicating movement in a clockwise direction](/assets/Topic/Machinery/Guarding-of-conveyors/manufacturing-guarding-of-conveyors-figure-3.png)
Personal Protective Equipment (PPE)
- Ear protection
- Foot protection
- Dust protection
Tasks
Hazard
- Discharge plate/ roller
- Pulleys
- Idler pulleys
- Conveyor frame, or between the belt pulley and conveyor frame
- Projecting shafting
- Belt cleats and belt fasteners
Harm
- Trapped hands – potential cut or crush injuries
- Serious injury from entanglement
Controls
- FIX guards, including interlocked guards.
- INSTALL fencing around pulleys to isolate hazards.
- INSTALL pop-out rollers to relieve trapping hazards where powered conveyors transfer goods to conveyors of idle rollers.
- Stop/start control switches MUST be in reach of the operator, including emergency stops.
- When belt conveyors are out of sight of the control start position, audible and visible warnings MUST occur before movement.
- NEVER ride on, or cross, conveyors.
- EQUIP crossovers with stairs and handrails.
- NEVER WEAR ties, loose clothing or gloves.
- DO NOT use conveyors with internal combustion engines UNLESS adequately ventilated.
Guarding & fencing for pulleys
Idler pulley: idler roller that supports the empty side of the belt. To prevent nips, use fencing between the conveyor belt and the idler pulleys to guard both sides of the conveyor.
Tail pulley: the terminal pulley at the loading end of the conveyor. Guard between the conveyor belt and the tail pulley for the in-running nip on the return run of the belt, considering nips between the pulley, and/or the belt and the framework of the conveyor. Firm fencing is preferred for full isolation.
Head pulley: the terminal pulley at the discharge end of the conveyor. The in-running nips between the belts and head pulleys require fencing that encloses dangerous parts with rigid guards that prevent reach into the conveyor from any angle, including underneath.
Figure 4: Dangerous parts of conveyors
![[Image] Conveyor with labels and red arrows showing dangerous parts](/assets/Topic/Machinery/Guarding-of-conveyors/manufacturing-guarding-of-conveyors-figure-4.png)
Hazard
Slips, trips and falls
Harm
- Contact or impact injuries
- Cuts
- Bruising
Controls
- KEEP up-to-date housekeeping procedures.
- KEEP the area around shears clear of slip and trip hazards.
- PROVIDE non-slip surfaces for treads and steps.
Task – Maintenance, cleaning & repairs
Hazard
Contact or entanglement from unexpected movement
Harm
- Trapping
- Crush or cut injuries
Controls
- PROVIDE safe conditions for maintenance, cleaning and repairs, including:
- guarding
- lock-out mechanisms
- training
- USE scrapers, brooms, or brushes with long handles for cleaning around and underneath conveyors.
- DO NOT clean or clear conveyors unless the conveyor is stopped and interlock systems are in place.
Tensioning, tracking, lubrication and other maintenance are usually done while the conveyor is moving. To reduce the risk of injury, rods and nuts should stick out beyond the guard end, or access made possible by a small slot in the side of the guard. Consider grouping the lubrication points for access outside the guards. Instructions MUST BE provided in a language that operators can understand.
Figure 5: Guards locked by bolts that required a tool to open
![[Image] Guards locked by bolts that require a tool to open](/assets/Topic/Machinery/Guarding-of-conveyors/manufacturing-guarding-of-conveyors-figure-5.png)
These guards are acceptable only if access is not required more than once per shift. If more frequent access is required, the guards MUST be interlocked to the power control.
Figure 6: Guards locked by bolts that required a tool to open
![[Image] Guards locked by bolts that require a tool to open](/assets/Topic/Machinery/Guarding-of-conveyors/manufacturing-guarding-of-conveyors-figure-6.png)
Download fact sheet
Guarding of conveyors
While this guidance has not been updated to reflect current work health and safety legislation (the Health and Safety at Work Act 2015 and regulations), it may still contain relevant information and practices to keep workers and others healthy and safe.
Please read this guidance in conjunction with all relevant industry standards that apply to you as a PCBU. This guidance will be progressively reviewed and either updated, replaced with other guidance, or revoked.
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